EFORT ER20-1100 User manual

ER20-1100 Mechanical Operation and
Maintenance Manual for Industrial Robot
EFORT Intelligent Equipment Co., Ltd
Service Hotline（Tel）：[phone]

Mechanical Operation and Maintenance Manual for ER20-1100 Industrial Robot
Statement
Thank you for purchasing EFORT Robot products. To ensure proper set-up
of products, please read this manual carefully before operation. The content
mentioned in this statement and manual involves your personal and property
safety. Not following the instructions and warnings of the manual may cause
injury to you and EFORT robots, as well as loss of surrounding properties. This
statement and manual are the latest version until this batch of products leave the
factory. Please visit the official website, www.efort.com.cn, to obtain up-to-date
information in the future.
This manual is only used as a normal operation guide. EFORT company
will not be liable for personal injury and property loss caused by other reasons
except product defects. Therefore, EFORT Company solemnly advise people
involved in robot operation, teaching, maintenance, repair, equipment check, and
other relevant activities complete the training courses offered by EFORT, before
being authorized to do so.
Version：V 1.1

Mechanical Operation and Maintenance Manual for ER20-1100 Industrial Robot
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Contents
CHAPTER 1 SAFETY............................................................................................................. 5
1.1 INSTRUCTIONS FOR SAFE OPERATION..............................................................................5
1.1.1 Safety precautions during adjustment, operation, maintenance, and other Work 5
1.1.2 Safety countermeasures for robot.........................................................................7
1.2 INSTRUCTIONS OF LABELS ON ROBOT BODY............................................................... 10
1.3 TRANSFER AND SALE OF ROBOT.................................................................................. 11
1.4 ABANDONMENT OF ROBOT........................................................................................... 11
CHAPTER 2 BASIC INSTRUCTIONS............................................................................... 13
2.1 COMPOSITION OF ROBOT..............................................................................................13
2.2 PACKAGE CHECK...........................................................................................................13
2.3 NAMEPLATE ON ROBOT BODY.......................................................................................14
2.4 BODY COMPOSITION AND DIRECTION IDENTIFICATION OF EACH AXIS.........................15
2.5 RANGE LIMIT AND HOME POSITION OF EACH AXIS....................................................... 15
2.6 ROBOT PERFORMANCE PARAMETERS............................................................................16
2.7 MAXIMUM WRIST PAYLOAD.......................................................................................... 17
2.7.1 Maximum carrying weight.................................................................................18
2.7.2 Maximum static payload torque.........................................................................18
2.7.3 Maximum moment of inertia............................................................................. 18
2.7.4 Allowable payload curve diagram......................................................................18
CHAPTER 3 TRANSPORTATION AND INSTALLATION............................................. 19
3.1 ROBOT TRANSPORTATION..............................................................................................19
3.1.1 Transportation precautions.................................................................................19
3.1.2 Auxiliary handling tooling................................................................................. 19
3.1.3 Transporting method.......................................................................................... 20
3.2 ROBOT INSTALLATION...................................................................................................22

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3.2.1 Setting of safety bar........................................................................................... 22
3.2.2 Robot installation method.................................................................................. 23
3.2.3 Ground installation.............................................................................................23
3.2.4 Bracket installation.............................................................................................25
3.2.5 Upside down installation....................................................................................25
3.3 INSTALLATION SITE AND ENVIRONMENT.......................................................................26
3.4 INTEGRATED APPLICATION INSTALLATION INTERFACE.................................................. 26
3.4.1 Interface of end load mounting flange............................................................... 26
3.4.2 Interface of peripheral installation..................................................................... 27
3.4.3 Terminal definition of wrist I/O signal cable..................................................... 28
3.4.4 Position of pneumatic interface and signal interface......................................... 28
CHAPTER 4 REPAIR AND MAINTENANCE...................................................................30
4.1 PREVENTIVE MAINTENANCE........................................................................................ 30
4.1.1 Routine Check....................................................................................................30
4.1.2 Quarterly check.................................................................................................. 30
4.1.3 Annual check......................................................................................................31
4.1.4 Every three-year check.......................................................................................31
4.2 REPAIR AND MAINTENANCE FOR MAIN BOLTS.............................................................. 31
4.3 CHANGE LUBRICANT.....................................................................................................32
4.3.1 Demand capacity of lubricant............................................................................ 32
4.3.2 Azimuth of axis when lubricant to be replaced..................................................32
4.3.3 Process for replacing lubricant in J1~J4 axes reducer and wrist part................ 32
4.3.4 Release the residue pressure in lubricant cavity................................................ 34
4.4 MAINTENANCE OF TIMING BELT................................................................................... 34
4.4.1 Tightening the timing belt.................................................................................. 35
4.4.2 Replacement of timing belt................................................................................ 36
4.5 ROBOT MAINTENANCE AND WORKING AREA................................................................36
4.5.1 The safety conditions required for working area............................................... 36

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4.5.2 Qualification requirements for maintenance personnel and precautions........... 36
4.6 CALIBRATION OF HOME POSITION.................................................................................37
4.6.1 Calibrating method of home position.................................................................37
4.6.2 Mechanical calibration of axis home position................................................... 38
4.7 BATTERY REPLACEMENT...............................................................................................39
CHAPTER 5 COMMON FAULTS AND TROUBLESHOOTING....................................40
APPENDICES......................................................................................................................... 44
A TORQUE TABLE OF TIGHTENING SCREW.......................................................................... 44
B LIST OF SPARE PARTS......................................................................................................44

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Chapter 1 Safety
1.1 Instructions for safe operation
Before performing installation, operation, repair and maintenance, and overhaul, please
be sure to read this manual and other attached documents thoroughly to use this product
correctly. Please fully understand the equipment and safety information, and all precautions
before using this product. The following symbols in this manual indicate each own
importance.
Mishandling could cause death or serious injuries to the operator and highly dangerous
situations.
Mishandling could cause death or serious injuries to the operator.
Mishandling could cause minor injuries to the operator or property damage.
1.1.1 Safety precautions during adjustment, operation, maintenance, and
other Work
1). Operators must wear uniforms, helmets, safety shoes, and other protective wear.
2). Please be sure operators are not within the motion range of the robot when switching
on power.
3). Operation within the motion range of the robot must not be allowed until the power is
cut off.
4). Overhaul, repair and maintenance, and other work need to be performed in power-on
state by two persons. One maintains the gesture that enables to immediately press the
emergency stop button, while the other keeps precautious and quickly perform work within
the robot’s motion range. Besides, the evacuation path should be confirmed before operation.
5). The load on the wrist and arm must be controlled under the limit of carrying weight
and torque, or else abnormal movements may occur or mechanical components may be

Mechanical Operation and Maintenance Manual for ER20-1100 Industrial Robot
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damaged.
6). Disassembling parts and work not involved in this manual are forbidden.
The robot is equipped with self-diagnostic and other abnormality detection function, so it
can stop safely in case of abnormality. However, accidents may still occur sometimes.
Common accidents are listed below:
1、Automatic operation is being performed without confirming whether anyone is within
the robot’ s motion range.
2、The robot makes sudden movements when the operator is within the motion range in
automatic mode.
3、Attention is not paid to other robots but the one in the front.
Reasons, such as ignorance of safety operation procedures, no awareness of robot’s
sudden movement, lead to above accidents. In other words, accidents are caused by insecure
human-made actions, such as temporary ignorance, failure to comply with the prescribed
steps.
Operators have little time to perform emergency stops, evacuate, or other actions to
avoid serious accidents in emergency situations, as shown below.
1). Low-speed movement suddenly changes to high-speed movement.
2). Other operators performed the operation.
3). Abnormality and program errors caused by peripheral equipment start different
programs.
4). Noise, fault, and other defects lead to abnormal movements.
5). Misoperation.
6). High-speed movement is performed instead of automatic low-speed movement.
7). The work pieces transported by the robot fall and scatter.
8). Workpieces in clamping or interlocking state suddenly lose control.
9). Neighboring robots or robots at the back perform action.
The above are some of the typical examples excluding many other emergency situations.
In most cases, the robot making sudden movements cannot be stopped and the operator cannot
evacuate. Therefore, optimal countermeasures should be implemented to avoid such
accidents.

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Approach the robot cautiously.
Press emergency stop button or cut off power, so the robot cannot make movement when
it’s not operation.
A supervisor (the third person) should be assigned to monitor the safety and be able to
immediately press the emergency stop button during robot’s movement.
Robot in operation should be stopped by emergency stop button at any time.
In order to comply with these principles, it is necessary to fully understand the following
precautions and follow them.
1.1.2 Safety countermeasures for robot
Unnecessary protrusions or sharp parts should be removed in robot design. Materials that
suit the working environment and safety protective structures against faults that are not
prone to damage or accidents during movements should be used. Additionally, safe
operation should be ensured by installing misoperation detection stop and emergency
stop functions, and interlocking function to avoid dangers when peripheral equipment
acts abnormally.
The body is a multi-joint mechanical arm structure, and the angle of each joint constantly
changes during movement.
If it is necessary to approach the robot for teaching and other work, be careful not to be
clamped by joints. The end of each joint’s movement is equipped with a mechanical stop,
which is highly risky for being clamped. Therefore, special attention should be paid to.
The arm may fall due to gravity or move to an uncertain direction if the servo motor is
removed or the break is released. Therefore, preventative measures must be implemented
and the surrounding safety conditions must be endured before operation.

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When installing attached machine on the end of the effector and the arm, strictly follow
the manual to use specified torque wrench to fasten screws of specified size and quantity.
Do not use rusty or dirty screws.
Fastening screws in unspecified and improper ways could cause loosening, which lead to
serious accidents.
The end effector should be designed and manufactured within the allowable payload
range of the robot wrist.
Protective structure against faults should be used to. Even if the power or compressed air
supply of the end effector is cut off, accidents, such as installed objects being released or
thrown, will not occur. The corners or protruding parts should be treated to prevent
damage to humans or objects.
It is forbidden to supply unspecified power, compressed air, and welding cooling water,
which could affect the mobility and cause abnormal movements, malfunctions or
damage, and other dangerous situations.
Electromagnetic interference, which is related to its type or intensity, cannot be handled
with current technology. Therefore, follow the precaution instructions and regulations in
robot operation and power-on. Recorded data will be lost due to electromagnetic waves,
noises, and substrate defects.
Please back up programs or frequently used data to external storage medium, such as a
compact flash card.
Operators working in distance in large systems should communicate with gestures to
convey intentions correctly.
noise in the working environment may cause misunderstandings, which lead to
accidents.

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Industrial Robot Control by Means of Gestures (Sample)
1. Connect: Connect to power.
2. No, disconnect: Raise right hand
and wave vigorously.
3. Confirm whether it is OK: Raise
right hand up high forward.
4. OK: Raise right hand up high
forward. Use thumb and index
finger to form a circle.
5. Hold on: Extend arm
horizontally with right hand facing
the other person.
6. Leave: Extend right arm
horizontally and wave to the left.
Operators must always keep awareness of evacuation at any time during operation.
Immediate evacuation must be ensured in an emergency.
Always keep attentive to robot’s movement. Do not turn your back to the robot during
operation. Slow reaction to the robot can cause accidents too.
Immediately press the emergency stop button in case of abnormality, which must be
thoroughly implemented.
Compile regulations and checklists, including robot startup, operation, and solutions to
abnormalities, according to the setting place and operation content. Operators working
with memory and existing knowledge could cause accidents due to wrong memories and
errors.

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Save completed programs to prevent accidental editing.
Confirm the program number and procedure number in teaching before operation.
Editing programs and procedures incorrectly could cause accidents.
When it is not necessary to make robot’s movement and operate it, please cut off the
power before proceeding.
When teaching is completed, check robot’s movement manually in low-speed state. If it
is operated with 100% full speed in automatic mode, accidents may occur due to program
errors.
Cleaning should be done and tools must be confirmed to be taken away after teaching is
completed. Oil contamination in the work area and forgetting tools may cause accidents,
such as falls.
Ensuring safety start with tiding up.
1.2 Instructions of Labels on Robot Body
Safety labels are affixed on specific parts of the robot to warn users of safety precautions
in operating and maintaining it.
Label
Name
Description
Attached part
Be careful
not to clamp
hands
The movable parts of the
robot may clamp your
hands.
It is generally pasted on the
rotating joint of the power
arm and the connecting rod.
Caution, hot
Robot operation causes
heat on some parts.
It is generally pasted on the
motor to suggest hot motor
and no touching with bare
hands.
Be cautious
of electric
shock
The risk of electric shock
exists at the electrical
connection parts.
It is generally pasted on the
motor and the panel of the
circular connector base to
remind the user be careful
when connecting and

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removing the cable
connector.
NO stepping
on
Stepping on the robot
during maintenance is
forbidden to avoid personal
injuries and damage of
components which will
affect the performance of
the robot.
It is generally pasted on the
motor.
1.3 Transfer and Sale of Robot
If the ownership of the robot is transferred or sold to a new user, attached documents,
including mechanical operation manual, electrical maintenance manual, and
programming manual, must be transferred.
If the robot is transferred to sold to a foreign country, the new user must modify the
languages in the above attached documents to comply with local laws and regulations.
Wrong or unsafe operation due to insufficient understanding of the manuals can lead to
accidents.
When the robot is transferred or sold to a foreign country, safety relevant terms in initial
contract which does not include specific provisions shall not be borne by the new
recipient.
The original user and the new recipient must sign a new contract.
1.4 Abandonment of Robot
The disassembly, heating, or incineration of batteries in control devices and robot body
could cause fire, rupture, and other accidents.
Please do not disassemble the board and components of control devices before
discarding them.
Sharp parts, such as cracks or cuts, and wires may cause injuries.
After the wires and external wiring are removed from the connector and junction box, do
not future disassemble them and discard them. Otherwise, injuries on hands or eyes
caused by conductors may occur.

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Attention should be paid to clamp or injuries when performing abandoning work.
Waste products should be discarded safely.

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Chapter 2 Basic Instructions
2.1 Composition of Robot
An industrial robot is composed of the following parts, as shown in figure 2-1：
Body
Control cabinet
Teach pendant
Cables (for power supply, etc)
Figure 2-1 Composition of Robot
2.2 Package check
1. Please confirm whether the packaging is intact before opening it;
2. Check whether each part or component is complete and consistent with the order.
Please contact the supplier in time for any missing or wrong part.
Table 2-1 robot packing list
Name
Configuration type
Quality
Unit
Remark
Robot body
ER20-1100
1
PC
/
Robot control cabinet
EC-S6
1
PC
/
Connecting cable from
robot body to electric
control cabinet
Power cable
1
PC
Standard length 8m
Optional length 16m
Encoder cable
1
PC
Standard length 8m
Optional length 16m
Teaching pendant
Cable of teaching
pendant
Robot body
Control cabinet
Earth wire
Power and signal cable of robot

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Earth cable
Standard
1
PC
Standard length 8.5m
Teaching pendant and
teaching pendant cable
Standard
1
PC
8M
Power cable of control
cabinet
Standard
1
PC
4M
IO cable from robot body to
electric control cabinet
Standard
1
PC
8M
IO cable of Small arm end
Standard
1
PC
1.5M
Fuse core
5×20-10A glass tube
1
PC
In the accessory case of control
cabinet
Direct-attached adapter for
25PIN
Standard
1
PC
In the accessory case of control
cabinet
Direct-attached adapter for
50PIN
Standard
1
PC
In the accessory case of control
cabinet
Operation manual
Mechanical operation and
maintenance manual
1
PC
QR code
Electrical operation and
maintenance manual
1
PC
Programming manual
1
PC
Product certification
Manufacturer's standard
1
PC
/
Others
/
/
/
/
Note: The above list is for standard configuration excluding customized models.
2.3 Nameplate on robot body
The nameplate on robot body displays information, including model type, weight, voltage,
manufacturing number, manufacturing date, etc.
Figure 2-2 Nameplate on body

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2.4 Body composition and direction identification of Each Axis
The mechanical body mainly includes base, rotating part, upper arm, forearm, wrist. The
joints are driven by the servo motor, each of which cooperate to achieve position and gesture
adjustment of the robot end in space. Names of each part and direction director of each axis
are shown at as follows.
Figure 2-3 Mechanical composition of ER20 - 1100 body
2.5 Range limit and home position of each axis
Each axis of the body sets a home position and range limit. When the system is in normal
operation, each axis is controlled to move within the allowable range. To further ensure safety,
some axes are equipped with mechanical end stops (shown as follows) to prevent malfunction
of the control device and operation beyond motion range.
Wrist
Forearm
Upper arm
Rotating part
Body base
Mechanical end stop
of axis J2
Home position
of axis J2
Home position of axis J1
Mechanical end stop of axis J1
Home position of axis J3
Mechanical end stop of axis J3

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Figure 2-4 Position of mechanical end stops and home position
2.6 Robot performance parameters
Table 2-2 Parameter list of performance
Model
ER20-1100
Motion type
Joint
Control axis
6 Axes
Maximum speed
axis/J1 轴
260°/sec
axis/J2 轴
255°/sec
axis/J3 轴
210°/sec
axis/J4 轴
450°/sec
axis/J5 轴
450°/sec
axis/J6 轴
600°/sec
Maximum motion
range
axis/J1 轴
±170°
axis/J2 轴
-160°～+83°
axis/J3 轴
-85°～+175°
axis/J4 轴
±190°
axis/J5 轴
±130°
axis/J6 轴
±360°
Maximum motion radius of robot arm
1143mm
Maximum payload of robot wrist
20 kg
Installation conditions
Ground, upside down, wall hanging
Protection class
IP65 (others) / IP67 (wrist)
Repeatability
±0.05mm
Body weight
145kg
Home position of axis J4
Home position of axis J5
Home position of axis J6