Estun Mini Series User manual

ESTUN
Robotics Mini Series
Robot Body Operation Instructions

ESTUN Mini Series
Robot Body Operation Instructions
M-0501CN-12

Thank you for purchasing ESTUN robots.
Before using the robot, be sure to read the SAFETY PRECAUTION and understand the content.
ESTUN endeavor to improve the products. All specifications and designs are subject to change without
notice.
All statements, information, and advice provided in this manual have been carefully processed, but no
guarantee is given for their complete accuracy. We shall not be held liable for any direct or indirect
losses arising from the use of this manual.
Users are solely responsible for the application of any products and should exercise caution when
using this manual and the associated products.
The interpretation of all content in this manual belongs to ESTUN Robotics Engineering Co., Ltd.
This manual may not be reproduced and copied in any way, in whole or in part,
without a license to any party.
ESTUN Robotics. All Rights Reserved Copyright.
Hotline: [phone]
ADD: NO.1888, Jiyin Avenue, Jiangning Development Zone, Nanjing Post Code: 211102
TEL: [phone]
WEB: www.estun-robotics.com
E-mail: expor[email protected]om

Instructions for Safe Use
s-1
Instructions for Safe Use
This Chapter describes the content to be observed for the safe use of the robot. Before using, be
sure to read and understand the content in this Chapter.
Companies and individuals using ESTUN Robotics should be familiar with the local and national
standards and laws. Appropriate safety facilities shall be provided to protect users. Before use
(installation, operation, maintenance and repair), please be sure to read and understand this Manual
as well as other ancillary materials thoroughly, and use it after being familiar with all knowledge on
equipment, safety and precautions. However, ESTUN would not guarantee that the user will absolutely
not be injured even if he follows completely all the safety information given in the Manual.
DEFINITION OF USER
The personnel can be defined as follows.
Operator
To turn the robot power ON/OFF.
To start the robot program from the panel.
Programmer
To operate the robot.
To teach the robot in a safe area.
Maintenance engineer
To operate the robot.
To teach the robot in a safe area.
To carry out the robot maintenance (repair, adjustment, replacement).
Operator must not work in a safe area.
Programmer and maintenance engineer can work in a safe area.
During operation, programming, and maintenance of the robot, the operator, programmer, and
maintenance engineer should take precautions to ensure the safety by wearing the following safety
items.
Clothes for operation
Safety shoes
A helmet
SPECIAL TRAINING
Tasks in the safe area including transportation, setting, teaching, adjustment, maintenance, etc.
Training course must be performed before operating the robot.
For more information about training course, contact ESTUN.
Safety Symbols
If the manual contains instructions marked as follows, users must read them carefully and follow
strictly.

Instructions for Safe Use
s-2
Symbol
Definition
Danger
Death or serious injury will be expected to occur if the user fails to follow the
approved procedure.
Caution
Minor or moderate injury of the user or equipment damage will be expected to
occur if the user fails to follow the approved procedure.
IN F O
Information
A supplementary explanation helps users operating the robot more efficiently.
Safety precautions for users
(1) The robot should be transported and installed as procedures recommended by ESTUN. Wrong
procedures may cause severe injuries or damage due to the robot fall.
(2) Draw an area clearly indicates the safety area. Install a fence or hang a warning board to ensure
the safety operation of the robot, and keep unauthorized personnel outside the safety area.
(3) Never hang any tools above the robot. Falling of these tools may cause damage to equipment.
(4) Never lean on the cabinet. Never touch any buttons without permission. Unexpected movement of
the robot may cause personnel injuries and equipment damage.
(5) Take precautions for falling parts to avoid injuries when disassemble the robot.
(6) Turn off the power when adjusting peripheral equipment.
(7) Peripheral equipment must be grounded.
(8) The robot should be operated in a low speed in the first operation. The speed should be added
gradually to check if there is any abnormal situation.
(9) Do not wear gloves when using the teach pendant. Operate with gloves may cause an operation
error.
(10) Programs, system variables, and other information can be saved on the memory card or USB
memories. Be sure to save the data periodically in case that the data is lost.
(11) Never forcibly move any axis of the robot. Move the axes forcibly may cause injuries or damage.
(12) Take precautions when wiring and piping between the robot, the cabinet, and peripheral
equipment. Put the pipes, wires or cables through a pit or covered with a protective lid, to avoid
stepped by personnel or run over by a forklift.
(13) Unexpected movement may occur on any operating robot, which will cause severe injuries or
damages in the working area. Test (safe door, brake, safe indicators, etc.) must be performed on
each safety measures before using the robot. Before turn on the system, make sure that no one is
in the working space.
(14) Never set motion range or load condition exceeds the rated range. Incorrect setting may cause
personnel injury and equipment damage.
(15) Observe the following precautions when teaching inside the working space of the robot
Do not enable the system unless the mode is switched to manual, and make sure that all
auto-control is cut off.
Speed must be limited under 250mm/s at manual mode. Only authorized person with fully
understand of the risks can adjust the robot to rated speed manually.
Be careful about rotating joints to prevent hair and clothes involved. Take precautions of injury
or damage caused by the manipulator or other auxiliary devices.

Instructions for Safe Use
s-3
Check the motor brake to avoid personnel injuries caused by unexpected situation.
Always have an escape plan in mind in case the robot comes towards you unexpectedly.
Ensure that there is a place to retreat to in case of emergency.
Under any circumstances, do not stand under any robot arm to prevent abnormal
motion of the robot or connection with other people.
A carbon dioxide fire extinguisher needs to be placed on site to prevent the robot
system from catching fire.
Operators:
(1) Before operate the robot, you should press E-stop button, which is on the teach pendant or the
upper right of electric cabinet, in order to check whether the indicator of Servo Ready is not light,
and make sure the power of the indicator is turnoff.
(2) In course of operation, never allow the non-work personnel to touch the control cabinet. Otherwise,
the robot might bring some unexpected movements, which can cause personal injury or
equipment damage.
(3) When you install a device on the robot, the power supplies of the control cabinet and the device
must be cut off (OFF), and then hang a caution sign. If you power on in your installation, it might
cause the danger of electric shock, or the robot might bring some unexpected movements, which
can cause personal injury.
(4) E-stop
The E-stop is independent of the electrical control of all robots, and it can stop all robot motions;
E-stop means that all power supplies to the robot are disconnected, but the power to the brake on
the servomotor is not disconnected. The robot can work again after releasing E-stop button and
re-starting the robot.
There’re several buttons for emergency stopping the robot. On the teach pendant
and at the upper right of control cabinet, each of these places has one red button,
as shown in the left side. Certainly, users can also set the E-stop button as
required.
The E-stop button must be installed in an accessible position so that the robot
can be stopped in an emergency.
Operators shall pay attention to the high-voltage danger of the power line of the
servomotor, as well as the power line connecting the fixture and other devices.
E-stop is just used for stopping the robot in the case of an emergency. That is to
say, it cannot be used in the normal stop.
Programmers:
While teaching the robot, and in some cases, the programmer needs to enter the range of the
robots movement, so be sure to keep himself safe.

Instructions for Safe Use
s-4
ON/OFF enabling is done by operating a Mot button on the teach pendant. When
pressing this button, the servomotor is enabled, and disabled when releasing it.
To ensure the safe use of the teach pendant, the following rules must be observed:
Ensure that the enable button works at all times.
Disconnect the enabling timely when temporarily stopping the robot, programming or testing.
When entering the robot working space, the demonstrator shall bring the teach pendant to
avoid other people operating the robot without the programmer is informed.
The teach pendant must not be placed within the working space of the robot to prevent
abnormal actions in case of collision between the robot and the teach pendant.
Maintenance personnel:
(1) Pay attention to the parts in the robot that are prone to become hot
Some parts of the robot in normal operation will become hot, especially the servomotor and
reducer, which may cause burns when being approached or touched. When it is inevitable, protective
equipment such as heat-resistant gloves should be worn.
Before touching these parts with your hands, try to feel the temperature of these
parts by approaching with your hand, in case you are scalded.
Wait for enough time after machine halt, so that the hot parts can be cooled
down, and then you can carry out the maintenance work.
(2) Safety precautions on removing parts
Ensure that the internal parts such as the gears are no longer rotating, and then you can open the
lid or the protection device. You shall not open the protection device when the gears and bearings are
rotating. If necessary, use the auxiliary device to make the internal unfixed parts remains its original
position.
The initial test upon repair, installation and maintenance shall be carried out by following the steps
below:
a) Clean up the robot and all maintenance and installation tools in the working space of the robot.
b) Install all the protective measures.
c) Ensure that people are standing outside the safe range of the robot.
d) Pay special attention to the working conditions of the parts repaired during testing.
In case of robot repair, do not use the robot as a ladder, and do not climb on the robot to avoid
falling
(3) Safety precautions on pneumatic/hydraulic components
After turning off the air source or hydraulic pump, a few residual gas or liquid exists in the
pneumatic system or hydraulic system. Beware these gases or liquid, which have a certain energy; we
must take some measures to prevent the residual energy from damaging to the human body and
equipment. Therefore, it is necessary to release the residual energy in the system before maintaining
the pneumatic or hydraulic components.
Mount a safety valve to avoid accidents.
(4) The power supply need be opened in many cases of fault diagnosis, but it must be shut when the
maintenance or repair is carried, moreover, you should cut off other power supply connections.

Instructions for Safe Use
s-5
(5) Brake detection
In general, the brake can be worn in the normal operation. Therefore, the brake detection is
necessary by following the steps below.
a) Move each joint to a position, where the joint can bear the maximum load.
b) Shut down the robot and brake.
c) Mark every joint of the robot.
d) Examine whether any joint moves after waiting for a moment.
(6) Safety precautions for adding lubricating oil
When add lubricating oil to the reducer, it might do harm to the person and the equipment.
Therefore, you must obey the below safety information before adding lubricating oil.
Wear the protective measures (e.g. gloves, etc.) when refueling or draining oil to prevent
damage to maintenance personnel caused by high-temperature oil or reducer.
Be cautious when opening the oil chamber cover. Keep away from the opening as there may
be pressure in the oil chamber to cause splashing.
Oil filling shall be made according to the fuel gauge, which shall be not too full. Check the oil
indicator port after oil filling.
Oil of different designations cannot be added to the same reducer, and the remaining oil must
be cleaned up before using the oil of different designation.
Drain the oil completely or check the oil indicator port after oil filling.
IN F O
Before emptying the oil in the reducer, you can run the robot for a period of time
to heat the oil, to allow easier draining.
Safety precautions for tools and peripheral equipment
The external equipment of the robot may still be running after the robot is turned off, so damage to
the power cord or power cable of the external equipment may also cause bodily injury.
Safety precautions for robot
In an emergency, any arm of the robot that clips the operator shall be removed. Please ask our
technicians for details to ensure the safe removal.
Small robot arms can be removed manually, but for large robots, cranes or other small equipment
may be required.
Before releasing the joint brake, the mechanical arm needs to be fixed first to ensure that the
mechanical arm will not cause damage again to the person trapped under the action of gravity.
Ways to stop robot
The stopping of robots has the following three ways.
Power-Off Stop
Servo power is turned off and the robot stops immediately. Servo power is turned off when the
robot is moving, and the motion path of the deceleration is uncontrolled.

Instructions for Safe Use
s-6
The following processing is performed at Power-Off stop:
An alarm is generated and servo power is turned off, and the robot operation is stopped
immediately.
Execution of the program is paused.
For the robot in motion, frequent power-off operations through E-stop buttons will cause robot
failure. The system configuration for daily power-off stop should be avoided.
Alarm Stop
The motion of the robot is decelerated and stopped through a control command after the robot
system issues an alarm (except for the power failure alarm).
The following processing is performed at Controlled stop:
The robot system issues an alarm due to overload, failure, etc. (except for power failure
alarms).
The servo system sends a command “Control Stop” along with a decelerated stop. Execution
of the program is paused.
The servo power is turned off.
Hold
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold:
The robot operation is decelerated until it stops. Execution of the program is paused.

Instructions for Safe Use
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Warning and Caution Signs
(1) Electric shock
Figure 0.1 Electric shock warning sign
Attention should be paid to the danger of high voltage and electric shock at the place where this
sign is affixed.
(2) High temperature
Figure 0.1 High temperature warning sign
Be cautious about a section where this label is affixed, as the section generates heat. If you have
to inevitably touch such a section when it is hot, use a protective provision such as heat-resistant
gloves.
(3) No stepping
Figure 0.2 No stepping warning sign

Instructions for Safe Use
s-8
Do not step on or climb the robot as it may adversely affect the equipment, and cause the bodily
injury to operators.
(4) Wounding by robot
Figure 0.4 Wounding by robot warning sign
There is a danger of wounding by robot when working within the motion range of robot.
(5) Handling
Figure 0.3 Handling sign (ER10-900-MI/HI)
This symbol indicates the precautions for handling robots.
(6) No disassembly

Instructions for Safe Use
s-9
Figure 0.4 No disassembly warning sign
Users are prohibited from disassembling the part affixed with this sign. Disassembly shall be
carried out by professionals using professional tools.

Preface
p-1
Preface
This manual is applicable to the following robot type.
Robot type Load capacity
ER10-900-MI/HI 10kg
List of relevant instructions
Mini Series Robot Body Operation Instructions of ESTUN Robotics
ERC Series Compact Control Cabinets Product Manual
Operation Instructions of ESTUN RCS2 System

CONTENTS
c-1
CONTENTS
Instructions for Safe Use .................................................................................................................................... 1
Preface.................................................................................................................................................................. 1
CONTENTS.......................................................................................................................................................... 1
1. Transportation & Installation ...................................................................................................................... 1
1.1. Transportation .............................................................................................................................. 1
1.1.1. Way of transport................................................................................................................... 2
1.2. Installation..................................................................................................................................... 3
1.2.1. Stand...................................................................................................................................... 6
1.3. Installation conditions.................................................................................................................. 7
2. Connection with the Controller................................................................................................................... 8
3. Specification ............................................................................................................................................... 10
3.1. Robot configuration ................................................................................................................... 10
3.2. External dimensions and operating space............................................................................. 11
3.3. Zero point position and motion limit ........................................................................................ 13
3.4. Wrist load condition ................................................................................................................... 16
4. Equipment Installation............................................................................................................................... 17
4.1. End flange mounting interface................................................................................................. 17
4.2. Equipment mounting face......................................................................................................... 17
4.3. External pipelines ...................................................................................................................... 19
4.3.1. Description of robot IO connector pins ........................................................................... 19
5. Check and Maintenance........................................................................................................................... 21
5.1. Daily checks................................................................................................................................ 21
5.2. Periodic checks and maintenance .......................................................................................... 21
5.3. Adjustment of drive belts .......................................................................................................... 23
5.4. Replacement of batteries.......................................................................................................... 25
5.5. Robot greasing........................................................................................................................... 25
5.5.1. Steps to replace grease.................................................................................................... 27
5.5.2. Steps to release residual pressure in the grease chamber......................................... 27
6. Zero Calibration ......................................................................................................................................... 28
6.1. Introduction ................................................................................................................................. 28
6.2. Calibration with instrumentation .............................................................................................. 28
6.3. Mechanical zero calibration...................................................................................................... 29
6.3.1. ER10-900-MI/HI mechanical zero calibration................................................................ 29
7. Troubleshooting ......................................................................................................................................... 32
7.1. Tools............................................................................................................................................. 32
7.2. Troubleshooting.......................................................................................................................... 32
7.3. Replacement of servo motor components ............................................................................. 33

CONTENTS
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Appendix ............................................................................................................................................................. 34
Appendix A Screw tightening torque list................................................................................................. 34
Appendix B Specifications and technical parameters of chemical bolts ........................................... 34
Appendix C List of recommended spare parts for ER10-900-MI/HI ............................................................ 34
Revision Record................................................................................................................................................. 35

Transportation & Installation
1
1.Transportation & Installation
1.1. Transportation
Before moving the robot, position each joint of the robot into the handling position to ensure that
the robot remains in the handling position without any movement or displacement during transportation.
The robot should maintain the handling position until it is fully installed and secured. The angular
rotation of each axis in the handling position is as follows, and it is crucial to handle the robot according
to the specified angles in the table. Failure to do so may result in safety accidents or equipment
malfunctions.
Angle
J1 axis
J2 axis
J3 axis
J4 axis
J5 axis
J6 axis
ER10-900-MI/HI
0° 0° +68° 0° +22° 0°
During the installation, disassembly, and transportation of the robot, the weight of the robot is a
critical parameter. The table below lists the theoretical weight of the main components of the robot.
Tab 1.1 Weight of main robot components (ER10-900-MI/HI)
Component
Weight (kg)
Complete robot 75
Big arm casting 8
Base assembly
(Including rotation base,J1-axis and J2-axis) 42.5
Small arm assembly (Including rotation base,
J3-axis and J4-axis)
10.3
Wrist assembly (Including wrist, J5-axis and
J6-axis) 6.3
IN F O
Some parts with less weight are not listed. Contact ESTUN if you need the
details.
During transportation, it is necessary to install the mounting bracket and protective pad for the
robot. Before installing the robot, the mounting bracket and protective pad should be removed. The
figure below provides the sizes of the mounting bracket screw holes and the positions of the protective
pad, to facilitate the disassembly process for users.
When transport the robot, be sure the robot is in safe and reliable condition, or it
may result in serious personnel injury or equipment damage.

Transportation & Installation
2
Fig. 1.1 Robot fixed bracket (ER10-900-MI/HI)
1.1.1. Way of transport
The robot described in this manual can be transported by a forklift. Set the robot to the handling
position and install special handling brackets (2 in total) on both sides of the base. Use steel cables (4
in total) for lifting. Prior to handling the robot, it is essential to ensure that all ground anchor bolts of the
robot have been completely removed.
Handling bracket
Protective
pad
Mounting holes 2 x M5*10 screws and flat gasket
Mounting holes 2 x M10*20
screws and flat gasket

Transportation & Installation
3
Handling conditions: Crane lifting capacity: 200kg; Hoisting cable capacity: 150kg.
Fig 1.2 Use a crane to transport the robot (ER10-900-MI/HI)
The customer is responsible for providing the eyebolts and hoisting cables.
1.2. Installation
Before starting any installation work with the robot connected to the power
supply, ensure that the robot's grounding wire is properly grounded.
The following precautions must be fully understood and observed before installing the robot:
Be sure to read and understand SAFETY chapter thoroughly;
ESTUN robots must be transported, mounted and operated by authorized person, and in
accordance with the applicable national laws, regulations and standards;
Check the external damage of the robot package. Open the package and check the external
damage of the robot;
Make sure the weight of the robot is within the forklift or crane load capacity. Details see
Section 1.1 TRANSPORTATION;
Storage and mounting condition should be complied with Section 1.3 INSTALLATION
CONDITION.

Transportation & Installation
4
When mounting the robot base, consider its structure and the force upon it.
Concrete on the base may not have any crack and conform to the specified
codes. The bearing capacity and compaction of the concrete foundation should
be in accordance with the design guideline. Concrete strength level C20/C25
should be in accordance with the following codes:
GB50010-2010 Code for design of concrete structures
GB/T50081-2002
Standard for test method of mechanical properties on
ordinary concrete
Name
Definition
Max. value
Mk
Max. overturning
torque
2450 (N·m)
Mr
Max. torsional
torque
2000 (N·m)
Fv
Max. vertical force
2500 (N)
Fh
Max. horizontal
force
1200 (N)
Fig 1.3 Robot base force (ER10-900-MI/HI)

Transportation & Installation
5
Fig. 1.4 Robot base mounting dimension (ER10-900-MI/HI)
Tab 1.2 Robot fixing components (ER10-900-MI/HI)
Name & model
Qty.
Fixed screw: M12X55 (GB/T 70.1 12.9 grade)
3
Spring washer: Spring washer 12 (GB/T 93)
3
Positioning pin: Cylindrical pin 8X20
2
IN F O
Installing positioning pins can greatly minimize the impact on the existing robot's
program trajectory caused by reinstalling or replacing the robot. It only requires
slight adjustments to the running program to restore the robot's normal operating
path. If you do not need to consider this aspect, you may choose to omit the
installation of positioning pins.
3-∅
13.5 Through hole