ROKAE xMate ER7 Pro Assembly instructions

xMate ER7 Pro
Hardware Installation
Manual

xMate ER7 Pro
Hardware Installation Manual
With Control System/Control Cabinet
Document ID: 202208081959
Document Version: V0.1
Copyright © ROKAE 2015-2022. All rights reserved.

Contents in this manual are subject to change without notice. We
assume no responsibility for any errors that may appear in this
manual.
Please understand that in no event shall we be liable for incidental
or consequential damages arising from the use of this manual and
the products described herein.
We cannot foresee all possible dangers and consequences.
Therefore, this manual cannot warn the user of all possible hazards.
Unauthorized copying or reprinting of some or all contents of this
manual is prohibited.
If you find the contents of this manual wrong or in need of
improvement or supplement, please do not hesitate to point them
out so that they can be corrected.
This manual is originally written in Simplified Chinese. Other
language versions are translated.
Copyright © ROKAE 2015-2022. All rights reserved.
ROKAE (Shandong) Intelligent Technology Co., Ltd.
Shandong, China

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xMate ER7 ProHardware Installation Manual I
Contents
1 Manual Overview........................................................................................................................3
1.1 About this manual........................................................................................................................................ 3
1.2 Target group..................................................................................................................................................3
1.3 How to read the product manual.............................................................................................................. 3
1.4 Illustrations in this manual......................................................................................................................... 3
1.5 Related product documents.......................................................................................................................3
1.6 Contact...........................................................................................................................................................3
2 Safety............................................................................................................................................ 4
2.1 Introduction.................................................................................................................................................. 4
2.1.1 Safety responsibilities................................................................................................................... 4
2.1.2 Intended use................................................................................................................................... 4
2.2 Safety notice..................................................................................................................................................5
2.2.1 Instructions..................................................................................................................................... 5
2.3 Safety protection devices............................................................................................................................5
2.3.1 Emergency stop............................................................................................................................. 5
2.3.2 Enabling switch.............................................................................................................................. 6
2.4 Emergency stop types................................................................................................................................. 6
2.4.1 Emergency stop............................................................................................................................. 7
2.5 Safety precautions....................................................................................................................................... 7
2.5.1 Operating safety............................................................................................................................. 7
2.5.2 Recovering from emergency stops............................................................................................. 7
2.5.3 Safety precautions in Manual mode........................................................................................... 7
2.5.4 Safety precautions in Automatic mode......................................................................................8
2.6 Pre-use assessment..................................................................................................................................... 8
3 Product Overview.................................................................................................................... 10
3.1 Introduction................................................................................................................................................ 10
3.2 Robot............................................................................................................................................................ 10
3.2.1 Overview........................................................................................................................................10
3.2.2 Robot system................................................................................................................................10
3.2.3 Definitions of rotation directions and coordinate systems.................................................. 11
3.3 Symbols and labels.................................................................................................................................... 12
4 Technical Specifications........................................................................................................ 14
4.1 Introduction................................................................................................................................................ 14
4.2 Model and nameplate............................................................................................................................... 14

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II xMate ER7 ProHardware Installation Manual
4.2.1 Model............................................................................................................................................. 14
4.2.2 Nameplate.................................................................................................................................... 14
4.3 Specifications..............................................................................................................................................14
4.3.1 Data sheet..................................................................................................................................... 14
4.4 Working space.............................................................................................................................................16
5 Unpacking and Installation................................................................................................... 17
5.1 Introduction................................................................................................................................................ 17
5.2 Installation flow chart................................................................................................................................17
5.3 Environmental conditions........................................................................................................................ 17
5.4 Unpacking and hardware installation.................................................................................................... 19
5.4.1 Unpack...........................................................................................................................................19
5.4.2 Robot angle and force application points during transportation....................................... 20
5.4.3 Check before installation............................................................................................................21
5.5 On-site installation.....................................................................................................................................21
5.5.1 Transportation............................................................................................................................. 21
5.5.2 Robot installation........................................................................................................................ 21
5.5.3 Flange............................................................................................................................................ 24
5.5.4 Power adapter.............................................................................................................................. 24
6 Electrical Connections............................................................................................................ 25
6.1 Electrical layout.......................................................................................................................................... 25
6.2 Robot base.................................................................................................................................................. 26
6.2.1 Robot power supply.................................................................................................................... 27
6.2.2 Powering on the robot................................................................................................................ 27
6.2.3 Handheld emergency stop and enabling device interface................................................... 27
6.2.4 General-purpose DIDO................................................................................................................28
6.2.5 Safety DIO......................................................................................................................................31
6.2.6 Extended EtherNet interface......................................................................................................33
6.2.7 EtherCAT servo drive debug interface...................................................................................... 34
6.2.8 Function buttons on the wrist................................................................................................... 34
6.2.9 Tool interface............................................................................................................................... 35
6.3 Power adapter............................................................................................................................................ 37
6.3.1 Power-on button of the power adapter................................................................................... 37
6.3.2 Power input.................................................................................................................................. 38
6.3.3 Power output................................................................................................................................39
7 Maintenance............................................................................................................................. 40
7.1 Introduction................................................................................................................................................ 40

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xMate ER7 ProHardware Installation Manual III
7.2 Maintenance safety.................................................................................................................................... 40
7.3 Maintenance outline.................................................................................................................................. 40
7.3.1 Battery replacement................................................................................................................... 40
7.4 Maintenance schedule.............................................................................................................................. 43
7.5 Check............................................................................................................................................................ 43
7.6 Cleaning....................................................................................................................................................... 43
8 Zero Calibration....................................................................................................................... 45
8.1 Introduction................................................................................................................................................ 45
8.1.1 Overview........................................................................................................................................45
8.1.2 What is a mechanical zero?........................................................................................................ 45
8.1.3 What is zero calibration?............................................................................................................ 45
8.1.4 When is zero calibration required?........................................................................................... 45
8.2 Calibration method....................................................................................................................................46
8.2.1 Soft calibration.............................................................................................................................46
8.2.2 Mechanical calibration................................................................................................................46
9 Decommissioning.................................................................................................................... 49
9.1 Robot decommissioning...........................................................................................................................49
9.2 Battery..........................................................................................................................................................49
9.3 Recycling......................................................................................................................................................49
Revision History...........................................................................................................................51

202208081959/V0.1 1 Manual Overview
xMate ER7 ProHardware Installation Manual 1

202208081959/V0.1 1 Manual Overview
xMate ER7 ProHardware Installation Manual 3
1 Manual Overview
1.1 About this manual
Thank you for choosing ROKAE robot system.
This manual contains the following instructions for correct installation and use of the
robot:
Mechanical and electrical installation of the robot
Maintenance and calibration of the robot
Please read this manual and other related manuals carefully before installing and using
the robot system.
After reading, keep it properly for future reference.
1.2 Target group
This manual is intended for:
Installation personnel
Maintenance personnel
Please ensure that the above personnel have the necessary knowledge of mechanical and
electrical installation and maintenance, and have received our training.
1.3 How to read the product manual
This manual includes a separate safety section that must be read through before
proceeding with any installation or maintenance procedures.
1.4 Illustrations in this manual
Due to product upgrades or other reasons, some figures in the product manual may differ
from the actual product. However, the operating procedures are correct.
Also, figures of other models may be used to describe some general information.
1.5 Related product documents
This document is the product manual for the xMate ER7 Pro robot and is intended to be
used with the following documents:
xCore Control System User Manual
1.6 Contact
For information about the maintenance and repair of the robot, please contact our
after-sales department or the local reseller.
Get the following information ready before contacting us:
Robot model/serial number
Software name/version
Problems with the system

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4 xMate ER7 ProHardware Installation Manual
2 Safety
2.1 Introduction
This section describes the principles and procedures that must be followed to ensure the
safe use of the xMate ER7 Pro robots. Robot integrators must read and understand the
information listed here before powering on the robot for the first time.
The contents related to the design and installation of the external safety protection devices
of the robot are not covered in this section. Please contact your system integrator to
obtain such information.
2.1.1 Safety responsibilities
ROKAE is dedicated to but not liable for providing reliable safety information. Even if all
safety instructions are followed, there is no guarantee that xMate ER7 Pro will not cause
any personal injury or property damage.
In addition to the safety section, this document contains further safety instructions.
2.1.2 Intended use
The xMate ER7 Pro robots should be used in accordance with local laws and regulations,
and must not be used for any purpose that violates such laws and regulations.
Using the robots in compliance with instructions also means observing the instructions in
the product manual of each component, including the operation, installation, and
maintenance instructions.
The following uses that go against the instructions are prohibited:
Use in human and animal transportation
Use in potentially explosive environments
Use in flammable environments
Use outside the permissible limits
Downhole use
xMate ER7 Pro robots are industrial robots intended to handle tools/end effectors and
fixtures, or to process or transfer components or products. xMate ER7 Pro robots are
equipped with special safety-related features, which are purposely designed to enable
collaborative operation, where the robot system operates without fences and/or together
with a human.
Collaborative operation is only intended for non-hazardous applications, where the
complete application, including the tools/end effectors, workpieces, obstacles, and other
machines, is without any significant hazards according to the risk assessment of the
specific application.
Any use or application deviating from the intended use is deemed to be impermissible
misuse.
This includes, but is not limited to:
Use in potentially explosive environments

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xMate ER7 ProHardware Installation Manual 5
Use in medical and life-critical applications
Use before performing a risk assessment
Use outside of stated specifications
Use as a climbing aid
Operation outside the permissible operating parameters
2.2 Safety notice
2.2.1 Instructions
A risk assessment must be conducted before operating or controlling the robot, and
the robot must be used according to the safety instructions described in this
document.
When the robot is controlled by an external controller using RCI, the safety
protection during the control process must be implemented by the external
controller. Any personal or device safety issues caused by the lack of safety features
in the external controller are not covered by robot safety management.
If you are unsure about the risks during the use of the robot, please contact ROKAE
Technical Support. Problems arising from non-intended use are not covered by our
support.
2.3 Safety protection devices
2.3.1 Emergency stop
2.3.1.1 Definition of emergency stop
Emergency stop possesses the highest priority in the robot system. Pressing the
emergency stop button will trigger the emergency stop and all the functions will be frozen
immediately. The robot will stop running and the power of each joint will be cut off. The
control system will be switched into the emergency stop state, which will be maintained
before releasing the emergency stop manually.
To resume the operation, release the emergency stop button first for the motor of each
joint to execute the power-on command.
Notes
Emergency stop should not be used for normal stops, otherwise it may cause extra and
unnecessary wear to the brake and transmission system, which will eventually reduce
the robot's lifespan.
1
Figure 1. Emergency stop button on the handheld emergency stop and enabling device
No. Name

2 Safety 202208081959/V0.1
6 xMate ER7 ProHardware Installation Manual
1 Emergency stop
button
2.3.2 Enabling switch
2.3.2.1 Enabling device
The enabling device is a special switch with two contacts and three positions, and is also
called a three-position enabling switch (hereinafter referred to as "enabling switch"). It is
used to power on/off the joints in Manual mode to enable robot motions.
The robot will be powered on and able to move only after the enabling switch is pressed
and held in the middle position. Releasing or pressing the switch all the way down will cut
the power off.
P o sition 1
P o sition 2
P osition 3
OFF
OFF
ON
P ress lightly R elease
P ress tightly
R elease
Figure 2. Positions of the enabling switch
Notes
When the enabling switch is pressed and held in the middle position in Manual mode,
the robot will be powered on, the system will enter the Motor On state, and you can jog
the robot or execute a program. The robot will be powered off and the system will
return to the Motor Off state when the switch is released or pressed all the way down.
To ensure safe use of the robot, the following requirements must be observed:
Make sure the enabling switch functions properly in any circumstances.
Release the enabling switch immediately when no robot motion is required
during programming or debugging.
Any person who enters the robot's working space must carry a handheld enabling
device to prevent others from starting the robot without the knowledge of the
involved personnel.
Warning
It is strictly prohibited to use external devices to hold the enabling switch in the middle
position.
2.4 Emergency stop types
Position 1

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2.4.1 Emergency stop
There are two types of stops for robots according to ISO 13850 and IEC 60204 safety
standards:
STOP0: The motor power is switched off and brakes are engaged.
STOP1: The robot comes to a controlled stop. Then the motor power is switched off
and brakes are engaged.
For the xMate ER7 Pro robots, STOP0 is used for collision detection in the case of external
control with RCI and handheld emergency stop signal processing.
2.5 Safety precautions
2.5.1 Operating safety
2.5.1.1 General principles
A few simple principles should be followed in order to operate the robot safely:
Always operate the robot in Manual mode if personnel are inside the safeguarded
space.
Always bring the handheld emergency stop device along when you enter the
safeguarded space so that robot control is in your hands.
Watch out for rotating or moving tools installed on the robot. Make sure those tools
are stopped before you approach the robot.
Watch out for grippers and objects gripped. If the gripper is opened, the workpiece
could fall and cause personal injury or equipment damage. The gripper can be very
powerful and can also cause injuries if not operated in a safe manner.
2.5.2 Recovering from emergency stops
2.5.2.1 Instructions
In the case of an emergency stop, a reset is required to return to normal operation. The
reset is a simple but important procedure. It ensures that the robot system is not returned
to production in a hazardous condition.
2.5.2.2 Emergency stop button and reset
The emergency stop button is located on the handle of the handheld emergency stop and
enabling device. It has a latching feature that must be released in order to remove the
emergency stop condition of the device. This can be done by rotating the button as
marked.
2.5.3 Safety precautions in Manual mode
2.5.3.1 About the Manual mode
In Manual mode, the robot's movement is under manual control. You can only jog the
robot or execute a program when the enabling switch is held in the middle position.

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8 xMate ER7 ProHardware Installation Manual
The Manual mode is used during programming, debugging, and commissioning of the
workstation.
2.5.3.2 Speed limit in Manual mode
In Manual mode, the speed of the robot's end effector is limited to 250 mm/s. This means
that the maximum speed of the robot will not exceed 250 mm/s whether you jog the robot
or execute a program, regardless of the speed set in the program.
2.5.3.3 Bypassing external safety signals
In Manual mode, signals of external safety devices such as the safety gate and safety
grating will be bypassed. This means that the emergency stop will not be triggered in
Manual mode even if the safety gate is open, which facilitates the debugging.
2.5.4 Safety precautions in Automatic mode
2.5.4.1 About the Automatic mode
The Automatic mode is used for running the robot program in production.
In Automatic mode, the enabling switch will be bypassed so that the robot can run
automatically without manual intervention.
DANGER
In Automatic mode, the robot moves at the speed set in the program, which is up to 2
m/s for the end effector. In this mode, personnel must not enter the working space of
the robot to avoid personal injury.
2.5.4.2 Enabling external safety signals
External safety devices such as the safety gate and safety grating will be enabled in
Automatic mode. Opening the safety gate will trigger an emergency stop.
2.5.4.3 Safe troubleshooting in production
In most cases, the robot is part of the production line. Therefore, the impact of a robot
fault may go beyond the workstation itself. Likewise, problems with other parts of the
production line may also impact the workstation. For this reason, a troubleshooting plan
should be designed by personnel who are familiar with the entire production line to
improve safety.
For example, a robot on the production line grabs workpieces from the conveyor belt.
When the robot encounters a fault, the robot maintenance personnel should consider
additional safety measures for working beside the moving conveyor belt to ensure
uninterrupted production while the robot is under repair.
For another example, when removing a welding robot from the production line for routine
maintenance, the robot supplying materials to it must also be stopped to avoid personal
injury.
2.6 Pre-use assessment

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The following tests must be conducted before using the robot for the first time or after
making any modifications. Verify that all safety inputs and outputs are correct and properly
connected. Test that all connected safety inputs and outputs are functioning. To do this,
you must:
Test that the emergency stop button on the handheld emergency stop and enabling
device can stop the robot and engage brakes.
Test that the robot can switch between Manual and Automatic mode.
Test that the 3-position handheld emergency stop and enabling device must be
pressed to enable motion in Manual mode and that the robot is under reduced speed
control.

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10 xMate ER7 ProHardware Installation Manual
3 Product Overview
3.1 Introduction
xMate ER7 Pro is a new generation of flexible collaborative robot that boosts industrial
productivity with highly sensitive force sensing and highly dynamic force control.
3.2 Robot
3.2.1 Overview
The basic configuration of xMate ER7 Pro:
Product name Maximum payload Maximum reach Weight
xMate ER7 Pro 7 kg 850 mm ~29 kg
3.2.2 Robot system
The new-generation flexible collaborative robot xMate ER7 Pro comprises a robot system
(robot and built-in controller), a handheld safety protection device, a power adapter and
cables, and other interfaces and accessories. For details, see Figure 3:
1
2
3
4
Figure 3. Robot system

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xMate ER7 ProHardware Installation Manual 11
No. Name
1 xMate ER7 Pro robot
system
2 Handheld safety
protection device
3 Power adapter and
cables
4 Other interfaces and
accessories
3.2.3 Definitions of rotation directions and coordinate systems
The flexible collaborative robot features 6 degrees of freedom, or 6 joints or axes (see
Figure 4 for details). The definitions of axis rotation directions and coordinate systems are
described below.
Base coordinate system: The -X axis points in the outgoing cable direction of the base, and
the +Z axis in a direction perpendicular to the mounting surface. The Y axis is determined
by the right-hand rule.
Flange coordinate system: When the robot is in the zero pose, the +Z axis points in the
outward direction vertical to the flange surface, and the +Y axis in the Pilot midline
direction. The X axis is determined by the right-hand rule.
Rotation axis directions: When the axes are in the zero position, the A1, A4, and A6 perform
forward rotation in the +Z direction of the base coordinate system, and the A2, A3, and A5
in the +Y direction.

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12 xMate ER7 ProHardware Installation Manual
A1+
A3+
A5+
A7+
A6+
A4+
A2+
法兰坐标系
基坐标系
x
z
x
z
Figure 4. Definitions of robot rotation directions and coordinate systems
3.3 Symbols and labels