Estun ERSA-4C Maintenance Manual
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Estun ERSA-4C Maintenance Manual

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ESTUN ERSA-4C Cabinet
（E-0301EN/01）
MAINTENANCE MANUAL

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Summary of Contents for Estun ERSA-4C

  • Page 1 ESTUN ERSA-4C Cabinet （E-0301EN/01） MAINTENANCE MANUAL...
  • Page 2 ESTUN ERSA-4C Cabinet MAINTENANCE MANUAL E-0301EN/01...
  • Page 3 In this manual, all specifications and information are checked on a regular basis. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. ESTUN assumes no responsibility for any direct or indirect losses arising from use of this manual and products described herein.

  • Page 4: Safety Precaution

    This chapter describes the precautions which must be followed to ensure the safe use of the robot. Before using the robot, be sure to read this chapter thoroughly. ESTUN robots must be transported, mounted and operated in accordance with the applicable national laws, regulations and standards. Appropriate safeguards must be correctly situated to protect the users. Before using (mounting, operating, maintaining, repairing) the robot, be sure to read and understand this manual and its relevant manuals.
  • Page 5 A supplementary explanation help users operating the robot more efficiently. SAFETY OF THE USER The robot should be transported and installed by accurately following the procedures recommended by ESTUN. Wrong transportation or installation may cause the robot to fall, resulting in severe injury or damage.
  • Page 6 SAFETY PRECAUTION ！ Never stand beneath the manipulator in case that the robot move unexpectedly or the system be turned on inadvertently. WARNING ！ Make sure that a CO2 fire extinguisher is always available in case of fire. CAUTION SAFETY OF THE OPERATOR Before operating the robot, check that the SERVO ON indicator goes out when the EMERGENCY STOP button on the right of the front door of the controller and the pendant are pressed.
  • Page 7 SAFETY PRECAUTION  Be sure that the enable switch is effective at any time.  Enable switch must be turned off when pausing, programming or testing the system.  Teach pendant must be taken with the programmer when performing teaching jobs in the work space, to avoid inadvertent operation by unauthorized person.
  • Page 8 For abnormal or emergency situations, e.g. persons trapped in or pinched by the robot, the robot axes should be moved. (Contact ESTUN for more details about dismantling). Small arms can be moved by hand. Lager arms should be moved by crane or other handling equipment.
  • Page 9 SAFETY PRECAUTION LABELS （1）Electric Shock Warning Fig 0.1 Electric Shock Warning This label indicates hazardous voltage or electric shock. （2）High-temperature Warning Fig 0.2 High-temperature Warning 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 protection provision such as heat-resistant gloves.
  • Page 10 SAFETY PRECAUTION （3）No Step-on Warning Fig 0.3 Step-on prohibitive Warning Never step on or climb the robot or controller as it may adversely affect the robot or controller and may get hurt if you lose your footing as well. （4）Personal Injury Warning Fig 0.4 Personal Injury Warning Never enter the operation area while the Manipulator is moving.
  • Page 11 Fig 0.5 Energy Storage Warning Balance cylinder contains spring, high-pressure gas or liquid. Never dismantle a balance cylinder without permission from ESTUN. （6）No Disassembly Warning Fig 0.6 No Disassembly Warning Never perform disassembly arbitrarily where the warning is affixed. Contact ESTUN for disassembly.

  • Page 12: Preface

    PREFACE PREFACE This manual describes the following manipulators: Manipulator Type Load Capacity ERS6-500 ERS6-600 ERS6-700 Related manuals ESTUN Robot ERS Series Mechanical Unit Operator’s Manual ESTUN Robot ERSA-4C Cabinet Maintenance Manual ESTUN Robot ERC20 System Operator’s Manual...

  • Page 13: Table Of Contents

    CONTENT CONTENT SAFETY PRECAUTION ............................. s-1 PREFACE ................................p-1 CONTENT ................................c-1 EQUIPMENT CONFIGURATION ........................ 1 Configuration ..........................1 1.1. Arrangement of Units ........................4 1.2. CHECK AND MAINTENANCE ........................6 Maintenance of the Cabinet ......................6 2.1. Periodic Checks ..........................8 2.2.

  • Page 14: Content

    CONTENT COMMUNICATION CONNECTION ....................31 PERIPFIRAL DEVICE INTERFACE....................32 HANDLING AND INSTALLATION ....................36 Handling Procedure ........................36 12.1. Using a Crane to Move the Cabinet ..................36 12.1.1. Using a Forklift to Move the Cabinet ................... 36 12.1.2. Place of Installation ........................36 12.2.

  • Page 15: Equipment Configuration

    EQUIPMENT CONFIGURATION 1. EQUIPMENT CONFIGURATION 1.1. Configuration Configurations are subject to change according to different types of manipulators, options and applications. Fig 1.1 Exterior View（1）...
  • Page 16 EQUIPMENT CONFIGURATION Tab 1.1 Specifications Model ERSA-4C Size 400*210*510 (mm) Ventilated, unsealed Location Min. Range: 900× 700× 1000 (mm, length*width*height) Weight 20kg Protection Level IP20 Ambient Temperature 0℃~45℃ (Need cooling equipment when ambient temperature exceed 45℃) Input Power Supply Single-phase three wire AC220V 50Hz Max.
  • Page 17 1. LCD display, 2. Emergency button, 3. Mode switch, 4. Keyboard, 5. Indicators, 6. Enable switch 7. Hanger bracket, 8. Cable connection joint, 9. USB interface, 10. Pen Tab 1.2 ESTUN Teach Pendant Parameters Teach pendant type ESTUN Teach pendant ERT72...

  • Page 18: Arrangement Of Units

    EQUIPMENT CONFIGURATION 1.2. Arrangement of Units ！ Regenerative resistor reaches extremely high temperature (max. 100-200℃) during system operation. Never touch the regenerative resistor. WARNING 温皓 机器人控制柜 ERS6-E2C-P-A Fig 1.3 Upper Layer Arrangement 布置图 温皓 机器人控制柜 ERS6-E2C-P-A...
  • Page 19 EQUIPMENT CONFIGURATION 布置图 温皓 机器人控制柜 ERS6-E2C-P-A Fig 1.4 Sub layer Arrangement Power supply filter: Filter for power supply to guarantee its quality. Main circuit servo driver on-off unit: Turn on or off the main circuit of servo driver. Turn off automatically when high 布置图...

  • Page 20: Check And Maintenance

    2.1. Maintenance of the Cabinet （1）Check if the Breaker on the Cabinet is Firmly Closed The ERSA-4C cabinet has a fully sealed construction, designed to keep external air containing oil mist out of the cabinet. The breaker must be turned to off before maintenance.
  • Page 21 CHECK AND MAINTENANCE Tab 2.1 Power Supply Voltage Confirmation Measuring Items Correct Value Correlate voltage 220V（+10%，-15%） （7）Open Phase Check Tab 2.2 Open Phase Check List Check Item Contents Confirm if the lead cable for the power supply is wired as shown in the following. If the wiring is Lead Cable Check wrong or broken, repair it.

  • Page 22: Periodic Checks

    CHECK AND MAINTENANCE 2.2. Periodic Checks ：Check） （●：Replace Check intervals Maintenance Check and Check points Maintenance method maintenance items Daily 1 year 4 years 5 years 8 years months  Cabinet Spatters or dusty Confirm and remove it.  labels Peeling or damage or dirt Confirm and clean it.

  • Page 23: Power Unit

    POWER UNIT 3. POWER UNIT After filtering, the 380V three-phase AC power is transformed to 220V by a transformer. (This is for cabinet with 200V servo motors. Cabinet with 400V servo motors has no transformer). When temporary voltage interruption or drop or any driver alarm occurs, turn off the power supply and servo power before maintenance.
  • Page 24 POWER UNIT Fig 3.2 Power supply（2） （ERS6-E2C-P-A） Pin E002 and E006 correspond to pin 1 and pin 2 of DB9 plug. A set of emergency stop signal or a ！ short-circuit should be connected between the two pins. Pin E004 and E008 correspond to pin 3 and pin 4 of DB9 plug. A set of emergency stop signal or a CAUTION short-circuit should be connected between the two pins.

  • Page 25: Control Unit

    CONTROL UNIT 4. CONTROL UNIT 4.1. Introduction Control unit is the motion control center of the robot system. The unit, which performs motion control and coordinate control, is a kernel unit to receive instructions from the teach pendant and send control signals from the terminals. COM2 COM1 Power Supply...

  • Page 26: Notes

    CONTROL UNIT 4.3. Notes COM1 电源 Fig 4.2 Dimension of Control Unit 22.5...

  • Page 27: Servo-Drive Unit

    SERVO-DRIVE UNIT 5. SERVO-DRIVE UNIT Do not connect the servomotor directly to the local electrical network. Failure to observe this may result in damage to servomotor. Do not plug or unplug connectors from servo drive when power is on. Failure to observe this may result in damage to servo drive and servomotor. Please note that even after power is removed, residual voltage still remains in the capacitor inside the servo drive.
  • Page 28 SERVO-DRIVE UNIT Charge indicator Lights when the main circuit power supply is ON and Power-on indicator stays lit as long as the main Lights when the controller is CHARGE POWER circuit power supply turned ON. capacitor remains charged. Connector for communication Main circuit power supply terminals Connecting...

  • Page 29: Input / Output Unit

    INPUT / OUTPUT UNIT 6. INPUT / OUTPUT UNIT 6.1. Coupler: EE-R00 6.1.1. Functions A coupler works as a hub between extensive modules and EtherCAT main station. The functions are shown as below:  Receive and execute the instructions from the main station. ...

  • Page 30: Technical Parameters

    INPUT / OUTPUT UNIT Tab 6.1 RJ45 interface signal definitions Signal Power interface is used to connect power supply. Its signal definitions are shown in the following table. Tab 6.2 Power supply interface definitions Signal NULL 24V+ Extensive interface is used as the power supply and communication interface with extensive modules. （3）LED indicators EE-R00 has these LED lamps: Sys/Rdy, Run and Err, and indicators on RJ45 interface.

  • Page 31: Digital Input: Er-1311

    INPUT / OUTPUT UNIT Technical parameters Specification Size (W * H * D) 112mm× 113mm× 45mm Weight About 400g Working temperature 0℃~40℃ ﹣25℃~55℃ Storage temperature 50％~95％, Relative humidity Relative humidity not less than 95％ at 0℃ Relative humidity not less than 50％ at 40℃ Anti-shock and vibration performance Consistent with EN 60068-2-6/EN 60068-2-27/29 Standard Anti electro-magnetic interference/radiation performance...
  • Page 32 INPUT / OUTPUT UNIT logical signal acquisition, and one extended interface. Signal interface definition of ER-1311 is shown as below. Tab 6.6 Signal port definition of ER-1311 Signal Signal NULL NULL NULL NULL COM1 COM2 COM1 COM2 Extensive interface is used as the power supply and communication interface with extensive modules. Pin 1~ pin 8 are reserved for system use.

  • Page 33: Technical Parameters

    INPUT / OUTPUT UNIT Channel indicators I1~I16 indicate communication condition of each channel. Tab 6.10 ER-1311 Channel indicators definitions Light condition Definition Light off The channel is abnormal. Light on The channel is normal. 6.2.3. Technical Parameters Technical parameters of digital input module are show in the following table: Tab 6.11 ER-1311 technical parameters Parameters Description...

  • Page 34: Signal Definition

    INPUT / OUTPUT UNIT 6.3.2. Signal Definition （1）Interface 信号接口 Signal Interface 拨码开关 Dial Switch 通道指示灯 Channel Indicators 电源指示灯 Power Indicator 信号接口 Signal Interface Fig 6.3 Interface of ER-2341 （2）Interface definition Digital output module has two external interfaces: one signal interface, which is a 24V DC logical output interface for 24V DC logical signal output, and one extended interface.

  • Page 35: Technical Parameters

    INPUT / OUTPUT UNIT Tab 6.13 Definition of Pin1~Pin8 & Pin16 Description Line No. of cabinet Operation indicator Alarm indicator Output when there is no teach pendant Output when module enabled (not supported currently) Emergency stop output (output when there is no emergency stop signal) System reserved System reserved System reserved...

  • Page 36: Mounting And Networking Of I/O Sub-Station

    INPUT / OUTPUT UNIT Parameters Description Power Supply Mode TBUS ( No external wiring is required.) ≤100mA TBUS Consumption Current Networking Mode Set module address by dial switch Size (W× H× D) 112mm× 113mm× 22.5mm Weight About 200g Working Temperature 0℃~40℃...

  • Page 37: Notes For Mounting

    INPUT / OUTPUT UNIT 卡住一侧 Stick one side 注意吻合 Clip into proper position 依次安装 Install in sequence Fig 6.4 Mounting the modules  Install T-BUS terminals: Install T-BUS terminals on standard U35 guide rail. Generally, the number of T-BUS terminals should match the number of modules.。...

  • Page 38: Dismounting

    INPUT / OUTPUT UNIT ER-1311 ER-2341 Fig 6.5 Sequence of Mounting （2）Mounting Direction Mount the guide rail horizontally instead vertically when mount the sub-station. Correct mounting direction Wrong mounting direction Fig 6.6 Mounting Direction 6.4.4. Dismounting There is a spring locks under each coupler and extensive module, which will well lock the guide rail automatically. When dismount the module, use a screwdriver to pull out the lock, then push up the module vertical to guide rail.

  • Page 39: Id Set

    INPUT / OUTPUT UNIT 2.Push up the module 2.推起模块 1.拉出锁扣 1.Pull put the lock Fig 6.7 Dismounting the module 6.4.5. ID Set In order to distinguish extensive module in EtherCAT sub-station, each module has a dial switch on the top side, which is used to set its ID address in the sub-station.

  • Page 40: Notes

    INPUT / OUTPUT UNIT 6.4.7. Notes （1）Keep Away From Interference Keep away from high-power electrical apparatus in a minimum 400mm distance, such as frequency converter, contactor, servo driver, etc., as shown in the following figure. Interference Fig 6.9 Keep Away From Interference （2）Mounting Position Distributed sub-module should be mounted as in the following figure, where is easy to wiring and mounting.

  • Page 41: Module Dimensions

    INPUT / OUTPUT UNIT 6.4.8. Module Dimensions （1）Coupler Dimensions Fig 6.11 Coupler Dimensions （2）Extended Module Dimensions 22.5 Fig 6.12 Extended Module Dimensions...

  • Page 42: Relay Module Unit

    RELAY MODULE UNIT 7. RELAY MODULE UNIT Relay module (type: 11261100001) is integrated with 18 LED indicators to indicate current condition, which is important to protect the internal circuit Fig 7.1 Relay module Diagram Indicator 1: Servo driver power supply indicator. Light on: Power on. Light off: Power off Indicator 2: Chief servo alarm indicator.

  • Page 43: Replacing

    REPLACING 8. REPLACING 8.1. Replacing Fuses ！ Power supply must be turned off before replacing fuses. CAUTION Replacement procedure: （1） Open the fuse slot and take out the fuse. （2） Install the new fuse of same type. （3） Close the slot firmly.

  • Page 44: Block Diagram

    BLOCK DIAGRAM 9. BLOCK DIAGRAM The following figure shows the block diagram of electric interface of the cabinet. Factory Monitor Extensive device (PLC, sensors, etc.) ESTUN Teach pendant (option) ERSA-4C Cabinet Manipulator (DEG) Power Supply (AC 380V) Fig 9.1 Block Diagram...

  • Page 45: Communication Connection

    CONNECTION COMMUNICATION CONNECTION Fig 10.1 Communication connection between controller and servo motors...

  • Page 46: Peripfiral Device Interface

    PERIPFIRAL DEVICE INTERFACE PERIPFIRAL DEVICE INTERFACE The figure below shows the interface and its definition of ESTUN controller and peripheral device. Fig 11.1 Input module terminals（1） ！ Pin 5 &6 of DB plug should connect to safe door signal, or a short-circuit.
  • Page 47 PERIPFIRAL DEVICE INTERFACE Fig 11.2 Input module terminals（2） ！ IO extensive pins are all connected to DB50 plug. CAUTION...
  • Page 48 PERIPFIRAL DEVICE INTERFACE Fig 11.3 Output module terminals（1） ！ IO extensive pins are all connected to DB50 plug. CAUTION Fig 11.4 Output module terminals（2）...
  • Page 49 PERIPFIRAL DEVICE INTERFACE ！ IO extensive pins are all connected to DB50 plug. CAUTION Fig 11.5 DB50 plug terminals...

  • Page 50: Handling And Installation

    HANDLING AND INSTALLATION HANDLING AND INSTALLATION 12.1. Handling Procedure Crane, sling, and folklift operations must be performed only by authorized personnel. Failure to ！ observethis caution may result in injury or damage. Avoid jarring, dropping, or hitting the cabinet CAUTION during handling.

  • Page 51: Connection

    HANDLING AND INSTALLATION  The cabinet must be installed in a location from which you can easily inspect it when the door is open.  The cabinet must be installed at least 500mm from the nearest wall to allow maintenance access. 12.4.

  • Page 52: Connection Methods

    HANDLING AND INSTALLATION 12.4.2. Connection Methods （1）Connect power cables  Remove the package, and take out the power cables. Connect the cable to the connectors on each side of the cabinet  Connect the manipulator to the cabinet. Confirm the shape and size of the cable connector, the key fitting, and the position of the pins of the manipulator. Push the cable connector into the manipulator side connector firmly, and tighten securely.

  • Page 53: Appendix Alarm Display

    APPENDIX APPENDIX ALARM DISPLAY Alarm Alarm Alarm Name Meaning Display Output ╳ A.01 Parameter breakdown The checksum results of parameters are abnormal. ╳ A.02 AD shift channels breakdown AD related electrical circuit is faulty. Overspeed The servomotor speed is excessively high and the ╳...
  • Page 54 APPENDIX Absolute encoder multiturn information Absolute encoder multiturn information is faulty. ╳ A.45 error Absolute encoder multiturn Absolute encoder multiturn information overflow. ╳ A.46 information overflow ╳ A.47 Battery voltage below 2.5V Absolute encoder multiturn information is lost. ╳ A.48 Battery voltage below 3.1V Battery voltage is too low.

  • Page 55: Revision Record

    Revision Record Revision Record Revision Date Contents 2017.11...

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