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EFORT ER15-4-1600 Operation And Maintenance Manual

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ER15-4-1600 Electrical Operation and
Maintenance Manual for Industrial Robot
EFORT INTELLIGENT EQUIPMENT CO., LTD
HOT LINE（Tel）：+86-400-0528877

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Summary of Contents for EFORT ER15-4-1600

  • Page 1 ER15-4-1600 Electrical Operation and Maintenance Manual for Industrial Robot EFORT INTELLIGENT EQUIPMENT CO., LTD HOT LINE（Tel）：+86-400-0528877...
  • Page 2 This manual is only used as a guide for the normal operation of the product. During the use of the product, EFORT will not be liable for personal injury and property damage caused by reasons other than product defects. EFORT solemnly recommends that: personnel involved...

  • Page 3: Table Of Contents

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Content Chapter 1 Safety Precautions...................... 4 1.1. Safety instructions......................4 1.2. General safety guidelines..................... 4 1.3. Safety precautions in each work process..............6 1.3.1. Safety of robot installation and connection............7 1.3.2. Safety before starting the robot................. 7 1.3.3.
  • Page 4 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Chapter 3 Robot Electric Control Cabinet System..............27 3.1. Robot control cabinet....................27 3.2. Safety function unit....................29 3.3. Human-computer interaction unit................31 3.3.1. Button operation panel..................31 3.3.2. Teach Pendant (enable/hand press)..............31 3.4.
  • Page 5 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 4.4.4. Check the working condition of main electrical components......50 4.4.5. Check the emergency stop switch..............50 4.5. Battery pack replacement...................51 4.6. Zero point quick recovery method................52 4.7. Cleaning activities......................52 4.7.1. Overview......................52 4.7.2.

  • Page 6: Chapter 1 Safety Precautions

    For safety, compliance with the requirements of this manual and other EFORT manuals is only a minimum requirement. As a general rule, the safety-related information recorded in this manual does not fully cover all aspects of the robot application system.
  • Page 7 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 4. Make sure that the emergency stop equipment is unobstructed, and no debris can be piled up in front of the emergency stop equipment. 5. It is forbidden to use the main machine to use unsuitable materials, adjust or modify the robot inappropriately.

  • Page 8: Safety Precautions In Each Work Process

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual area. 11. Before starting the automatic mode, all temporarily disabled safety functions must be restored to their normal working conditions. WARNING Gravity and release of the braking device may cause a fall hazard.

  • Page 9: Safety Of Robot Installation And Connection

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual from collision and impact. 8. When the total power supply at the installation site is turned on, the power cable of the control cabinet must not be connected. Otherwise it will be extremely dangerous and may cause electric shock.

  • Page 10: Robot Startup Safety

    1. Before operation, please read and understand all manuals, specifications and other relevant documents provided by EFORT. In addition, fully understand the operation, teaching, maintenance and other processes. At the same time, confirm that all safety measures are in place and effective.

  • Page 11: Trial Run Safety

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual same time, confirm that the safety devices are functioning properly before starting the robot. 4. If there are several operators working together in the robot application system, make sure that all operators and their related personnel know that the robot has been activated before they can start the robot.

  • Page 12: Safety During Teaching

    .3.5 Safety during teaching Danger EFORT recommends that the teaching should be completed outside the safety fence. But if you really need to enter the safety fence, please strictly abide by the following matters, and refer to the following national/international safety standards.
  • Page 13 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 4. Before entering the safety fence, the instructor must turn the teaching switch on the teaching pendant to the manual position to prevent the control cabinet mode switch from turning to the automatic mode and causing an accident. Once...

  • Page 14: Safety During Automatic Running

    12. After the robot's movement teaching is completed, please set the robot's software limit to a little bit outside the robot's teaching movement range. For how to set the software limit, please refer to the EFORT industrial robot operation manual。...

  • Page 15: Safety During Fixing

    Before servicing, please confirm that all switches are functioning properly. 1. Before operation, please read and understand all manuals and other related documents provided by EFORT. In addition, fully understand the operation, teaching, maintenance and other processes. At the same time, confirm that all safety measures are in place and effective.

  • Page 16: Safety During Inspection And Maintenance

    9. When replacing, please use only the spare parts provided by EFORT. 10. Before removing the servo motor of any joint shaft, please support the robot arm with a suitable lifting device. Removing the motor will invalidate the brake mechanism of the shaft, and if there is no reliable support, the arm will fall.
  • Page 17 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual documents provided by EFORT. In addition, fully understand the operation, teaching, maintenance and other processes. At the same time, confirm that all safety measures are in place and effective. 2. Before inspection and maintenance work, remove unnecessary objects and clear the passage to the installation location.
  • Page 18 11. Please use only the parts approved by EFORT to replace. Also, during inspection/maintenance, be sure to use the teaching mode and move the robot at the lowest possible speed.
  • Page 19 18. Do not change or modify the robot without the permission of the company. In the event of unauthorized modification, EFORT will not be held responsible. 19. A variety of data backup batteries are built into the robot arm and control cabinet.

  • Page 20: Chapter 2 Installation And Commissioning

    Before starting any installation work, it is very important to check all the safety information. Please be sure to carefully read the "EFORT Robot Safety Manual" and Chapter 1 of this manual. There are several general safety aspects that must be paid attention to. More specific safety information for hazards and safety risk avoidance when performing operating procedures .2 Unpack...

  • Page 21: Start The Robot In A Cold Environment

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Minimum ambient temperature 0℃ Maximum ambient temperature +45℃ Maximum ambient humidity 40%-90%（40℃） .2.2 Start the robot in a cold environment This procedure describes how to start the robot in a cold environment. The heating rate must be adjusted according to the ambient temperature and the operating procedures used.

  • Page 22: On-Site Installation

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 2-1 Robot control cabinet dimensions When the control cabinet is placed, please do not block the vents of the electric cabinet, which will affect the heat dissipation of the electric cabinet. Please leave more than 150mm space around the electric cabinet.
  • Page 23 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual In principle, cranes should be used for robot handling operations. First, set up the robot in the posture shown in Figure 2-2. Then, rotate the base and install 4 eye bolts (M10), and lift with 4 steel cables. It is recommended that the length of the steel cable is 1.5m, and rubber hoses should be used to protect the part...

  • Page 24: Control Cabinet Transport

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual .3.3 Control cabinet Transport Transport method 1 When moving the electric control cabinet of the robot, first place the discharge cabinet in the posture shown in Figure 2-4, and then use two soft slings to lift the two M10 eyebolts on the top of the electric cabinet. It is recommended that the length of the soft sling should not be less than 2m, and rubber hoses should be used to protect the part where the soft sling is in contact with the electrical cabinet.

  • Page 25: Robot Power

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Warning 1. The cable connection operation must be carried out after the power supply is cut off. 2. Do not wind the excess part (more than 10m) of the robot connection cable in a coil.
  • Page 26 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Table 2-7 Robot cables Cable category description Robot power brake The driving power is transmitted from the driving device in the control line cabinet to the robot motor. Robot encoder line Transmit the encoder data to the drive serial measurement circuit board.

  • Page 27: Introduction To External Emergency Stop

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Reserved signal line Main power line Encoder cable Power brake line Figure 2-7 Schematic diagram of robot control cabinet connection .5 Introduction to external emergency stop The emergency stop buttons include the emergency stop button of the teach pendant, the emergency stop button of the control cabinet, and the external emergency stop button.
  • Page 28 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual The emergency stop function can only be used for its specific purpose and established conditions. The emergency stop function is used to stop the device immediately in the event of an emergency.

  • Page 29: Chapter 3 Robot Electric Control Cabinet System

    This section aims to explain the components of the ER15-4-1600 robot electric control cabinet (model: EC-M4) Figure 3-1 EC-M4 control cabinet ER15-4-1600 robot uses the control cabinet EC-M4, the main power supply of the control cabinet is AC220V. 第 27 页...
  • Page 30 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-2 The composition of the robot system Basic parameters of control cabinet Table 3-1 Control cabinet parameters Control cabinet model EC-M4 IP rating IP54 IO port 16 digital inputs/16 digital outputs (support expansion) communication method TCP/IP、Modbus-TCP、CAN、ProfibusDP、EtherCAT...

  • Page 31: Safety Function Unit

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Left component mounting plate Right component mounting plate Front component mounting plate .2 Safety function unit This safety circuit includes electric cabinet emergency stop, external emergency stop short wiring, teach pendant emergency stop, safety relay, safety relay expansion module and contactor...
  • Page 32 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual The safety circuit is implemented using safety relay RT6 and expansion module E1T: The safety loop adopts dual loop redundancy design, and the dual loop is high and low level error-proof design. RT6 safety relay pins S23 and S24 are a pair of 24V loops, S13 and S14 are a pair of 0V loops, and the safety loop passes the teach pendant first.

  • Page 33: Human-Computer Interaction Unit

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual .3 Human-computer interaction unit .3.1 Button operation panel The buttons on the front panel of the robot electric control cabinet are shown in Figure 3-5, including main power switch, servo confirm button (Power), mode switch (Servo on), hot plug button (Hot plug),...
  • Page 34 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-6 EFORT teach pendant 1、Functional area and interface Figure 3-7 Function definition of teach pendant Table 3-3 Functions of each part of the teach pendant Name Description Film panel 3 Company LOGO painting...
  • Page 35 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-8 Right button Table 3-4 Right button definition Name Name Three-color light Axis 4 movement- Start Axis 5 movement+ time out Axis 5 movement- Axis 1 movement+ Axis 6 movement+ Axis 1 movement-...

  • Page 36: Brake Release Unit

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Multifunction key F2 Back to homepage Multi-function key F3 tentatively determined: program operation speed- mode (continuous, single step entry, single step skip, etc.) Multifunction key F4 Speed+ Turn page Servo power up 2、How to hold the teach pendant...

  • Page 37: Manually Release The Motor Holding Brake

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-11 Schematic diagram of brake release button Manually release the motor holding brake .4.3 The motor brakes of each axis of the robot body should be manually released when the power is on.

  • Page 38: Hot-Swappable Unit

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Danger When the robot motor brake is released, the robot axis may move very fast, and sometimes it is unpredictable how it will move! So before releasing the motor holding brake, please consider: 1.
  • Page 39 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 、 Keep pressing button Unplug teach pendant 2、 3、 After inserting the emergency stop short connector and tightening it, release the hot swap button Figure 3-12 Pull out steps of the teach pendant Hot insertion of teach pendant: 1.

  • Page 40: Faq

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Note: Both the teach pendant connector and the emergency stop short connector must be turned to the fully unlocked state (see the unlock symbol at the far left) before they can be inserted to prevent short circuits.

  • Page 41: Servo Drive Unit

    10 M5*16 screws. When installing, make sure that the corresponding axis wiring is correct to avoid wiring errors that may cause runaway. If you need to replace the drive, please contact EFORT after-sales service to replace the drive and drive parameters.
  • Page 42 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-14 Drive interface Table 3-6 Introduction to drive interface functions Name Mark Signal name content Regenerative Regenerative resistor connection P port resistor B1/B2 Regenerative resistor connection N port connection AC control power input...

  • Page 43: Motion Control Unit

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Primary- L3 (when single phase is used, the phase Power 3 should not be connected） Motor power Motor power U phase output output Motor power V phase output U/V/W Motor power W phase output...
  • Page 44 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Table 3-7 IO output definition Explanation System occupation System occupation Servo confirmation status System occupation System occupation Custom Custom Custom IO power supply 24V+ IO power supply 24V- Except for the IO output signal ports with the words "user-defined", the other ports are fixed functions used by the system and cannot be changed.

  • Page 45: Controller Extension Io

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual used by the system and cannot be changed. Users can expand the IO or remote IO modules as needed. Please consult EFORT for details. IO input signal No. 7 pin, which can be used as the input signal of the controller after the safety door and safety grating function is triggered.
  • Page 46 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 2. Connect the bus coupler to the bus base module and install it on the DIN rail 3. Install the controller and IO module on the bus coupler and bus base module respectively 4.

  • Page 47: Motion Control Card

    (2) Be sure to use the motion control card recommended by EFORT. Other motion control cards not recommended by EFORT cannot guarantee the normal operation of the controller functions.
  • Page 48 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 3-16 Schematic diagram of motion control card 3、Steps to pull out the motion control card Please follow the steps below to insert the motion control card: (1) Turn off the power of the control cabinet (2) Press the eject button.

  • Page 49: Chapter 4 Maintenance

    It is based on the maintenance plan introduced at the beginning of this chapter. The plan contains information on required maintenance activities (including maintenance intervals) and refers to the operating procedures for these activities. For the maintenance activities of the robot body, please refer to "ER15-4-1600 Robot Machinery Maintenance Manual" Warning 1.

  • Page 50: Maintenance Plan

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 8. In the case of replacement (due to cutting, tearing, etc.), the cable connecting the electrical cabinet to the facility power outlet must have a suitable cross-sectional area to meet the cable length and installed power.

  • Page 51: Inspection Activity

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Electric Whether the pressure seal of the √ √ √ cabinet door is deformed, and the cabinet is Check sealing sealed Information Whether the label is dirty or √ Check label damaged Robot wiring 1.

  • Page 52: Check Harness

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual EFORT logo (upper right corner of the electric cabinet door), (1) Warning label "High voltage control cabinet electric shock hazard", (the upper part of the electric cabinet door lock), (1) Warning label "Always keep the cabinet door closed", (the upper part of the electric cabinet door lock), (1) Warning label "ventilation attention"...

  • Page 53: Battery Pack Replacement

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Manual inspection Whether the emergency stop of the electric control cabinet can be pressed and restored normally Can the Teach Pendant Emergency Stop be pressed and resumed normally Whether the external emergency stop can be pressed and resumed normally .5 Battery pack replacement...

  • Page 54: Zero Point Quick Recovery Method

    .7.1 Overview To ensure a long uptime, please clean the ER15-4-1600 regularly. The cleaning interval depends on the environment in which the robot works. According to the different protection types of each part of the ER15-4-1600 robot, different cleaning methods can be used.

  • Page 55: Matters Needing Attention

    3. Never aim the cleaning water column at the connector, contact, seal or gasket. 4. Never use compressed air to clean the robot. 5. Do not use solvents that are not approved by EFORT to clean the robot. 6. The distance of spraying cleaning fluid should not be less than 0.4 m.

  • Page 56: Chapter 5 Repair And Mending

    .2 Replacement of core components This chapter describes the recommended replacement and maintenance work and maintenance activities for the main components of the ER15-4-1600 robot control cabinet. It consists of separate operating procedures, each of which describes specific maintenance activities.

  • Page 57: Replacing The Safety Relay

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual .2.2 Replacing the safety relay Figure 5-2 Safety Relay The following table details the steps to replace the safety relay Table 5-2 Safety relay replacement steps Operation steps Disconnect power to the cabinet.

  • Page 58: Replace The Switching Power Supply

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Table 5-3 Drive replacement steps Operation steps The drive parameters need to be changed for backup, and the robot restores the mechanical zero position. Disconnect power to the cabinet. Disconnect the wiring terminals on the drive. These terminals need to be marked with relevant numbers to ensure that they will not be connected incorrectly when reconnecting.

  • Page 59: Replace The Fan

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 5-5 Fuse and fuse The following table details the steps to replace fuses, fuses, and fuses Table 5-5 Steps for replacing fuses and fuses Operations step Disconnect the power supply of the control cabinet;...

  • Page 60: Fault Display

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 5-6 Fan The following table describes the steps to replace the fan Table 5-6 Fan replacement steps Operations step Disconnect power to the cabinet. Remove the M4 Phillips screw from the fan mounting plate and take it out.
  • Page 61 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 5-7 System login interface Erro Alarm clear Detail error description Figure 5-8 Teach Pendant Alarm 第 59 页...

  • Page 62: View Event Log

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual View event log Figure 5-9 Event log interface Number meaning: 1. Event log display area. Display the relevant code, date and content of the event. 2. Event description area. Show the cause of the specified event and the solution given.

  • Page 63: Controller Alarm Fault Light

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Figure 5-11 Clear event log operation Controller alarm fault light Figure 5-12 Controller alarm Table 5-7 LED light information description What LED stands for Info code Color Alarm code L7 flashing: non-serious error alarm; L8 flashing: serious error alarm.

  • Page 64: Abnormal Diagnosis And Treatment Suggestions

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual yello The controller has been supplied with 24V power CAN bus channel 1 CAN1 UP green CAN bus channel 1 CAN1 DOWN CAN bus channel 2 CAN2 UP green CAN bus channel 2...
  • Page 65 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 1. The upper device uses communication to modify parameters and write to EEPROM too 1. Parameters are read and written too frequently. Please check whether there are frequently; instructions to frequently modify parameters and Err.003: Failure in...
  • Page 66 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual cable correctly; 6. Check whether the resistance between the cables of the motor is the same, if they are different, replace the motor; 7. Reduce the load. Increase the capacity of the drive and motor, and extend the acceleration and deceleration time;...
  • Page 67 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 3. Abnormal communication verification; 1. The serial encoder is disconnected Err.014: Encoder data or has poor contact; Check the wiring, or replace the encoder cable; is abnormal 2. Abnormal reading and writing of data stored in serial encoder;...
  • Page 68 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 1. AI wiring error; Err.023: AI sampling Connect the AI input correctly, and set the input 2. The external input voltage is too voltage is too large voltage within ±10V; high; 1. Reduce the speed command;...
  • Page 69 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual deviation (P00.19) The value set is too smoothing functions such as adding position small; command acceleration and deceleration time 6. Servo drive/motor failure; parameters; 7. The brake is released abnormally, 5. Confirm whether the position deviation fault the motor is blocked or driven by value (P00.19) is appropriate and set the value...
  • Page 70 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual following reasons: 2. Confirm that the motor is not blocked or driven 1. The motor UVW wire or encoder by external force, and confirm that the wire is bad or the connection is loose;...
  • Page 71 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual wire, and the input wire and power wire are wired separately; 1. Confirm whether the external encoder cable is connected correctly, and replace the external Err.051: Full closed 1. The external encoder is abnormal;...
  • Page 72 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Check whether there is interference in the In CANOPEN IP or CSP mode, the Err.073: CANOPEN communication line, and confirm that the host synchronization clock is lost more track buffer underflow computer is operating normally; the NMT node is than 2 times;...
  • Page 73 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 1. The motor UVW wire or encoder by external force, and confirm that the wire is bad or the connection is loose; mechanical brake (brake) has been opened; 2. The motor is blocked or driven by 3.
  • Page 74 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Energy consumption braking power overload: 1. Wrong wiring or poor contact of braking resistor; 1. Check whether the wiring of the braking 2. When using built-in resistors, the resistor is normal; default short wiring may fall off;...

  • Page 75: Chapter 6 Deactivation

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Chapter 6 Deactivation .1 Introduction This chapter describes the environmental information that is recommended for the ER6-2000 robot to be deactivated and the precautions for the disposal of abandoned robots. Proper handling can effectively prevent the harm to the environment and avoid personal injury.

  • Page 76: Annex 1 Schematic Diagram

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Annex 1 Schematic diagram 第 74 页...
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  • Page 92: Appendix2 Spare Parts

    ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Appendix2 Spare parts Name Model Remarks 11500010206 Controller RP1 Controller 10900022461 Motion control card 10900011262 ROBOX bus module 10900015264 Digital input and output module Teach Pendant 10900019866 Teach Pendant Wire Harness Wiring...
  • Page 93 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual 10900018947 Contactor accessories Contactor 10900019492 Contactor Power brake 10900023245 Robot wiring line harness\EC-M4-SC-PB-8M-V1.2\\\ Signal line 10900023246 Robot wiring harness\EC-M4-SC-S-8M-V1.2\\\ Pipeline 10900023247 Robot wiring harness\EC-M4-C00-V1.2\\\ package 10900000251 Relay-PYF14A-E Relay 10900000252 Relay-MY4N-GS 10900017725 Relay-MY2N-D2-GSDC24...
  • Page 94 ER15-4-1600 Industrial Robot Electrical Operation and Maintenance Manual Service Hotline: +86-400-0528877 This product's rated product power, specifications, external dimensions, etc. subject to change without modification without notice. Technical data and illustrations are for reference only, and the right to change is reserved 埃夫特智能装备股份有限公司...

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