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CMA Dishmachines GR Series Operation And Maintenance Manual

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GR Painting Robot Series
Electrical Operation and Maintenance Manual
Version No.：ZL-GR6150-003-V1
Issue Date: January, 2020
The copyright is reserved for CMA (WUHU) Robotics Company Limited
For customer use only and any unauthorized use of this manual is strictly prohibited
CMA (WUHU) Robotics Company Limited
No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province
TEL：400-052-8877
CMA
CMA (WUHU) Robotics Company Limited
Supplier of Intelligent Painting Robots

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  • Page 1 GR Painting Robot Series Electrical Operation and Maintenance Manual Version No.：ZL-GR6150-003-V1 Issue Date: January, 2020 The copyright is reserved for CMA (WUHU) Robotics Company Limited For customer use only and any unauthorized use of this manual is strictly prohibited CMA (WUHU) Robotics Company Limited No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province TEL：400-052-8877 CMA (WUHU) Robotics Company Limited...
  • Page 2 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Statement Thank you for purchasing the painting robots designed by CMA (WUHU) Robotics Company Limited (CMA, in short). The contents stated in the manual are directly related to your safety, lawful rights and responsibilities. Please ensure to read through the manual and correctly set the operation parameters before use.
  • Page 3 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 About the Manual The target readers of the manual include professionals involved in robot operation, maintenance and technical service. This manual intends to explain the electrical maintenance instructions of the GR6150 painting robot and the matters needing attention during maintenance.
  • Page 4 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 CMA is not responsible for any consequence caused by unauthorized modification of the  robot which is not within the scope of the company’s warranty. CMA (WUHU) Robotics Company Limited...

  • Page 5: Table Of Contents

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Contents CHAPTER ONE SAFETY ..............1 1.1 S ..........................1 AFETY NSTRUCTIONS 1.2 A ..........................1 BOUT AFETY IGNS 1.3 S ..........................3 AFETY EGULATIONS 1.3.1 T : .............3 AFETY EGULATIONS OLLOWED BY THE OBOT YSTEM 1.3.2 S ............3 AFETY EGULATIONS THE...
  • Page 6 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 2.2.1 U ......................12 NPACKING AND NSPECTION 2.2.2 Preparation Before Installation ......................14 2.2.3 S .................... 14 TORAGE NVIRONMENT FOR OBOT 2.2.4 Operation Environment for Robot ....................15 2.2.5 Start Robot in Cold Environment ....................15 2.3 C ............................
  • Page 7 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 2.3.13 E ) ................... 39 THERNET ONNECTION TANDARD 2.3.14 C (PROFI A ) ..........40 ONNECTION OF ROFIBUS ODULE CCESSORIES CHAPTER THREE CONTROL CABINET ............43 3.1 D .......................43 ESCRIPTION OF LECTRIC ABINET 3.1.1 Basic Parameters ..........................45 3.1.2 L .....................
  • Page 8 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.4.3 S ..........................64 ERVO RIVE 3.4.4 B ..........................69 ODULE 3.5 S PLC .............................70 AFETY CHAPTER FOUR MAINTENANCE ............72 4.1 I ............................72 NTRODUCTION 4.2 M ..........................72 AINTENANCE LANS 4.2.1 C ..............73 LEAN THE NTERIOR OF THE LECTRICAL...
  • Page 9 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.4.3 R ..................84 EPLACE THE ADIATOR OOLING 4.4.4 R ..................85 EPLACE THE OOLING AN OF THE RIVE CHAPTER FIVE TROUBLESHOOTING ............86 5.1 T ........................ 86 ROUBLESHOOTING ETHODS CMA (WUHU) Robotics Company Limited...

  • Page 10: Chapter One Safety

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Chapter One Safety 1.1 Safety Instructions According to relevant national and local laws, regulations, and ordinances, safety instructions are the most basic focus in operating industrial systems including robots. The factory using robots are liable for personal injury and property damage led by the operation of robot. Therefore, this manual and relevant materials together with regulations and standards concerning health and safety must be understood and abide by.
  • Page 11 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Risk of electric It is reminded that the current operation may have the risk of electric shock shock and cause serious or even fatal injury. If the content with this logo is not operated in accordance with the Caution regulations, it may cause injury to personnel and damage to the robot.

  • Page 12: Safety Regulations

    GB 5226.1:2008 equipment- part one: general technical requirements 1.3.2 Safety Regulations the Safety Module Complies with The safety module safety level of GR series painting robots is SIL3, PLe, and the safety standards followed are: Standard Description...

  • Page 13: Safety Precautions During Each Work Process

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 functional safety of electrical/electronic/programmable electronic related safety systems-requirements for electrical/electronic/programmable electronic EN 61508-2:2010 related safety systems functional safety of electrical/electronic/programmable electronic related EN 61508-3:2010 safety systems- requirements for software functional safety of electrical/electronic/programmable electronic related EN 61508-4:2010 safety systems- definitions and abbreviations safety of machinery- functional safety of safety-related electrical, electronic...

  • Page 14: Safety Before Starting The Robots

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 9. Please place the motor/signal cable connecting the robot in the cable duct to prevent damage. Please also take measures to prevent them from extrusion. Do not connect to the power supply until all the connections between the control cabinet and the robot are completed.

  • Page 15: Safety In Robot Test Run

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 robot. 3. Never enter the safety fence unless the robot is powered off. Meanwhile, please confirm that the safety protection devices are working normally before starting the robot. 4. If there are several operators working together in the robot application system, make sure that all operators and related personnel know that the robot has been activated before starting the robot.

  • Page 16: Safety In Teaching

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 1.4.5 Safety in Teaching CMA advises teaching should be administered outside the safety fence. However, if it is necessary to enter it, strictly follow the precautions below. 1.Please read and understand all manuals, specifications and other related documents provided by CMA before operation.

  • Page 17: Safety In Automatic Operation

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Warning: Confirm the emergency stop switch is working properly before teaching . Warning 1.4.6 Safety in Automatic Operation Since the teaching program generally reproduces the edited trajectory at high speed, please strictly follow the precautions below and refer to national/international standards. 1.Please read and understand all manuals, specifications and other related documents provided by CMA before operation.

  • Page 18: Safety In Repair

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Warning: In automatic operation, the robot may seem to stop while waiting for the delay of the timer or external signal input. However, do not approach it at this time because it Warning immediately resumes operation when the two conditions mentioned above are met. 1.4.7 Safety in Repair For repair, please strictly follow the precautions below and refer to relevant national/international standards.

  • Page 19: Safety In Equipment Check And Maintenance

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Prompt: Please confirm all switches function properly before repair. 1.4.8 Safety in Equipment Check and Maintenance Please strictly follow the precautions below and refer to relevant national/international standards for robot clean, check, maintenance, and replacement of parts to prevent system faults. 1.Please read and understand all instruction and other relevant documents provided before operation.
  • Page 20 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 12. The robot must remain the same posture before and after the maintenance. Please record posture data before the replacement of parts. 13. When the application devices (water, compressed air, protective gas, etc.) are used, please turn off their supply sources and release the remaining pressure in the pipeline before check/maintenance.

  • Page 21: Chapter Two Installation And Connection

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Chapter Two Installation and Connection 2.1 Overview This chapter includes installation instructions and information about GR Painting Robot Series in workplace. It is vitally important to read all the safety information before any installation. Please be sure to read the following information carefully: CMA robot safety manual, general safety information in the first chapter of this manual that must be read thoroughly, and introduction of dangers and safety risks during operation.
  • Page 22 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Robot (including accessories) Control cabinet Teach Pendant Power cord (the power cord between the robot and the control cabinet) Instructions control cabinet robot teach pendant power cable a set of instructions Fig. 2-1 Contents in Packing Table 2-1 Packing List Packing List Number...

  • Page 23: Preparation Before Installation

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 User's manual Standard configuration Factory inspection Enterprise standard report Product certification Enterprise standard Accessories Accessory box 380V main power In the Standard configuration circular connector accessory In the Zero point bolt Standard configuration accessory The color of the body is green;...

  • Page 24: Operation Environment For Robot

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 minimum environment temperature -10℃ maximum environment temperature +55℃ 95% no condensation at constant maximum environment humidity temperature 2.2.4 Operation Environment for Robot The following table shows operation requirements for robot: Table 2-4 Operation Requirements Parameter Value minimum environment temperature...
  • Page 25 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 inverter caused by high frequency leakage wrong action. In addition, the high-frequency leakage current produced by the drive inverter is harmless to the human body. If customers use an AC type leakage protector, use a leakage protector of at least 100mA.(One machine with one to reduce the trigger of misaction) Requirements for the inductive load load in the control cabinet: Emotional load in on or off power generation generate reverse momentum voltage, this voltage will...

  • Page 26: Transportation

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 2.3.1 Transportation According to relevant regulations of various countries, lifting operations such as lifting rings, driving operations, and driving forklifts must be carried out by personnel with operating qualification certificates or personnel permitted by the company . Otherwise, it may cause personal injury and equipment damage.

  • Page 27: Installation

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 When placed on the ground, it can be  moved to and placed in the final position using a pallet truck. Please keep balance and drive slowly at a constant speed to prevent the electric control cabinet from tipping or tilting during transportation.
  • Page 28 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 After the installation of the robot , the fixed fixture for transportation must be removed before the power is turned on for the first time. Otherwise, the main driving parts of the robot may be damaged. Attention The electric cabinet and the robot body is connected via the circular connector on the side of the electric cabinet and the circular connector behind the robot body.

  • Page 29: Set Up A Safety Fence

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 The left side of the electric control cabinet is the air inlet of the fan, and the USB, Ethernet debugging port, the electric power inlet, and circular connector are all located on this side. In front of the control cabinet is the switch door of the electric cabinet, on which there are the switch of the electric cabinet and the production counter (the old version of the electric cabinet has while the new version cancels the production counter and puts the relevant buttons here).

  • Page 30: Connection Of Ground Wire

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 The robot test area is divided to make the  factory area clear, work in an orderly manner, and expand the utilization rate of the site. Most workshops and factories hope to get the maximum utilization rate within the smallest space.

  • Page 31: Connection Of Power Cord

    2.3.5 Connection of Power Cord The power cord connecting the GR series painting robot and peripheral equipment should be wired separately from the main power cord. In addition, keep away from high-voltage power lines and parallel wiring. Please use metal pipes or metal slots to prevent electrical signal interference if it is unavoidable.
  • Page 32 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Safety First wiring piping Fig. 2-7 Diagram of Wire Connection Configuration initial position of handle plug in automatic Steps to plug in the power cord:  rotation Confirm that the plug of the power cord is ...
  • Page 33 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 initial position of handle manual rotation Steps to plug out the power cord:  Press the buckle of the overload connector  until a "click" sound is heard (about 60º); Pull out the plug directly. ...

  • Page 34: Connection Of Teach Pendant

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 The servo power supply will be cut off due to sudden power failure or voltage drop. Please connect the control cabinet to a stable voltage power supply. Attention 2.3.6 Connection of Teach Pendant Connection of the teach pendant: ...

  • Page 35: Connection Of The Robot

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 2.3.7 Connection of the Robot explosion hazard area safe area explosion-proof cabinet teach pendant control cabinet robot body air pipe inter-panel cables Fig. 2-12 Connection of the Robot There are two circular connections on the right side of the robot control cabinet. Figure 2-13 below shows the physical diagram of the power cable (including brake wire) and the encoder cable circular connection ports of the robot control cabinet.

  • Page 36: Connection Of Safety Signal (Safety Door)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 enter and seal the main body. 2.3.8 Connection of Safety Signal (Safety Door) Safety fences and safety switches with interlocking function are set around the robot. Operators cannot enter without opening the door. The robot stops working if the door is open. range of motion for the robot safety fences servo on signal light...
  • Page 37 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Connection of the safety door:  Remove the jumpers on X13 terminals 1,  2 and 3, 4. The two normally closed contacts of the  safety door switch are connected to 1, 2 and 3, 4 of the X13 terminal respectively.

  • Page 38: Connection Of Safety Signal (Safety Light Curtain)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 2-16 Diagram of the Connection of Multiple Safety Doors The figure on the left shows an  example of how the four safety door switches are connected: These four switches are connected to ...
  • Page 39 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 alarm device. The alarm device will send out an alarm to remind the operator that he has entered the dangerous area. After the stray person comes out, press the reset button to restart the device to reduce the occurrence of safety accidents.
  • Page 40 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 According to ISO:13855, it is clearly indicated that the speed of the body approaching the machine needs to be considered when installing the safety protection devices: The light curtain can be  placed at the following distance to the robot working area: S = K (t1 + t2) + C...

  • Page 41: Connection Of Safety Signal (External Emergency Stop)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Modules L and O are in the electric  cabinet; Module L is a safe PLC, and the safety  performance level can reach PLe; Module O is composed of a safety relay  and a robot driver.
  • Page 42 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 emergency stop button safety safety door start the machine door grating safety door emergency stop button Fig. 2-24 Simplified Diagram of Robot Application Scenario The figure shows the location of the X4  wiring terminal; The emergency stop circuit of the robot ...

  • Page 43: Input Signals Available

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 2-26 Schematic Diagram of External Emergency Stop Wiring 2.3.11 Input Signals Available This photo shows the location of the X2  terminal block. The wiring on the X2 terminal comes from  the input module of the controller, which is convenient for customers to use.
  • Page 44 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Table 2-6 Input Signals Number Definition Effect common terminals 2，3 and 4 X2.1 COM 1 （24V） gun 2 selection X2.2 GUN 2 SELECTION X2.3 FREE X2.4 FREE X2.5 FREE enter turn table rotation used X2.6 ENABLE TURN TABLE ROTATION to enable G version...

  • Page 45: Output Signals Available

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 2-28 Schematic Diagram of Input Signal Wiring 2.3.12 Output Signals Available This photo shows the location of the X3  terminal block If the output terminal is passive, the  voltage of the normally open contact terminal can be selected: 115 vAC or 30 v The definition of each terminal can be ...
  • Page 46 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 point of the program and is used for remote start. common terminal 2 (no X3.18 COMMON 2 potential) The signal indicates that the robot's job list contains at X3.2 ROBOT BUSY least one program. common terminal 3 (no X3.19 COMMON 3...
  • Page 47 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 free X3.12 FREE common terminal 13 (no X3.29 COMMON 13 potential) signal to enable conveyor X3.13 ENABLE CONVEYOR common terminal 14 (no X3.30 COMMON 14 potential) The enable signal of a single device support X3.14 ELECTROSTATIC DEVICE painting device...

  • Page 48: Ethernet Connection (Standard)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 2-31 Basic Timing Diagram 2.3.13 Ethernet Connection (Standard) The electric cabinet of the robot can be connected to the company network to apply the CMA remote assistance function or send programs to the robot automatically. The connection can be made via the Ethernet jack on the right side of the cabinet or by installing a switch inside the cabinet.

  • Page 49: Connection Of Profibus Bus Module (Profi Accessories)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 left hand side of the electrical cabinet Fig. 2-33 Ethernet Connection Unscrew the protective cap and connect  the network cable Refer to the cable diagram on the left and  use a shielded Category 5 Ethernet cable. Fig.
  • Page 50 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Table 2-8 Accessories Profibus slave module X20IF1063-1 B&R Profibus connector 0G1000.00-90 B&R Power off the cabinet and open the cabinet  door; Find the first free slot on the left side of  the I/O board assembly; Remove the orange cap.
  • Page 51 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Wire the DB9 connector connection  according to the signs on the left; With more panels on the same network,  turn the terminal switch on the last panel to ON. Fig. 2-39 Module Connection CMA (WUHU) Robotics Company Limited...

  • Page 52: Chapter Three Control Cabinet

    Chapter Three Control Cabinet 3.1 Description of Electric Cabinet All the main components of the GR series painting robot control system are installed in a control cabinet, also called EC (abbreviation for EFORT Cabinet). The EC control cabinet consists of all the necessary components to control the movement of the robot, such as the main controller, IO modules, safety modules, servo drives, power modules, etc.
  • Page 53 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 External equipment of the  APS version electric cabinet: Electric cabinet switch  Counter  Main control panel  Manual control panel  USB interface, Ethernet  interface 17-inch display   APS = Automatic Painting System Fig.

  • Page 54: Basic Parameters

    Starting current at 400V The temperature range of the 0~40℃ workplace The temperature range of storage –10~55℃ 6-axis GR series robot for joint used B&R system ROBOT Indoor installation Avoid sunlight Keep away from dust, fume, salt, iron Working environment filings, etc.

  • Page 55: Layout Of Control Cabinet

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.1.2 Layout of Control Cabinet control unit safety module fuse drive module Fig. 3-4 Layout of Control Cabinet CMA (WUHU) Robotics Company Limited...

  • Page 56: Buttons

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.1.3 Buttons A: The main power switch, which controls the  power of the entire robot system; B: Alarm button. When the robot alarms, the red  button is always on; C: Servo confirmation button, used for manual ...

  • Page 57: Teach Pendant

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.2 Teach Pendant 3.2.1 Parameters of Teach Pendant The teach pendant is an embedded handheld device with complete hardware and software. You can complete all functions related to the robot with the teach pendant, such as writing and debugging programs, viewing system status, setting system parameters, and so on.
  • Page 58 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 H. Robot motion control button area E. Joystick handle, used to control the motion robot in the teaching mode I. Robot Servo Power-on Hand Press (Hold-To-Run) Fig. 3-7 Teach Pendant Hand press switch: The hand press switch on the teach pendant is a special switch with 2-stage pressing and 3 positions, also known as a three-stage enable switch (hereinafter referred to as enable switch).
  • Page 59 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 The enable switch is installed on the back of the teach pendant. When it is pressed to  the middle position, the motor power is turned on and automatically enabled. The system is in the Motor On state and can be inching or running programs. When it is released or pressed to the end, the power of the motor will be cut off, and the system will return to the Motor Off state.
  • Page 60 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Button Function Manual spray Automatic spray Start in the automatic mode Hold running Stop Wash Cycle Run-Spray cycle Alarm-Fault alarm Motion-Motor enable on Gun-Spray gun open CMA (WUHU) Robotics Company Limited...

  • Page 61: How To Hold The Teach Pendant

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Button Function Reset alarm Motor enable on/off In the teaching mode, control the robot's single-axis movement in the negative direction under different coordinate systems In the teaching mode, control the robot's single-axis movement in the positive direction under different coordinate systems Selection of auxiliary axis...

  • Page 62: Operation And Cleaning

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-10 How to Hold the Teach Pendant 3.2.4 Operation and Cleaning Handle with care to avoid falling, throwing or strong impact on the teach pendant, otherwise it may cause the teach pendant to malfunction; If the teach pendant has experienced a strong impact, it must be verified that the enable switch and emergency stop button are still in a normal and usable state before using it again;...

  • Page 63: Motion Controller

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.3 Motion Controller 3.3.1 Controller X20CP3584 X20 CPU meets a wide range of requirements.  They can be implemented in standard applications and solutions that require the highest performance. Basic models include USB, Ethernet, ...
  • Page 64 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Green / Status/error indicator. The status of this LED is described in the LED "S/E" section. A link to the POWERLINK peer site has been established. Green A link to the POWERLINK peer site has been Flashing established.When Ethernet activity occurs on the bus, the LED flashes.
  • Page 65 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-12 Composition of X20CP3584 Integrated power supply-pin arrangement: Fig. 3-13 Pin Arrangement Connection example with 2 independent power supplies: CMA (WUHU) Robotics Company Limited...
  • Page 66 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-14 Diagram of Power Connection Connection example with power supply and jumper: Fig. 3-15 Connection Example with Power Supply and Jumper The non-electrically isolated RS232 interface is mainly intended to be used as an online interface for communication with programming devices.

  • Page 67: Industrial Computer Apc2100

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-16 Interface RS232 3.3.2 Industrial computer APC2100 APC2100 system unit consists of a CPU  board, housing and mounting board. They include all necessary interfaces and installation options. The main memory is permanently soldered to the CPU board and cannot be replaced or expanded.

  • Page 68: Power Module And Servo Drive

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.4 Drive Power Module and Servo Drive 3.4.1 Main Power Module Voltage: 3×380V-500VAC  Frequency: 50/60HZ±4%  Capacity: MAX 15.2KVA  Rated power: 8KW  IP rating: IP20  Weight: 4.7Kg  Length×width×height:  107mm×385mm×263mm Working environment: ...
  • Page 69 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-19 Wiring Diagram of the Main Power Module Fig. 3-20 Definition of Port X1 CMA (WUHU) Robotics Company Limited...
  • Page 70 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-21 Definition of Port X3A and X3B Fig. 3-22 Definition of Port X5A Fig. 3-23 Definition of Port X6 CMA (WUHU) Robotics Company Limited...

  • Page 71: Auxiliary Power Module

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.4.2 Auxiliary Power Module Rated power: 445W  Rated voltage: 24VDC±6%  IP rating: IP20  Weight: 3.2Kg  Length×width×height:  53.5mm×385mm×263mm Working environment:  Avoid sunlight Keep away from dust, fume, salt, iron filings, etc. Keep away from flammable and corrosive liquids and gases No contact with water...
  • Page 72 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-25 LED Status Indicator of Auxiliary Power Module Table 3-3 LED Status Indicator Status Type Color Function Description Indicator Green The 24 VDC internal system power supply is Power 24 V OK within the allowable tolerance. supply The 24 VDC internal system power supply Overload...

  • Page 73: Servo Drive

    Fig. 3-27 Definition of Port X1 of Auxiliary Power Module Fig. 3-28 Definition of Port X2 of Auxiliary Power Module Fig. 3-29 Definition of Port X3 of Auxiliary Power Module 3.4.3 Servo Drive The drive used by the GR series painting robot  complies with 11291.1-2011/ISO...
  • Page 74 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-30 Drive Fig. 3-31 LED Status Indicator on the Drive Table 3-4 Definition of Indicator on the Drive Status Indicator Label Color Function Description Green / Preparation / Error POWERLINK Green Data communication on L/D1 port 1 is successful Green...
  • Page 75 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Green/ Preparation / Error Status backup battery Green 24V normal power Power supply 24 V supply voltage of 24 V module is within tolerance. Orange Rotation direction encoder Encoder SLOT1 encoder + position connected encoder changes positive...
  • Page 76 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-32 Wiring Diagram of the Drive Fig. 3-33 Definition of Port X1 on the Drive CMA (WUHU) Robotics Company Limited...
  • Page 77 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Fig. 3-34 Definition of Port X2 on the Drive Fig. 3-35 Definition of Port X3A and X3B on the Drive Fig. 3-36 Definition of Port X4A on the Drive Fig. 3-37 Definition of Port X5A on the Drive CMA (WUHU) Robotics Company Limited...

  • Page 78: Bus Module

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3.4.4 Bus Module HIPERFACE encoder interface  plug-in module 8BAC0121.000-1 can be used in the ACOPOSmulti slot. The module contains a HIPERFACE encoder interface. This module can be used to evaluate  encoders installed in motors of other manufacturers and encoders for external shafts (encoders that sample machine motion).

  • Page 79: Safety Plc

    Fig. 3-40 Safety PLC The safety circuit design of the GR series painting robot meets the performance requirements in GB11291.1-2011/ISO 10218-1:2006: 1. A single failure of any component should not lead to the loss of safety functions;...
  • Page 80 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 emergency stop of teach pendant emergency stop of control cabinet external emergency stop test pulse emergency stop alarm safety relays Motion controller emergency stop alarm disconnect STO EtherCAT bus servo drive slow down close the brake servo motor brake Fig.

  • Page 81: Chapter Four Maintenance

    (including maintenance intervals) and refers to the operating procedures for these activities. For the maintenance activities of the robot body, please refer to " GR Series Painting Robot Mechanical Maintenance Manual". 1. Please check all safety information before starting any maintenance work! 2.

  • Page 82: Clean The Interior Of The Electrical Cabinet

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 confirmation of abnormal heat, controller inspection √ √ √ √ noise and smell check the rotation of the fans cooling unit and whether the air outlet is inspection √ √ √ √ blocked check whether the action is emergency stop normal, and check the servo inspection...

  • Page 83: Check The Ventilation Of The Operation Cabinet (Forced Ventilation Version)

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.3.2 Check the Ventilation of the Operation Cabinet (Forced Ventilation Version) Turn off the power supply of the electric  cabinet Open the cabinet door  Operate the control lever of the QS100  switch to reopen the electric cabinet directly with the pliers Fig.

  • Page 84: Check The Operation Of The Drive And Radiator Fan

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.3.3 Check the Operation of the Drive and Radiator Fan Turn off the power supply of the electric  cabinet Open the cabinet door  The electrical cabinet is switched by directly  operating the QS100 lever Fig.

  • Page 85: Check Whether The Safety Device Is Working Properly

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.3.4 Check Whether the Safety Device is Working Properly Press the mushroom emergency stop button on  the control panel and make sure that the stop and emergency stop status reports are displayed on the teach pendant screen.

  • Page 86: Check The Sealing Of The Electrical Cabinet

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 The robot is adjusted to automatic mode, the  servo is turned on, and the tripping safety device is installed on the protective net. When the servo is off, the emergency stop status is displayed on the screen.

  • Page 87: Check The Working Condition Of Main Electrical Components

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 3. Check whether the control cabinet-body wiring harness is intact, broken or loose. 4.3.7 Check the Working Condition of Main Electrical Components whether the drive is working normally  whether the controller is working normally ...

  • Page 88: Temporary Work

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.3 Temporary Work All maintenance work must be carried out when the industrial robot is stopped and the  power supply is disconnected. The work must be carried out by appropriately trained personnel, and precautions ...

  • Page 89: Replace The Fuse

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 (1) Sudden damage (2) Regular maintenance 4.4.1 Replace the Fuse The following table shows the code of the fuse and possible problems: Table 5-1 Reference List for Fuse Code and Fault Fuse Code Function Electric cabinet failed to connect FU11 The fan failed to turn on...

  • Page 90: Replace The Drive

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Hold the 10x38 fuse and pull it out  Insert a new fuse and close the protective  cover. Fig. 4-14 Replace the Fuse Refer to the rated current and wiring diagram of the fuse, and replace it with a new one of the same specification.
  • Page 91 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Disconnect the connecting terminals at  the bottom of all drives The motor cable connection terminal  (orange) The brake cable connection terminal  (gray) Fig. 4-16 Replace the Drive Loosen the fastening bolts shown in the ...
  • Page 92 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Lift the drive, pull it out from the bottom,  and take it out completely. Fig. 4-19 Replace the Drive Insert the new drive into the old drive  slot, hook it on the top of the back plate, and tighten the corresponding bolts with a No.

  • Page 93: Replace The Radiator Cooling Fan

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 address of the drive, as shown in the table below. Fig. 4-22 Replace the Drive 4.4.3 Replace the Radiator Cooling Fan Turn off the power of the control cabinet  and open the cabinet door The radiator and cooling fans are all in ...

  • Page 94: Replace The Cooling Fan Of The Drive

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 4.4.4 Replace the Cooling Fan of the Drive Turn off the power of the control cabinet  and open the cabinet door Disassemble the fan of the drive that  needs to be replaced according to the above instructions.

  • Page 95: Chapter Five Troubleshooting

    Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 Chapter Five Troubleshooting 5.1 Troubleshooting Methods This chapter provides two troubleshooting methods, namely: 1. Troubleshoot according to the fault phenomenon. If the fault occurs during the system startup process, or there is no corresponding log, the troubleshooting is performed according to the fault phenomenon, and the faulty modules or units are checked one by one.
  • Page 96 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 when reading Check the damage of the Rn  initialization Initialization or Dn connecting cable 7022 motor feedback encoder activated Motor feedback encoder is  has not been completed defective The amplitude of the Check the damage of the Rn ...
  • Page 97 Electrical Operation and Maintenance Manual ZL-GR6150-003-V1 EFORT Intelligent Equipment Co., Ltd. CMA(Wuhu) Robotics Co., Ltd No. 96 Wanchun East Road, Jiujiang District, No. 96 Wanchun East Road, Jiujiang District, Wuhu City, Anhui Province Wuhu City, Anhui Province www.efort.com.cn www.cmarobot.com.cn service hotline：400-052-8877 service hotline：400-052-8877 CMA (WUHU) Robotics Company Limited...

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