ELITE ROBOT CS Series Service Manual

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ELITE ROBOTS CS Series

CS612 Service Manual

Suzhou Elite Robot Co., Ltd

2023-12-12

Version: 2.10.0

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Summary of Contents for ELITE ROBOT CS Series

Page 1 ELITE ROBOTS CS Series CS612 Service Manual Suzhou Elite Robot Co., Ltd 2023-12-12 Version: 2.10.0...
Page 3 ELITE ROBOT Co., Ltd. shall assume no liability for any errors which will occur in the manual probably. ELITE ROBOT Co., Ltd. shall assume no liability for the accident or indirect injury as a result of using this manual and the product mentioned herein.
Page 5: Table Of Contents
3.1.2 Recommended Tools ............... 10 3.2 Robot Arm Disassembly and Assembly ............. 11 3.2.1 Robot Arm Configuration ..............11 3.2.2 Brake Release ................... 12 3.2.3 General Guidelines for Joints Disassembly and Assembly ....13 3.2.4 Torque Value ..................16 Version 2.10.0 CS Series...
Page 6 3.3 Controller Aisassembly ................30 3.3.1 Replace the Safe IO Board ..............30 3.3.2 Replace the Brake Board ..............35 4 Alarm Information 4.1 Robot Program Alarm Information ............38 5 Spare Parts List 6 Robot Packaging CS Series Version 2.10.0...
Page 7: General Information
It's also an option to order parts from the nearest dealer, which can be found on the official website of Elite Robots：www.eliterobots.com. 1.2 Company Details Suzhou ELITE ROBOT Co.Ltd Address: Suzhou Industrial Park Changyang Street No. 259 Zhongxin Zhongyuan Industrial Park Industrial Park 4 Building 1F Tel:0512-83951898 Version 2.10.0...
Page 8: Disclaimer
Natural disasters such as fires, earthquakes, tsunamis, lightning strikes, high winds  and floods. The faults other than the above are not caused by the responsibility of Suzhou Elite Robot Co., Ltd. The following conditions are not covered by the warranty: The date of manufacture or the date of commencement of warranty could not be ...
Page 9: Warning Symbols
1 General Information liable for such warranties. In addition, Suzhou Elite Robot Co., Ltd. does not assume relevant liability for any form of indirect damage or consequences arising from related products. 1.4 Warning Symbols The following warning symbols define the hazard level regulations contained in this manual, pleasecomply with these symbols.
Page 10: Recommended Inspection Activities
2.1.1 Inspection Plan Below is a checklist of inspections that the Elite robots recommends performing based on marked time intervals. If the inspector finds that the condition of the relevant part is not qualified, correct it immediately. CS Series Version 2.10.0...
Page 11: Safety Function
Observe the robot stop and power off the joints;  Start the robot again.  Test free drive mode:  Depending on the tool specifications, remove the attachment or set the tool center  point (TCP)/payload/CoG; Version 2.10.0 CS Series...
Page 12: Visual Inspection
Check the inside of the controller for dirt/dust and, if necessary, clean with a vacuum  cleaner that prevents electrostatic discharge. 2.1.4 Clean and Replace the Filter The controller has two filters, one on each side;  CS Series Version 2.10.0...
Page 13 Remove the filter from the controller and clean it thoroughly with low-pressure air;  Replace the filter as needed;  Gently remove the outer plastic frame and maintain the filter.  Figure 2-3 Controller filter disassembly and assembly Version 2.10.0 CS Series...
Page 14: Robot Arm
Check the robot cable connection Check the robot arm mounting bolts* Inspection tool mounting bolts* Check the screws/bolts that connect the joints* V=Visual inspection F= Functional inspection *= It must also be checked after a serious collision CS Series Version 2.10.0...
Page 15: Functional Inspection
 The correct torque value of the screws on the joint lids is 0.5 Nm.  If any damage to the robot is found during the warranty period, please contact the dealer who supplied the robot. Version 2.10.0 CS Series...
Page 16: Repair And Replacement Of Parts
When using the heating during the colder weather, be very careful about using parts that are susceptible to static damage, since low humidity will the increase generation of static electricity. 3.1.2 Recommended Tools Repair Kit - Item No.:NB80000004 CS Series Version 2.10.0...
Page 17: Robot Arm Disassembly And Assembly
Section 3.2.10 Wrist 1 Joint-Lower Arm Joint Section 3.2.9 Elbow Counterpart-Elbow Joint Section 3.2.8 Elbow Joint-Upper Arm Section 3.2.7 Upper Arm-Shoulder Joint Section 3.2.6 Shoulder Joint-Base Joint Section 3.2.5 Base Joint-Base Mounting Bracket Figure 3-1 Robot arm configuration Version 2.10.0 CS Series...
Page 18: Brake Release
Brake pins on the base Brake pins on the elbow joint Brake pins on the wrist joint and shoulder joints Figure 3-2 Lift the brake pin upwards Replace the joint lid and tighten the screw to 0.5Nm;  Connect the power supply.  CS Series Version 2.10.0...
Page 19: General Guidelines For Joints Disassembly And Assembly
Figure 3-3 Move rubber rings and support rings Slide the plastic supporting ring backwards. Use external hex wrench to loosen the  hexagonal screws on both side of the joint; Gently separate the joints that need to be disassembled.  Version 2.10.0 CS Series...
Page 20 The times the light flashes is equal to the joint number; Note: If the number of flashes is incorrect, press and hold the white button, and then release the flashing light after the corresponding number of flashes to reset. CS Series Version 2.10.0...
Page 21 Connect the wires and tie them well as shown in Figure 3-7:  Figure 3-7 The joint with properly tied wires Install the joint lid, put in the cross screw of M3×6, and tighten the screw to 0.5Nm  using a cross wrench. Version 2.10.0 CS Series...
Page 22: Torque Value
1.7Nm Outer hexagon M3 End Flange - J6 Wrist 3 1.7Nm Outer hexagon M3 Joint Lid 0.5Nm Cross screws M3 1.7Nm 1.7Nm 1.7Nm 3.6Nm 3.6Nm 3.6Nm 7.8Nm 7.8Nm 7.8Nm Figure 3-8 Torque value of each joint CS Series Version 2.10.0...
Page 23: Base Joint - Base Mount Bracket
Align the mark according to the position of the locating pin, locate the joint, and gently  push the base joint and the base mounting bracket together; Use the hexagon wrench to tighten the 14 M5×20 screws on the flange shaft, and  tighten them crosswise to 7.8Nm; Version 2.10.0 CS Series...
Page 24: Shoulder Joint � Base Joint
7.8Nm with a torque wrench; Put down the plastic supporting ring and gently superimpose the rubber ring onto the  supporting ring; Reconnect the wires and tie with nylon zip ties, as shown in Figure 3-10:  CS Series Version 2.10.0...
Page 25: Upper Arm - Shoulder Joint
Figure 3-11: Figure 3-11 Remove the upper arm rubber ring and the supporting ring Using an external hex wrench, loosen the 14 screws;  Pull the upper arm away from the shoulder joint.  Version 2.10.0 CS Series...
Page 26: Elbow Joint - Upper Arm
1X Brown wires 48VDC 1X Black wires earthing 1X Twisted pair 485 Communication lines Gently remove the rubber ring and hang it around the upper arm to remove the  supporting ring as shown in Figure 3-13: CS Series Version 2.10.0...
Page 27  crosswise to 3.6Nm; Reconnect the wires and tie them as shown in Figures 3-14:  Figure 3-14 Reconnect the wires Mount the joint lids with 4 screws of M3×6, tighten them crosswise to 0.5Nm.  Version 2.10.0 CS Series...
Page 28: Elbow Pairing Joint - Elbow Joint
Insert the wire bundle through the wire guard. Then install the wire guard to the wire  rack. After reconnecting the wire, use nylon zip ties to keep the wires at proper position as shown in Figure 3-15: CS Series Version 2.10.0...
Page 29: Wrist 1 Joint - Lower Arm
The procedure for assembling the wrist 1 joint from the lower arm is similar to assemble upper arm to elbow joint. Please read Section 3.2.8 for details and photos; Thread wire bundle on the link through the wrist 1 joint;  Version 2.10.0 CS Series...
Page 30: Wrist 2 Joint - Wrist 1 Joint
Lift the plastic supporting ring, use a hex wrench, and loosen the 12 screws;  At this time, the wrist 1 joint and the wrist 2 joint have been loosened, and the wrist 2  joint is gently pulled away from the wrist 1 joint. CS Series Version 2.10.0...
Page 31: Wrist 3 Joint - Wrist 2 Joint
Using a slotted screwdriver or forceps, gently remove the rubber ring and hang it  around the wrist joint shell; Lift the plastic supporting ring, use an external hex wrench, and loosen the 12 screws;  Version 2.10.0 CS Series...
Page 32: Wiring Guide
After reconnecting the wire, use nylon zip ties to keep the wires at proper position; Mount the joint lids with 3 screws of M3×6, tighten them crosswise to 0.5Nm.  3.2.14 Wiring Guide Wiring for the joints CS Series Version 2.10.0...
Page 33 Connect the brown wire to positive pole and black wire to GND pole. Plug the 485 wire into the specified port. The wires excess the necessary length need to be wrapped around the wire track and zip tied to keep in proper position as shown in Figure 3-20: Version 2.10.0 CS Series...
Page 34 Figure 3-21: Figure 3-21 Tie the wire Place the retaining ring in the middle hole of the wire rack, as shown in Figure 3-22:  CS Series Version 2.10.0...
Page 35 After finishing the wiring on the elbow side, thread the wire bundle through the elbow  pairing joint, then attach the eblow paring joint to the lower arm link. The installation method is similar to installing upper arm to shoulder joint, please see details in the section 3.2.7. Version 2.10.0 CS Series...
Page 36: Controller Aisassembly
Figure 3-23 Controller hex flange side nylon anti-loosen nut position Remove or disconnect the following parts, as shown in Figures 3-24:  1-Fan cable  2-Flash card (press to eject)  3-Teach pendant cable  4-IO interface plug  5-Fuses  CS Series Version 2.10.0...
Page 37 Take the sheet metal module out from the box and place it on the box bracket as shown in Figure 3-25: Figure 3-25 Screw position, power ground connection location and sheet metal module placement Version 2.10.0 CS Series...
Page 38 Figure 3-26: 1-Black 48Vx2  2-White GNDx2  3-Switching power signal control line x1  4-Red and blue 220V power cord X2  Figure 3-26 The connect position of the power cable on the controller CS Series Version 2.10.0...
Page 39  2-White GNDx2  3-485 communication x1 (twisted pair red and black)  Figure 3-28 Cable location on Safe IO Disconnect the cable from the brake pads to Safe IO as shown in Figure 3-29:  Version 2.10.0 CS Series...
Page 40 Safe IO and secure the screws as shown in Figure 3-30: Figure 3-30 Screw position Install the power supply back in place and connect all disconnected cables as shown  in Figure 3-31: Figure 3-31 Cable connection CS Series Version 2.10.0...
Page 41: Replace The Brake Board
Disconnect the fan cable and teach pendant cable. Remove the sheet metal module and put it on the box bracket, please do not let the flash memory card and fuse to interfere with the box; Version 2.10.0 CS Series...
Page 42 3-White GNDx1  4-Fan connection extension cable x1  Figure 3-35 Disconnect the cable Remove the 4 cross slot head screws and remove the brake board that need to be  replaced, as shown in Figure 3-36: CS Series Version 2.10.0...
Page 43 Figure 3-38: Figure 3-38 Install sheet metal, nuts, and reconnect cables Turn on the power and test whether the functions can work properly through the teach  pendant. Version 2.10.0 CS Series...
Page 44: Alarm Information
(2) Restart the robot. Try the following in turn: (1) Check whether the Emergency Stop System emergency Emergency stop IO is E2S2 function of the safety input IO is stop triggered. configured correctly and release the trigger state. CS Series Version 2.10.0...
Page 45 (1) Make sure that the robot structure Current robot current robot type is correct. E3S6 structure does not structure type (2) Update the controller software. support calibration incorrect. (3) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 46 Try the following in turn: (1) Check whether the robot position, Exceeds the safety Tool position exceeds E6S4 TCP and safety plane parameters are plane safety plane. correct to ensure that the robot TCP position does not exceed the safety CS Series Version 2.10.0...
Page 47 Elbow joint speed state is correct to ensure that the joint E6S9 exceeds safety speed ({float} °/s) is too fast speed does not exceed the safety limit. limits. (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 48 (1) Check whether the robot running The joint target position {joint} position limit state, robot payload and speed E6S16 is too different from the violated parameters are correct. actual position. (2) Contact ELITE ROBOTS after-sales service for assistance. CS Series Version 2.10.0...
Page 49 Try the following in turn: safeguard stop reset Safety IO input signal is (1) Please ensure that the safety IO E6S22 safety IO input inconsistent. connection is correct and the signal is signal is inconsistent switched at the same time. Version 2.10.0 CS Series...
Page 50 The force of the robot (1) Check the safety of the robot Tool force is beyond E6S30 tool exceeds the safety operation space to ensure that there is max limit limit. no collision. (2) Check whether the robot tool force CS Series Version 2.10.0...
Page 51 (3) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: Fail to turn on the Robot 48v power can't E6S40 (1) Please turn on and off the 48v power robot 48v power be controlled. again. Version 2.10.0 CS Series...
Page 52 2. Joint data is corrupt. For the initial 1. Dynamic data is Try the following in turn: E6S46 configuration of configured for the first (1) Power off and restart the controller. dynamics data, time. CS Series Version 2.10.0...
Page 53 (1) Please check the status of the robot, RUNNING mode, The robot's brakes are then power on the robot and release the E7S2 hand drag mode engaged. brakes. started failed (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 54 (2) Check if payload, mounting, zero Failed to start hand E7S8 disabled since dynamic position and dh parameters are correct. drag mode model check failed. (3) Restart the robot after clearing the alarm. (4) Contact ELITE ROBOTS after-sales service for assistance. CS Series Version 2.10.0...
Page 55 3. The teaching pendant service for assistance. cable is damaged. Try the following in turn: Teach pendant is in (1) Re plug the teach pendant. E9S2 alarm, alarm code: (2) Contact ELITE ROBOTS after-sales {signed} service for assistance. Version 2.10.0 CS Series...
Page 56 {hex} controller software. (3) Contact ELITE ROBOTS after-sales service for assistance. The pointer value is An error occurred in Try the following in turn: E11S4 controller software. (1) Power off and restart the controller. CS Series Version 2.10.0...
Page 57 (2) Check whether the payload and E12S21 overcurrent large and exceeds the acceleration parameters are set load characteristic correctly. curve. (3) Check whether the payload is too 3. Mechanical jamming large and exceeds the load characteristic Version 2.10.0 CS Series...
Page 58 If the e- {joint} Joint e-stop pressed. E12S40 stop button is pressed, rotate the button state 2. False alarm of e-stop for reset and synchronous operation. caused by external (2) Contact ELITE ROBOTS after-sales interference. service for assistance. CS Series Version 2.10.0...
Page 59 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: (1) Restart the robot after clearing the {joint} Abnormal E12S65 alarm. joint zero calibration (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 60 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: (1) Restart the robot after clearing the E12S101 {joint} Joint collision alarm. (2) Contact ELITE ROBOTS after-sales service for assistance. CS Series Version 2.10.0...
Page 61 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: (1) Restart the robot after clearing the {joint} Flash write E12S199 alarm. exception (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 62 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: (1) Restart the robot after clearing the [M] {joint} salve 3.3v E12S504 alarm. power supply fault (2) Contact ELITE ROBOTS after-sales service for assistance. CS Series Version 2.10.0...
Page 63 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: [M] {joint} motor (1) Restart the robot after clearing the E12S511 encoder validation alarm. error (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 64 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: (1) Restart the robot after clearing the [S] {joint} 12v power E12S602 alarm. supply fault (2) Contact ELITE ROBOTS after-sales service for assistance. CS Series Version 2.10.0...
Page 65 (2) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: [S] {joint} slave MCU (1) Restart the robot after clearing the E12S611 communication over alarm. time (2) Contact ELITE ROBOTS after-sales service for assistance. Version 2.10.0 CS Series...
Page 66 Try the following in turn: Robot's {joint} is in collision. (1) Please check the safety of the robot E13S1 collision (2) The robot is operation space to ensure that there is mounting type or the no collision. CS Series Version 2.10.0...
Page 67 [{string}] servo firmware. (4) Contact ELITE ROBOTS after-sales service for assistance. Try the following in turn: The robot type is not E15S7 Unknown robot type (1) Configure the robot type in expert configured. mode. Version 2.10.0 CS Series...
Page 68 Try the following in turn: E16S3 module not plug (1) P2R_REG2 module plug slot. RTSI Watchdog E17S0 Alarm Try the following in turn: RTSI Watchdog (1) Check Profinet, EthernetIP and other E17S1 Alarm fieldbus. (2) Check RTSI watchdog. CS Series Version 2.10.0...
Page 69: Spare Parts List
25 Joint Electromagnet Assembly-C NB20100017 32 Joint Electromagnet Assembly-C NA60400047 End Aviation Cap-C NB50000114 17-Joint Back Cover-C (Sprayed) NB50000116 25-Joint Back Cover-C (Sprayed) NB50000117 32-Joint Back Cover-C (Sprayed) NA60300128 Link Supporting Ring 17-C NA60300130 Link Supporting Ring 25-C Version 2.10.0 CS Series...
Page 70 NA20100009 48V Power Supply RSP-2000-48V NA20200164 Power Outlet 4301.0501 NA31400119 Power Outlet Shield 3-125-661 NA20600047 Rocker Switch KCD4-201-2 NA31400128 Stuffy Cover M25X1.5, black, with NA30600033 Rubber Coil GM-4 NA20300004 Power Cable 3-100-527 NA60300180 Nylon Thread Plug-C CS Series Version 2.10.0...
Page 71 Open End Wrench 5.5-7 3mm thick NA50200123 Open End Wrench 8-10 3mm thick NE00000058 1 Set of the Ball-headed Allen 1.5/2/2.5/3/4/5/6M Keys (7 pieces in total) NE00000123 8mm Allen Key 8*200*36 NE00000044 Hexagon Screw Socket 19400-M5 Version 2.10.0 CS Series...
Page 72: Robot Packaging
If the robot cannot run or the power supply is not available, the brakes for each joint can be manually released individually and the robot can be packaged accordingly. For the release of the brake, see 3.2.2 Brake release. Figure 6-1 Robot packaging diagram CS Series Version 2.10.0...
Page 74 Twitter Facebook Contact US Sales & Service: contact@elibot.com Technical Support: service@elibot.com Shanghai Elite Robot Co., Ltd. Suzhou Elite Robot Co., Ltd. Building 18, Lane 36, Xuelin Road, Shanghai 1F, Building 4, No. 259 Changyang Street, Suzhou Shenzhen Elite Robot Co., Ltd.

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Cs612