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Electrical Operation and Maintenance Manual for Control Cabinet of EC2-S Industrial Robot

RO6

RO7

RO8

R24VG1

X18

（

input

）

RI1

RI2

RI3

RI4

RI5

RI6

R24VP1

3.4 Safety Function Unit

This safety function loop includes motion controller watchdog, control cabinet emergency

stop, external emergency stop, teach pendant emergency stop, safety relay, safety relay expansion
module, and servo drive STO function.

Fig. 3-14 Block Diagram of the Safety Control Loop

teach pendant emergency stop

control cabinet emergency stop

external emergency stop

safety relays

external safety door signal

server driver STO

servo motor brake

Содержание EC2-S

Страница 1: ...EC2 S Control Cabinet Operation and Maintenance Manual for Industrial Robot Apply to ER7 700 ER7 900 ER3 600 ER10 3 900 EFORT Intelligent Equipment Co Ltd Service Hotline Tel 400 0528877...

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Страница 3: ...oss of surrounding properties This statement and manual are the latest version until this batch of products leave the factory Please visit the official website www efort com cn to obtain up to date in...

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Страница 5: ...of Starting Robot 5 1 3 4 Safety in Robot Test Run 6 1 3 5 Safety in Teaching 6 1 3 6 Safety in Automatic Operation 8 1 3 7 Safety in Repair 8 1 3 8 Safety in Equipment Check and Maintenance 10 Chapte...

Страница 6: ...Cabinet System 23 3 1 Composition of Robot Control Cabinet 23 3 1 1 Basic Parameters 23 3 1 2 Distribution of Components 23 3 2 Motion Control Unit 26 3 2 1 Motion Controller 26 3 2 3 Definition and E...

Страница 7: ...ion 53 4 2 Maintenance Plan 53 4 3 Check Activity 54 4 3 1 Check the Control Cabinet Seal 54 4 3 2 Check the Information Label 55 4 3 3 Check the Wiring Harness 56 4 3 4 Check the Working Condition of...

Страница 8: ...3 3 Controller Fault Handling 69 5 4 Drive Fault Handling 69 5 5 Program Running Fault Handling 70 Chapter Six Deactivation 71 6 1 Overview 71 6 2 Environmental Information 71 6 3 Discard the Robot 7...

Страница 9: ...ration and Maintenance Manual for Control Cabinet of EC2 S Industrial Robot V 1 2 3 Warnings 4900 4999 92 Appendix 3 Drive Alarms and Warnings 96 1 3 EC2 A Drive Alarm 1000 1199 Warning 4050 4099 96 1...

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Страница 11: ...ble safety laws and regulations of the host country and proper design and installation of necessary safety equipment for robot system operators whereas operators must familiarize themselves with the f...

Страница 12: ...ll operators must receive training on operation and maintenance of industrial robot 3 The foreman shall continuously monitor the normal operation of all programs and ensure the correct application of...

Страница 13: ...ion Only allow qualified personnel to operate forklifts and cranes and to move transport robot body control cabinet etc Never approach or walk under the lifted robot body or control cabinet during tra...

Страница 14: ...cations and other relevant documents provided by EFORT before operation In addition completely understand procedures of operation teaching and maintenance Meanwhile make sure all safety measures are e...

Страница 15: ...afety measures are effective in place 2 Check the names and functions of all switches displays and signals needed for robot operation 3 Do not enter the safety fence unless the power supply is disconn...

Страница 16: ...such as the emergency stop button and hold run switch operate properly Accidents cannot be prevented if robot cannot be stopped in case of dangerous situations 2 Set the operating speed to low speed...

Страница 17: ...ata please clear all the personnel and obstacles left within the safety fence and around the robot The confirmation work should be done outside the safety fence The speed of the robot should be equal...

Страница 18: ...ece may be thrown off during the movement of the robot Be sure to confirm that the workpiece has been firmly grasped When the workpiece is grasped by a pneumatic gripper an electromagnetic mechanism e...

Страница 19: ...the fence Once the robot makes incorrect movement in repair the supervisor must be able to press the switch very conveniently to stop the robot immediately In addition if you need to restart the robot...

Страница 20: ...es which should be fastened in case of any sudden movement 5 Please cut off the power supply of the entire line or the power of the robot Also cut off the power supply up to the main power supply as n...

Страница 21: ...pply is 0V The heat sink or regenerative generator may main hot right after the stop of the movement Therefore please be cautious do not touch any hot part 13 Please support the robot arm with proper...

Страница 22: ...bag for disposal to prevent them from being in contact with other metals Please also handle them properly in accordance with local regulations 20 Make sure the emergency stop signal of the auxiliary...

Страница 23: ...it 2 Confirm each part and each component is complete Please contact the supplier in time for any missing or wrong part Table 2 1 List of Parts and Accessories List of Parts and Accessories No Item M...

Страница 24: ...f the robot before it 7 After the above conditions are met move the robot to site and install it according to instructions below 2 2 3 Storage Environment for Robot The following table shows storage r...

Страница 25: ...et of EC2 S Industrial Robot 15 Table 2 5 Work Cycle of Starting Robot in Cold Environment Work Cycle Speed Rate 3 cycles 20 5 cycles 50 5 cycles 80 5 cycles 100 2 2 6 Placement of Control Cabinet Dim...

Страница 26: ...16 horizontal vertical When installing the control cabinet on the rack the threaded holes need to be processed to the right size See the figure below for reference air inlet wind direction air inlet a...

Страница 27: ...Maintenance Manual for Industrial Robot ER7 700 Mechanical Operation and Maintenance Manual for Industrial Robot ER9 700 Mechanical Operation and Maintenance Manual for Industrial Robot ER3 600 Opera...

Страница 28: ...d to avoiding violent vibration tipping and slipping Fig 2 2 Transporting by Special Tools recommended for long distance transporting 2 4 Electrical Connection The robot and control cabinet are connec...

Страница 29: ...n range is 10 2 Please use 3C 1 5mm and above cable for the power cord 3 Disconnect devices such as isolation switch must be installed between the power grid and the control cabinet to ensure human sa...

Страница 30: ...devices They function to cut off the output of the driver quickly and stop the robot s movement immediately Turn the emergency button clockwise to release it Emergency stop prioritizes all control op...

Страница 31: ...cessary wear of robot 1 External Emergency Stop When an external emergency stop is required refer to the definition table of emergency stop interface to pull out the short cable which was connected be...

Страница 32: ...EMGO AM EMGO BP and EMGO BM in the external emergency stop terminal block of the EC2 S control cabinet are a pair of double circuit output contacts in the emergency stop state Users can wire accordin...

Страница 33: ...inet 3 1 1 Basic Parameters Table 3 1 Parameters of Control Cabinet control cabinet model EC2 S IP rating IP20 IO port 32 digital inputs 32 digital outputs support expansion communication method TCP I...

Страница 34: ...EFORT INTELLIGENT EQUIPMENT CO LTD 24 15 19 21 front left side panel bottom plate 16 17 20 18...

Страница 35: ...tion of Components Number Name Number Name 1 emergency button 13 external emergency stop terminal 2 plug 14 power filter connector 3 power indicator 15 controller 4 brake release 16 IO module 5 servo...

Страница 36: ...ace definitions of the motion controller RP2 in the EC2 S robot control cabinet 3 2 1 Motion Controller 1 Motion Controller Power Port Fig 3 2 Location Indication Diagram of Power Port Fig 3 3 Definit...

Страница 37: ...Cabinet of EC2 S Industrial Robot 27 voltage range 22V 28V power 15W baud rate 10 100Mbit s a power failure signal occurs at the voltage threshold 18V connection terminal FK MCP1 5 7 STF 3 81 Phoenix...

Страница 38: ...ification signal specification comply with the signal specification of the Ethernet specification IEEE 802 3u 100 10 BASE T cable length comply with Ethernet specifications IEEE 802 3u 100 10 BASE T b...

Страница 39: ...iagram Table 3 5 Parameters of SER1 Port SER1 Specification RS232 signal specification follow the EIA RS232 E specification cable length The cable length does not exceed 20 meters for longer cables pl...

Страница 40: ...e 3 6 Parameters of CAN Port CAN Port Specification maximum frequency maximum frequency 1 0MHz length type signal specification follow the SPEC ISO11898 specification connection terminal DSUB female 9...

Страница 41: ...pied DI5 emergency stop alarm 2 system occupied DI6 safety door 1 system occupied DI7 safety door 2 system occupied DI8 3 user defined DI9 4 user defined DI10 5 user defined DI11 6 user defined DI12 7...

Страница 42: ...ed DO7 system occupied DO8 27 user defined DO9 28 user defined DO10 29 user defined DO11 30 user defined DO12 31 user defined DO13 32 user defined DO14 33 user defined DO15 34 user defined DO16 35 use...

Страница 43: ...ed by up to 2 16DI 16DO modules input 24 VDC output 24 V DC 500mA Table 3 8 List of Local IO Module Extension Type Illustration Quantity Remarks bus coupler 1 bus base module n prepare according to ex...

Страница 44: ...rresponding motion control card to run the corresponding application In some applications the motion control card can also be used to store machine data 2 Be sure to use the motion control card recomm...

Страница 45: ...ay attention to the direction as shown in the figure below Fig 3 10 Insert the Motion Control Card 3 Steps to Pull Out the Motion Control Card Please follow the steps below to pull out the motion cont...

Страница 46: ...Servo Drive Unit Fig 3 11 Introduction to Drive Port J6 motor power port power input port J3 motor power port J2 motor power port braking resistor port J5 motor power port 24VDC power port J4 motor p...

Страница 47: ...ical Operation and Maintenance Manual for Control Cabinet of EC2 S Industrial Robot 37 Fig 3 12 Introduction to Drive Port motor brake port motor brake power supply manual brake release port STO input...

Страница 48: ...Terminal Definition Table of DI DO Terminal Terminal Number Terminal Hole Position IO Wire Label Definition Overload Hole Position X17 output 1 RO1 55 2 RO2 67 3 RO3 8 4 RO4 20 5 RO5 32 EtherCAT commu...

Страница 49: ...afety function loop includes motion controller watchdog control cabinet emergency stop external emergency stop teach pendant emergency stop safety relay safety relay expansion module and servo drive S...

Страница 50: ...rive STO When an emergency stop is photographed the STO signal is directly cut off an emergency stop instruction is issued to make the robot stop urgently and the motor brake is closed at the same tim...

Страница 51: ...ops The default setting is 0 stop However since 1 stop can avoid unnecessary wear of the robot and the additional operations required to restore the system to production it is recommended to choose 1...

Страница 52: ...s locked the two safety signals STOP1 AP STOP1 BM and STOP1 BP STOP1 BM on the X13 external safety signal terminal block can be connected to the controller It is recommended that the wire diameter is...

Страница 53: ...w Fig 3 17 Wiring Diagram of X13 Safety Door Lock 3 5 Human Computer Interaction Unit 3 5 1 Button Operation Panel The buttons on the front panel of the robot electric control cabinet are as shown in...

Страница 54: ...eeds to be confirmed before the robot runs at high speed manually and automatically teach pendant hot swap button Press the button to terminate the emergency stop of the teach pendant shield the netwo...

Страница 55: ...all the functions of controlling the robot such as manual control of robot movement programming to control robot movement setting of IO interaction signals and so on Fig 3 19 EFORT Teach Pendant 1 Fu...

Страница 56: ...Fig 3 21 Buttons on the Right Side Table 3 15 Buttons on the Right Side Number Name Number Name 1 three color light 11 axis 4 movement 2 start 12 axis 5 movement 3 pause 13 axis 5 movement 4 axis 1 m...

Страница 57: ...5 turn page 10 servo power up 2 How to Hold the Teach Pendant Hold the teach pendant with your left hand When you jog the robot your left finger needs to press the hand pressure switch to make the ro...

Страница 58: ...l situations and one person can move each axis of the robot The purpose of the brake release function in an emergency or abnormal situation one person can release the motor brakes of each axis of the...

Страница 59: ...arted Releasing the robot motor holding brake may cause personal injury and property damage Do this only when it is urgent and necessary and it requires special care The following table is the operati...

Страница 60: ...EFORT INTELLIGENT EQUIPMENT CO LTD 50 corresponding motor brake After releasing the button the motor holding brake will resume work...

Страница 61: ...peration will not generate any alarm and change the current running state of the robot 2 What will happen if the mode switch of the teach pendant is inconsistent with the state before hot plugging If...

Страница 62: ...ring the running of the program in the automatic mode Hot plugging of the teach pendant during the running of the program in automatic mode will not affect the current robot operation After inserting...

Страница 63: ...ion introduces general safety guidelines You should also read the Efort Robot Safety Manual carefully 3 If you want to connect to the EC2 S make sure to ground the EC2 S protectively before starting a...

Страница 64: ...ase refer to the ER7C ER7L and ER3B industrial robot mechanical maintenance manual Before the robot leaves the factory it has been calibrated with special equipment for zero point After the calibratio...

Страница 65: ...p panel of the control cabinet fits tightly with the top of the surrounding side panels and there is no abnormal tilting 2 check whether the sealing of the reserved interface cable lock head on the le...

Страница 66: ...control cabinet is intact and loose Number Description Post Location Pieces 1 grounding mark the bottom of the panel grounding screw hole 1 2 hot hand sign the rear brake resistor 1 3 warning note co...

Страница 67: ...ectric control cabinet can be pressed and restored normally 2 whether the emergency stop of the teach pendant can be pressed and restored normally 3 whether the external emergency stop can be pressed...

Страница 68: ...wer supply of the control cabinet 2 disconnect all terminals and network cables on the front of the controller 3 use a flat blade screwdriver to pick up the stop washer as shown in the figure and pry...

Страница 69: ...ect the power supply of the control cabinet 2 disconnect the top and bottom wiring terminals of the safety relay These terminals need to be marked with relevant numbers to ensure that they will not be...

Страница 70: ...e drive These terminals need to be marked with relevant numbers to ensure that they will not be connected incorrectly when reconnected 3 Use a screwdriver to remove 8 M4 Phillips screws and 2 M3 Phill...

Страница 71: ...e right side of the switching power supply These terminals need to be marked with relevant numbers to ensure that they will not be connected incorrectly when reconnected 3 use a screwdriver to remove...

Страница 72: ...nnect the cables restore the control cabinet and power on Mandatory Measures When replacing the fuse or fuse gear please keep the new fuse the same as the factory specifications so as to prevent the d...

Страница 73: ...environment in which the robot works According to the different protection types of each part of the EC2 S robot different cleaning methods can be used Warning Be sure to confirm the type of protectio...

Страница 74: ...abinet boots 1 Check and reset the E stop button on the control cabinet 2 Check whether the teach pendant is successfully connected and if its E stop button has been reset 3 Check whether the E stop b...

Страница 75: ...ant is properly connected and locked 4 Please contact the service professionals if the fault still exists It is strongly recommended that an operator should strictly follow the Electrical Operation an...

Страница 76: ...t types the area displays different events For example if you check the alarm option the value in the information display area displays all the alarms recorded 4 Operating area It includes viewing det...

Страница 77: ...ion 5 3 2 Fault Light Display on the Controller Table 5 1 explains the meanings that the different states of the LED lights in Figure 5 5 stand for Fig 5 5 Controller Table 5 1 LED Light Information D...

Страница 78: ...Green light goes out and red light is always on This is the HW communication error or COC0 CFG initial configuration error file use the REPORT S command to diagnose Whether the cable is disconnected o...

Страница 79: ...ff Module is not configured WI FI LED is used for WI FI Channel Link Activity MODE LED is used for program signal running flashing stop closed ALM alarm light flashing is different for low priority an...

Страница 80: ...NT EQUIPMENT CO LTD 70 Fig 5 6 Drive Monitoring Interface 5 5 Program Running Fault Handling The program running alarm can be viewed in the log on the program editing interface Fig 5 7 Program Running...

Страница 81: ...oil reducer gear lubrication steel gears screws base frame etc neodymium brake motor plastic rubber cables connectors etc battery nickel cadmium or lithium drive circuit board encoder battery 6 3 Disc...

Страница 82: ...in the robot The batteries will explode when heated such as from a blowtorch 2 Be sure to clean up the oil grease in the gearbox The oil will catch fire when heated such as from a blowtorch 3 If the...

Страница 83: ...electrical component and a way of expressing the relationship between each other Understanding the electrical schematic diagram is helpful for the analysis of electrical circuits excluding circuit fa...

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Страница 89: ...Electrical Operation and Maintenance Manual for Control Cabinet of EC2 S Industrial Robot 79...

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Страница 93: ...015264 1 16DI 16DO bus module 10900011262 1 servo drive 10900021999 1 power supply switch 10900010307 1 filter 10900002302 1 filter fuse core 10900017878 2 10A fuse FU1 10900018426 1 FU1 fuse core 109...

Страница 94: ...EFORT INTELLIGENT EQUIPMENT CO LTD 84 robot wiring harness 10900023270 1 hot swap wiring harness optional robot wiring harness 10900011250 1 4M control cabinet to main body ground wire...

Страница 95: ...hat of the last time when it was switched off Solutions If an alarm occurs when the controller is powered on please keep pressing the red ADV button on the controller and restart it 1 1 1 3 Alarm 3 Fa...

Страница 96: ...the positive limit Fault Reasons The target position exceeds the maximum limit that has been set Solutions Reset the target position 1 1 1 8 Alarm 21 Fault Description Abnormity in encoder connection...

Страница 97: ...4 Fault Description The encoder definition in RTE CFG file is illegal Fault Reasons Error in encoder configuration parameter Solutions Check the project configuration or the encoder definition in the...

Страница 98: ...ons Error in joint motion Solutions Code 1 Invalid axis group Check the axis group settings of the controller Code 2 Invalid target point Check whether the target point is reasonable Code 3 Invalid sp...

Страница 99: ...tion and reconfigure it 1 2 1 5 Alarm 1804 Fault Description Error in I O module configuration Please go to the setting interface to modify it code_h u code_l u Fault Reasons I O module configuration...

Страница 100: ...Please check the auxiliary axis drive 1 2 1 11 Alarm 1810 Fault Description The target position of auxiliary axis d exceeds the maximum limit Fault Reasons The target position of single step exceeds...

Страница 101: ...unching machine is greater than the shortest time Solutions Reset the pulse width time in the attribute setting of the punching machine 1 2 2 6 Alarm 3905 Fault Description Non single shot mode of the...

Страница 102: ...program Solutions Please check the program log and troubleshoot the problem based on it 1 2 3 5 Warning 4904 Fault Description XPL program error The program is loaded remotely while the program is run...

Страница 103: ...xiliary axis parameter file will prompt an alarm Solutions Check whether the application AuxAxis auxParData txt exists in the card directory and check whether it is saved successfully If it does not e...

Страница 104: ...Warning 4917 Fault Description Waiting for reclaiming timeout Fault Reasons Timeout of waiting for the reclaiming will prompt an alarm Solutions 1 Please check whether there are any materials at the...

Страница 105: ...nfigure and generate the file 1 2 3 24 Warning 4923 Fault Description External IO module configuration error Fault Reasons External IO module configuration error prompts an error Solutions Check wheth...

Страница 106: ...ction of the drive Fault Reasons There is a problem with the Ether CAT connection of the drive Solutions 1 Optimize the EtherCAT communication wiring and strengthen anti interference measures such as...

Страница 107: ...whether it has poor contact 2 Check whether the drive parameters are set properly 3 Replace the draught fan 4 Restart the electric cabinet 1 3 1 6 Alarm 641 Fault Description Fault activation on PFC...

Страница 108: ...ver frequency 0x0080 PFC temperature is too high 0x0400 PFC circuit hardware fault 0x0800 PFC circuit hardware fault 0x1000 PFC power supply undervoltage overvoltage or Vref fault Solutions 1 Check wh...

Страница 109: ...inet 1 3 1 12 Alarm 647 Fault Description The temperature of the power board is too high Fault Reasons The temperature of the power board is too high Solutions 1 Check whether the drive parameters reg...

Страница 110: ...s reliable 2 Replace the battery 3 If it is a Tamagawa encoder execute the encoder multi turn reset command 4 Restart the electric cabinet 1 3 1 17 Alarm 730 Fault Description The motor cannot follow...

Страница 111: ...e first time the initialization of the motor position sensor does not start Solutions 1 Check the wiring of the motor encoder to ensure that it is connected correctly 2 The encoder cable and the motor...

Страница 112: ...sensor are configured correctly 5 Replace the motor encoder 6 Remove the strong interference source around the drive The drive and the surrounding strong interference source can be powered separately...

Страница 113: ...ns Position sensor storage phase error Solutions 1 Check the wiring of the motor encoder to ensure that it is connected correctly 2 The encoder cable and the motor power cable increase magnetic rings...

Страница 114: ...Replace the drive 9 Upgrade the drive DSP firmware 10 Restart the electric cabinet 1 3 1 28 Alarm 741 Fault Description Braking overvoltage fault of the brake Fault Reasons Braking overvoltage fault...

Страница 115: ...ns An error occurred in the cabinet temperature And the temperature of its base plate is higher than the selected threshold Solutions 1 Check whether the drive parameters regarding the temperature set...

Страница 116: ...lue And then the power of the dynamic braking resistor can be increased 6 Replace the drive 7 Restart the electric cabinet 1 3 1 35 Alarm 754 Fault Description Drive I2T value is greater than the thre...

Страница 117: ...mode of mechanical load to ensure that there is no jamming or any other phenomenon 4 Check the wiring of the motor brake to ensure that it is reliable 5 Check whether the drive parameters are set prop...

Страница 118: ...1 3 1 43 Alarm 771 Fault Description Error in reading hardware code Fault Reasons Error in reading hardware code Solutions 1 Enter mreport a in RDE shell for more information 2 Restart the electric ca...

Страница 119: ...Manual for Control Cabinet of EC2 S Industrial Robot 109 1 3 1 46 Alarm 775 Fault Description Self tuning fault Fault Reasons Self tuning fault Solutions 1 Enter mreport a in RDE shell for more inform...

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Страница 121: ...duct are subject to change without notice if they need to be improved The technical data and illustrations are for reference only and the right to change is reserved EFORT INTELLIGENT EQUIPMENT CO LTD...

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