ESTUN KEBA Series Cabinet

（E-0101EN/01）

MAINTENANCE MANUAL
ESTUN KEBA Series Cabinet

MAINTENANCE MANUAL

E-0101EN/01
Thank you for purchasing ESTUN Robot.
Before using the robot, be sure to read the SAFETY PRECAUTION and understand the content.
ESTUN endeavor to improve the products. All specifications and designs are subject to change without notice.
In this manual, all specifications and information are checked on a regular basis. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. ESTUN assumes no
responsibility for any direct or indirect losses arising from use of this manual and products described herein.
The information contained in this manual is the property of ESTUN Robotics Co., Ltd.

No part of this manual may be reproduced in any form.

ESTUN Robotics@2017, All Rights Reserved Copyright

Service Line: 400-025-3336

ADD: No.178, Yanhu Road, Jiangning Area, Nanjing, China Post Code: 211102
TEL: 025-81031813
FAX: 025-85097089
WEB: www.estun.com
E-mail: robot@estun.com
 SAFETY PRECAUTION

SAFETY PRECAUTION
This chapter describes the precautions which must be followed to ensure the safe use of the robot. Before using the robot, be
sure to read this chapter thoroughly.
ESTUN robots must be transported, mounted and operated in accordance with the applicable national laws, regulations and
standards. Appropriate safeguards must be correctly situated to protect the users. Before using (mounting, operating, maintaining,
repairing) the robot, be sure to read and understand this manual and its relevant manuals. Be sure to have familiarization with the
knowledge of robot system and the safety precaution. Even if all instructions are followed, this is not a guarantee that the robot
will not cause personal injuries or material damage.

DEFINITION OF USER
The personnel can be classified as follows.
 Operator
Turns the robot controller power on/off.
Starts the robot program from operator panel.
 Programmer
Operates the robot.
Teaches the robot inside the safety zone.
 Maintenance engineer
Operates the robot.
Teaches the robot inside the safety zone.
Maintenance (repair, adjustment, replacement)
Operator is not allowed to work in the safety zone.
Programmer and maintenance engineer is allowed to work in the safety zone.
During the operation, programming, and maintenance of the robot system, the programmer, operator and maintenance
engineer should take additional care of their safety by wearing the following safety items.
 Adequate clothes for operation
 Safety shoes
 A helmet

SPECIAL TRAINING
Tasks in the safety zone including transportation, teaching, calibrating, repairing, etc.. Have the operator attending the
training courses before using the robot system.
For more information of training courses, contact ESTUN sales office.

DEFINITION OF SAFETY NOTATIONS

This manual indicates each precaution on safety with “WARNING” or “CAUTION” according to its severity. Supplementary
information is indicated by “INFO”. Read the contents of each notation before using the robot.

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 SAFETY PRECAUTION
Symbol Definitions
Danger notation
！ Death or serious injury will be expected to occur if the user fails to follow the approved procedure.
WARNING

Caution notation
！ Minor or moderate injury of the user or equipment damage will be expected to occur if the user fails to
CAUTION follow the approved procedure.
Information
INFO
A supplementary explanation help users operating the robot more efficiently.

SAFETY OF THE USER

(1) The robot should be transported and installed by accurately following the procedures recommended by ESTUN. Wrong
transportation or installation may cause the robot to fall, resulting in severe injury or damage.
(2) Draw an outline on the floor, clearly indicating the range of safety zone before install the robot. If necessary, install a safety
fence or warning board to ensure the safety operation of the robot and keep unauthorized person outside the safety zone.
(3) Never hang any items above the robot. Failure to observe this caution may result in injury or equipment damage.
(4) Never lean on the controllers, and avoid inadvertently pushing buttons. Failure to observe this caution may result in injury or
damage by unexpected movement of the manipulator.
(5) Take precaution for falling parts when disassemble the robot.
(6) When adjusting each peripheral equipment independently, be sure to turn off the power of the robot.
(7) The peripheral equipment must be grounded.
(8) In the first operation of the robot after installation, the operation should be restricted to low speed. Then, the speed should be
gradually increased to check the operation of the robot.
(9) Operators should be ungloved while manipulating the operator panel or teach pendant. Operation with gloved fingers could
cause an operation error.
(10) Programs, system variables, and other information can be saved on memory card or USB memories. Be sure to save the data
periodically in case the data is lost in an accident.
(11) Never forcibly move the robot axes. Failure to observe this caution may result in injury or equipment damage.
(12) Take precaution when wiring and piping between the controller, the robot and the peripheral equipment. Run the piping,
wiring, or cables through a pit or use a protective cover, so that they are not stepped on by personnel or run over by folklift.
(13) Any robot in working condition may cause severe personnel injury or equipment damage due to unexpected moving. Test
must be performed on each safety measure (safe door, brake, safe indicators, etc.). Before turn on the system, make sure that
no one is in the working space.
(14) Never set motion range or load condition that exceeds the range indicated in specification table. Incorrect setting may result
in personnel injury and equipment damage.
(15) Observe the following precautions when performing teaching operations within the working space of the robot:
 Do not enable the system unless the mode is switched to manual, and make sure that all auto-control is cut off.
 Speed must be limited under 250mm/s at manual mode. Only authorized person with fully understand of the risks can
adjust the robot to rated speed manually.
 Be careful about rotating joints to prevent hair and clothes involved. Take precautions of injury or damage caused by the
manipulator or other auxiliary devices.
 Check the motor brake to avoid personnel injuries caused by unexpected situation.
 Always have an escape plan in mind in case the robot comes towards you unexpectedly.
 Ensure that there is a place to retreat to in case of emergency.

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 SAFETY PRECAUTION

！ Never stand beneath the manipulator in case that the robot move unexpectedly or the system be turned
on inadvertently.
WARNING

！ Make sure that a CO2 fire extinguisher is always available in case of fire.
CAUTION

SAFETY OF THE OPERATOR

(1) Before operating the robot, check that the SERVO ON indicator goes out when the EMERGENCY STOP button on the right
of the front door of the controller and the pendant are pressed. And confirm that the power is turned off.
(2) Never allow unauthorized personnel to touch the controller during operation. Failure to observe this precaution may result in
unexpected movement of the robot, severe injuries and material damage.
(3) When attaching an equipment such as a welding torch to the robot, be sure to turn off the power of the controller and the
peripheral equipment, and display a warning sign. Turning the power on during equipment installation may cause electric
shock or injury due to unexpected movement of the robot.
(4) Emergency stop
Emergency stop is an external button of the controller that can stop the robot operation.
When emergency button is pressed, the power of the robot (except the power of the servo) is cut off. The system will not run
unless the pressed emergency button being released and the system being turned on.

There may be several emergency stop buttons in a robot system to stop the robot in case of emergencies.
The red button, as shown in the left figure, shall be mounted on the teach pendant and the controller.
Certainly, the emergency buttons can be mounted by your requirement.
Emergency stop button shall be located on the place where is easy to reach, so that the buttons can be
pressed down immediately in case of emergencies.

！ Emergency button is used in case of emergency only. It cannot be used to stop the manipulator for
normal operation.
CAUTION

！ Operators must take precautions to avoid high voltage from cables of servo motors, grippers and other
devices.
WARNING

SAFETY OF THE PROGRAMMER

While teaching the robot, the programmer must enter the robot operation area. The programmer must ensure the safety
especially.

！ Turn on the system by press Mot button on the teach pendant. Turn off the system by release Mot
button.
CAUTION

To use the teach pendant safely, the following precautions should be taken.
 Be sure that the enable switch is effective at any time.
 Enable switch must be turned off when pausing, programming or testing the system.
 Teach pendant must be taken with the programmer when performing teaching jobs in the work space, to avoid
inadvertent operation by unauthorized person.

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 SAFETY PRECAUTION
 Teach pendant must not be left within the work space of the robot, as injury or damage can occur if the robot comes in
contact with the teach pendant.

SAFETY OF THE MAINTENANCE ENGINEER

(1) Heated parts
Some parts of the robot are heated when the robot is operating, especially the servo motor and reducer. If a maintenance user
needs to touch such a part in the heated state, the user should wear heat-resistant gloves or use other protective tools.

Try to feel the temperature of heated parts before touching them, to avoid burn injuries.
！ After turning off the power supply, wait until the heated parts cool down before performing any
CAUTION maintenance.

(2) Disassembly parts

Open the cover or shell only after interior parts such as gears are not moving any more. Never open the cover or shell when
the gear or bearing is moving. Use auxiliary device to keep interior part to its position.
Observe the following precaution when performing the first test after installation, inspection or maintenance:
a) Clear tools to proper locations outside of the working space of the robot.
b) Make sure that all precaution measures are available.
c) Make sure that there is no one in the working space of the robot.
d) Pay special attention to working condition of the maintenance parts when performing test.
Never use the manipulator as a ladder when performing maintenance. Never climb on the manipulator. Failure to observe this
caution may result in injury.
(3) Pneumatic / hydraulic pressure
There may be air/liquid residue in the system when the air pump or hydraulic pump is turned off. Before checking the
pneumatic or hydraulic parts, release remaining pressure from the system to avoid personnel injury or equipment damage.

！ Install a safety valve in case of accident.

CAUTION

(4) Although the power supply need to be turned on during fault diagnosis, it must be turned off when perform maintenance.
(5) Brake inspection
Brake may be wearing in daily operation. So brake inspection should be performed by the following procedure:
a) Move each joint to the position where the joint bears maximum load.
b) Turn off the robot. The brake works.
c) Mark each joint.
d) Check if the joint moves over a period of time.
(6) Greasing
Personnel injury or equipment damage may occur during greasing. Observe the following precautions before greasing.
 Take additional care of safety by wearing safety items (such as gloves) to avoid injury from heated oil or reducer..
 Open the oil chamber with special caution and keep away from the opening. Oil may spray due to oil pressure.
 Feed the oil according to required quantity and never fill up the oil chamber. Check the oil indicator when finished.
 Never mix different types of oil into one reducer. Clean remained oil thoroughly before changing another type.
 Oil draining must be performed thoroughly. Check the oil indicator when finished.

INFO Operate the robot for a short period of time before oil draining to heat the oil.

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 SAFETY PRECAUTION

SAFETY OF THE TOOLS AND PERIPHERAL EQUIPMENT

Peripheral device may still be running even after the system has been turned off. Personnel injury may occur due to damaged
power lines.

SAFETY OF THE ROBOT MECHANICAL UNIT

For abnormal or emergency situations, e.g. persons trapped in or pinched by the robot, the robot axes should be moved.
(Contact ESTUN for more details about dismantling).
Small arms can be moved by hand. Lager arms should be moved by crane or other handling equipment.
Fasten the arms of the manipulator firmly before releasing the brake to avoid secondary injury caused by falling arms.

STOP TYPE OF ROBOT

The following three robot stop types exist:

Power-off stop
Servo power is turned off and the robots stops immediately. Servo power is turned off when the robot is moving, the path of
the deceleration in uncontrolled.
The following processing is performed at Power-off stop:
 An alarm is generated and servo power is turned off immediately.
 Execution of the program is paused.
Frequent Power-off stop of the robot during operation can cause failures of the robot. Avoid system designs that require
routine or frequent Power-off stop conditions.

Alarm stop
The robot system sends alarm (not include power-off alarm), and the robot is decelerated until it stops by control instructions.
The following processing is performed at Alarm stop:
 An alarm (not include power-off alarm) is generated due to overload, system faulty, etc.
 Control instruction is send from servo system. The robot operation is decelerated until it stops. Execution of the program
is paused.
 Servo power is off.

Hold
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold:
 The robot operation is decelerated until it stops. Execution of the program is paused.

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 SAFETY PRECAUTION

LABELS

（1）Electric Shock Warning

Fig 0.1 Electric Shock Warning

This label indicates hazardous voltage or electric shock.

（2）High-temperature Warning

Fig 0.2 High-temperature Warning

Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a
section when it is hot, use a protection provision such as heat-resistant gloves.

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 SAFETY PRECAUTION
（3）No Step-on Warning

Fig 0.3 Step-on prohibitive Warning

Never step on or climb the robot or controller as it may adversely affect the robot or controller and may get hurt if you lose
your footing as well.

（4）Personal Injury Warning

Fig 0.4 Personal Injury Warning

Never enter the operation area while the Manipulator is moving. This is extremely hazardous and may result in serious safety
problems.

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 SAFETY PRECAUTION
（5）Energy Storage Warning

Fig 0.5 Energy Storage Warnin

Balance cylinder contains spring, high-pressure gas or liquid. Never dismantle a balance cylinder without permission from
ESTUN.

（6）No Disassembly Warning

Fig 0.6 No Disassembly Warnin

Never perform disassembly arbitrarily where the warning is affixed. Contact ESTUN for disassembly.

s-8
 PREFACE

PREFACE
This manual describes the following manipulators:
Manipulator Type Load Capacity
ER6A-1450 6kg
ER10-1600 10kg
ER16-1600 10kg
ER20-1780 20kg
ER20/10L-2000 10kg
ER20/10HI-2000 10kg
ER30-1900 30kg
ER50-2100 50kg
ER80-2565 80kg
ER100-3200 100kg
ER120-2400 120kg
ER170-2605 170kg
ER180-3200 180kg
ER220-2605 220kg

Related manuals
ESTUN Robot Mechanical Unit Operator’s Manual
ESTUN KEBA Series Cabinet Maintenance Manual
ESTUN KEBA System Operator’s Manual

p-1
 CONTENTS

CONTENTS

SAFETY PRECAUTION ..................................................................................................................................... s-1

PREFACE............................................................................................................................................................ p-1
CONTENTS ............................................................................................................................................................c-1
1. EQUIPMENT CONFIGURATION ................................................................................................................ 1
1.1. Specifications ................................................................................................................................. 1
1.2. Configuration.................................................................................................................................. 2
1.3. Functions of units ........................................................................................................................... 5
2. CHECK AND MAINTENANCE ................................................................................................................... 7
2.1. Maintenance of the Cabinet ............................................................................................................ 7
2.2. Periodic Checks .............................................................................................................................. 9
3. POWER UNIT ............................................................................................................................................. 10
4. CONTROL UNIT ......................................................................................................................................... 18
4.1. Functions ...................................................................................................................................... 18
4.2. Interface ........................................................................................................................................ 18
4.3. Notes............................................................................................................................................. 19
5. SERVO UNIT............................................................................................................................................... 20
6. INPUT AND OUTPUT UNIT ...................................................................................................................... 22
6.1. Interface Definition ...................................................................................................................... 22
6.2. Technical Parameters .................................................................................................................... 24
7. RELAY MODULE UNIT............................................................................................................................. 26
8. REPLACING ............................................................................................................................................... 27
8.1. Replacing Fuses ............................................................................................................................ 27
9. BLOCK DIAGRAM .................................................................................................................................... 28
10. COMMUNICATION CONNECTION ................................................................................................. 29
11. PERIPFIRAL DEVICE INTERFACE.................................................................................................. 31
11.1. Input and Output Module Wiring ................................................................................................. 31
11.2. Terminal Wiring............................................................................................................................ 32
11.3. Plug Wiring................................................................................................................................... 35
12. HANDLING AND INSTALLATION .................................................................................................. 39
12.1. Handling Procedure ...................................................................................................................... 39
12.1.1. Using a Crane to Move the Cabinet...................................................................................... 39
12.1.2. Using a Forklift to Move the Cabinet ................................................................................... 39
12.2. Place of Installation ...................................................................................................................... 39
12.3. Location ........................................................................................................................................ 39
12.4. Connection.................................................................................................................................... 40
12.4.1. Notes on Cable Junctions ..................................................................................................... 40
12.4.2. Connection Methods............................................................................................................. 41
12.5. Adjustment and Confirmation ...................................................................................................... 41
APPENDIX ALARM DISPLAY ...................................................................................................................... 42
REVISION RECORD .......................................................................................................................................... 44

c-1
 EQUIPMENT CONFIGURATION

1. EQUIPMENT CONFIGURATION

1.1. Specifications
Tab 1.1 Basic Specifications of the Cabinet
Size Weight Max. Load
Model Applicable Manipulators
(mm) (kg) (kW)
ER6A-K6B-P-D 620*850*600 160 4.8 ER6A-1450
ER16-K6B-P-D 620*850*600 160 6.2 ER10-1600、ER16-1600
ER20-K6B-P-D 750*850*700 164 14.1 ER20-1780、ER20/10L-2000、ER20/10HI-2000
ER30-K6B-P-D 620*850*600 165 9.5 ER30-1900
ER50-K6B-P-D 750*850*700 199.5 16 ER50-2100
ER80-K6B-P-D 750*850*700 190 23 ER80-2565
ER100-K6B-P-D 750*850*700 199.5 18 ER100-3200
ER170-K6B-P-D 800*1000*700 205 21 ER120-2400、ER170-2605
ER180-K6B-P-D 800*1000*700 195 24.5 ER180-3200、ER220-2605

Tab 1.2 Mounting Specifications

Location Ventilated, unsealed
Min. Mounting Range 2500×2500×1200 (mm, length*width*height)
Protection Level IP20
Ambient Temperature 0°—45°(Need cooling equipment when ambient temperature exceed 45℃)
Input Power Supply Three-phase four wire AC380V 50Hz
Communication interface with
Profibus, EtherCAT, Ethernet IP, Modbus TCP, Serial Port
peripheral device
Cables connect to robot 8m
Noise 50-63dB

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 EQUIPMENT CONFIGURATION

1.2. Configuration
Configurations are subject to change according to different types of manipulators, options and applications.

Front View Right View

Fig 1.1 Exterior View（1）

Back View Left View

Fig 1.2 Exterior View（2）

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 EQUIPMENT CONFIGURATION

Front View Inside the Door

20
Waterproof Waterproof Waterproof
Waterproof connector connector connector
connector M40 M25 M20
M25

Note: The size of servo motor is subject to its power.

Fig 1.3 Exterior View（3）

启动 停止
2 3

本地 远程
4

Fig 1.4 Buttons on the Teach Pendant Panel

Tab 1.3 Description of Buttons on the Panel
Button Description
○1 Emergency Stop Button
○2 Start Button and Operation Indicator
○3 Stop Button and Alarm Indicator
○4 Local/Remote Mode Switch
○5 Power Supply Switch of the Cabinet

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 EQUIPMENT CONFIGURATION

！ Make sure that the door is closed before using the system.
WARNING

Fig 1.5 Configuration of Teach Pendant

1. LCD display, 2. Emergency button, 3. Mode switch, 4. Keyboard, 5. Indicators, 6. Enable switch 7. Hanger bracket, 8. Cable
connection joint, 9. USB interface, 10. Pen
Tab 1.4 ESTUN Teach Pendant Parameters
Teach pendant type KEBA Teach Pendant KeTop T70-rqa-Ak0-Lk
Size (length*width*height) 212*251*73mm
CPU： Freescale Single-core 1GHZ
Memory RAM: 1GB, FLASH: 4GB
Operation system Linux
Color touch screen 7-inch TFT-LCD, pixel 1024×600
Protection level IP65
Length of cable 5m (extensible to 15/20m)
Communication interface Ethernet 100MBit
Data storage USB (high speed)
Power consumption 12W
Weight 950g

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 EQUIPMENT CONFIGURATION

1.3. Functions of units

！ Regenerative resistor reaches extremely high temperature (max. 100-200℃) during system operation.
Never touch the regenerative resistor.
WARNING

Interior Front View Interior Back View

Switching Power Supply VC1

Switching Power Supply VC2

Power Unit

Tubular Resistance
Servo Drivers

Transformer

Interior Left View from Front Interior Right View from Front

Relay Module

Terminals

Power Unit

Air Inlet

Fig 1.6 Interior Configuration (1)

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 EQUIPMENT CONFIGURATION
Interior Back View Interior View of the Right Door

Air Outlet

25
Slot

Air Outlet
Control Unit Input / Output Unit

Fig 1.7 Interior Configuration (2)

(1) Power supply filter: Filter for power supply to guarantee its quality.
(2) Main circuit servo driver on-off unit: Turn on or off the main circuit of servo driver. Turn off automatically when high
current occurs to protect the servo driver circuit.
(3) Servo driver unit: 6 servo drivers in this unit each controls a servo motor of the manipulator.
(4) Main controller: Programmable unit, achieve functions such as motion control of manipulator and peripheral device,
security safeguard, fault alarm, emergency stop, etc.
(5) Reserved connection port: reserved for extensive functions, such as extensive axes, extensive welding work station.
(6) Fan unit: four fans are used to cool interior units. The filter fixed at the air inlet, which is used to keep the interior
cabinet clean, needs to be replaced in daily maintenance.
(7) Connection port: Reserved for safe door and external emergency stop.
(8) Relay module: Integrated with 18 intermediate relay to realize circuit interlock, 18 LED indicators to indicate current
condition, which is important to protect the internal circuit.
(9) Connector unit: The interface between the cabinet and external equipment.
(10) Fuse: Protect 220V circuit, such as control circuit of servo power supply. Protect switching mode power supply circuit.
(11) Filter, transformer, switching power supply unit: This unit transform the power to AC power with required voltage,
then transform it to DC power. Also the filter and protection is provided.
(12) Regeneration resistor: A regeneration resistor on the servo driver is needed to release inverse electric field strength.

6
 CHECK AND MAINTENANCE

2. CHECK AND MAINTENANCE

Please check the following items in daily operation:
 Check that the cable of teach pendant is not extraordinarily bendy. Check that the controller and peripheral devices are in
normal condition.
 Check that the air outlet of the cabinet is not dirty. If it is dirty, immediately clean up dirt.
Check the cooling fans every month. If the cooling fans are dirty, clean up the dirt.
Daily or periodic check and maintenance is essential to keep robot system reliable.

2.1. Maintenance of the Cabinet

（1）Check if the Breaker on the Cabinet is Firmly Closed
The ER cabinet has a fully sealed construction, designed to keep external air containing oil mist out of the cabinet. The
breaker must be turned to off before maintenance.
（2）Check for Gaps or Damage in the Sealed Construction Section
Check the seal around the door is undamaged.
 Check that the inside of the cabinet is not excessively dirty. If it is dirty, determine the cause, take measures to correct the
problem and immediately clean up dirt.
 Fully close each door lock and check that no excessive gaps exist around the edge of the door.
（3）Cooling Fan Inspections
A defective fan can cause the cabinet to malfunction because of excessive high temperature inside.
The interior circulation fan and backside duct fan normally operate while the power is turned on. Check if the fans are
operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet.
（4）Emergency Stop Button Inspections
The emergency stop button is located on the front door of the cabinet and teach pendant. Confirm the servo power is off by
pressing the emergency stop button after the servo on, before the manipulator is operated.
（5）Enable Switch Inspections
The teach pendant is equipped with a three-position enable switch. Perform the following operation to confirm the enable
switch operates.
a) Set the mode switch on the teach pendant to “TEACH”.
b) Press [Mot] on the teach pendant, the [Motion] lamp blinks.
c) When the enable switch is grasped lightly, the servo power is turned on. When the enable switch is grasped firmly or
released, the servo power is turned off.
If the [Motion] lamp does not light in previous operation b), check the following:

！ 

The emergency stop button on the teach pendant is pressed.
The emergency stop button on the front door of the cabinet is pressed.
CAUTION
 The emergency stop signal is input from external.

If the servo is not turned on in a previous operation c), check the following:
！  The overrun limited switch is operating
CAUTION  If a major alarm is occurring

（6）Power Supply Voltage Confirmation

7
 CHECK AND MAINTENANCE
Check the voltage of terminal 1, 3 and 5 of the circuit breaker (QS1) with an electric tester.

Tab 2.1 Power Supply Voltage Confirmation

Measuring Items Terminals Correct Value
Correlate voltage 1-2 2-3 3-1 380V（+10%，-15%）

Voltage to ground 1-PE 2-PE 3-PE 220V（+10%，-15%）

（7）Open Phase Check

Tab 2.2 Open Phase Check List

Check items Contents

Confirm if the lead cable for the power supply is wired as shown in the power unit. If the wiring is
Lead Cable Check
wrong or broken, repair it.
Input Power Supply Check the open phase voltage of input power supply with an electric tester.
Check (Normal value: 330V AC (+10%, -15%))
Main Circuit Power Check the open phase voltage of breaker, filter, transformer, and contactor with an electric tester.
Supply Check (Normal value: 330V AC (+10%, -15%))

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 CHECK AND MAINTENANCE

2.2. Periodic Checks

（●：Replace ：Check）
Check intervals Maintenance Check and
3 Check points Maintenance method
Daily
months
1 year 4 years 5 years 8 years maintenance items
 Cabinet Spatters or dusty Confirm and remove it.

 The labels on Peeling or damage or dirt Confirm and clean it.

cabinet Replace it when peeling or serious
dirt occurs.

 Cooling fans Confirm normal operation Confirm and clean it.

 Filter sponge Check for dirty or blocking Confirm and clean it or replace it.

 Teach pendant panel Check lamps, switches Confirm it.

Operation panel Check buttons
Other switches

 Teach pendant panel Check emergency buttons Confirm that all emergency buttons
Operation panel Check enable switches and enable switches can shut off the
servo power.

 ● ● Cables Check for damage or Confirm it.

Teach pendant fragmentation Tighten it.
cables Check for loosen connectors Replace it when serious damage
Other cables occurs.

 ● Teach pendant Check for damage Confirm and clean it.

Clean the operation site Replace the teach pendant when
Check LCD obvious dark occurs on the LCD.

● Repair

Use a soft cloth to clean dust. Do not use a fan to blow the dust. Wind pressure may blow dust into the
！ fan, which may cause excessive speed and malfunction, or shorten the service life of the fan. Apply
CAUTION vacuum cleaner only to fan blade. Do not use vacuum cleaner on rotating parts or the manipulator.

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 POWER UNIT

3. POWER UNIT
After filtering, the three-phase AC power of 380V is transformed to 220V by a transformer. (This is for cabinet with 200V
ER6A-K6B-P-D
servo motors. Cabinet with 400V servo motors has no transformer). When temporary voltage interruption or drop or any driver
alarm occurs, turn off the power supply and servo power before maintenance.

AC380V 3PH/50HZ

Power Supply Wire

2.5mm2
Device Boundary

Connector
Waterproof

Main Switch
QS1

32A

Main Breaker
25A
QF1
FU3
16A

FU1
4A
L
+V

AC220V
350W

VC1

DC24V
DC24V

N
1.5mm2

-V
10A
FU4

Brake Power
L
+V

AC220V

DC24V
200W

VC2
DC24V

N
0.75mm2

-V

2.5mm2
SG-2KVA 380V/200V
1.2KVA,22OV 800VA
FU2
4A

AC220V

Fans
EV4

EV3

EV2

EV1

TC1

Servo Power Supply1

QF2
16A
KM2
18A

AC200V
1.5mm2

Power
Servo Control
AC200V
1.5mm2

EMI1

KM1
18A
20A

Servo Power Supply2

A
C
B

AC380V
1.5mm2

Fig 3.1 Power Supply Wire（ER6A-K6B-P-D、ER16-K6B-P-D）

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 POWER UNIT
ER20-K6B-P-D

Main Switch Servo Control

Power Supply Wire Main Breaker Brake Power Fans Servo Power Supply1 Servo Power Supply2
Power
AC380V 3PH/50HZ 40A 32A DC24V DC24V AC220V AC200V AC200V AC380V

Fig 3.2 Power Supply Wire（ER20-K6B-P-D）

Waterproof
Connector
SG-5KVA 380V/200V
4KVA,22OV 800VA

11
Device Boundary

L N L N A
AC220V AC220V B
DC24V DC24V C
+V -V +V -V
 POWER UNIT
ER30-K6B-P-D

Main Switch Main Breaker Servo Control

Power Supply Wire Brake Power Fans Servo Power Supply1 Servo Power Supply2
Power
AC380V 3PH/50HZ 40A 32A DC24V DC24V AC220V AC200V AC200V AC380V
2.5mm2 QS1 QF1 2.5mm2

Fig 3.3 Power Supply Wire（ER30-K6B-P-D）

Waterproof
Connector
TC1
SG-2KVA 380V/200V
1.2KVA,22OV 800VA

12
FU1 FU2 KM1
Device Boundary

4A 4A QF2
16A 25A
EV1
VC1 VC2
L N L N EV2 A
AC220V AC220V KM2 EMI1 B
DC24V DC24V C
+V -V +V -V
18A 20A
350W 200W
EV3
FU3 FU4
16A 10A
EV4
1.5mm2 0.75mm2 1.5mm2 1.5mm2 1.5mm2
 POWER UNIT
ER50-K6B-P-D

Power Supply Wire Main Switch Brake Power Fans Servo Power Supply
AC380V 3PH/50HZ 40A DC24V DC24V AC220V AC380V
4mm2 QS1 4mm2
0.75mm2

Fig 3.4 Power Supply Wire（ER50-K6B-P-D）

FU1
Waterproof 4A
Connector
QF1
TC1
32A
JBK5-800VA 380V/220V
EMI2 Filter

13
6A
KM1
Device Boundary

32A
FU2 FU3
4A 4A
A
EMI1 B
EV1 C
30A
VC1 VC2
L N L N EV2
AC220V AC220V
DC24V DC24V
+V -V +V -V
350W 200W
EV3 2.5mm2?á2
FU4 FU5
16A 10A
EV4
1.5mm2 0.75mm2
ER80-K6B-P-D
POWER UNIT

DC24V Power
Power Supply Wire Filter Brake Control Power
220V Control Power
-A Waterproof Connector

Fig 3.5 Power Supply Wire（ER80-K6B-P-D）

Device Boundary

14
 POWER UNIT
ER100-K6B-P-D

Servo Control
Power Supply Wire Main Switch Main Breaker Brake Power Fans Servo Power Supply1 Power Servo Power Supply2
AC380V 3PH/50HZ 40A 40A DC24V DC24V AC220V AC200V AC200V AC380V
4mm2 QS1 QF1 4mm2

Fig 3.6 Power Supply Wire（ER100-K6B-P-D）

1.5mm2 4mm2
Waterproof
Connector
TC1
SG-2KVA 380V/200V
AC220VAC200V
1.2KVA,22OV 800VA

15
FU1 FU2 KM1
QF2
Device Boundary

4A 4A
16A 32A
EV1
VC1 VC2
L N L N EV2 A
AC220V AC220V KM2 EMI1 B
DC24V DC24V C
+V -V +V -V
12A 30A
350W 200W
EV3
FU3 FU4
16A 10A
EV4
1.5mm2 0.75mm2 1.5mm2 1.5mm2 2*2.5mm2
 POWER UNIT
ER170-K6B-P-D

Power Supply Wire Main Switch Brake Power Fans Servo Power Supply
AC380V 3PH/50HZ 63A DC24V DC24V AC220V AC380V
6mm2 QS1 6mm2
0.75mm2

Fig 3.7 Power Supply Wire（ER170-K6B-P-D）

FU1
Waterproof 4A
Connector
QF1
TC1
50A
JBK5-800VA 380V/220V
EMI2 单相滤波器
6A

16
Device Boundary

KM1
50A
FU2 FU3
4A 4A
A
EMI1 B
EV1 C
50A
VC1 VC2
L N L N EV2
AC220V AC220V
DC24V DC24V
+V -V +V -V
350W 200W
EV3 2.5mm2?á2
FU4 FU5
16A 10A
EV4
1.5mm2 0.75mm2
 POWER UNIT
ER180-DQYL-01

DC24V Power
Power Supply Wire Main Switch KeMotion KeTop I/O Power Servo Control Power Control Circuit Servo Control Power

Fig 3.8 Power Supply Wire（ER180-K6B-P-D）

FU1
4A
Waterproof TC1
Connector
AC380/220V
800VA
Device Boundary

17
KM1
FU2
6A
A
B
C
FU3 FU4
20A 10A
 CONTROL UNIT

4. CONTROL UNIT

4.1. Functions
Control unit is the motion control center of the robot system. The unit, which performs motion control and coordinate control,
is a core unit to receive instructions from teach pendant and send control signal from terminals.

Fig 4.1 Interface Arrangement of Control Unit

4.2. Interface
Tab 4.1 Interfaces of Controller
No. Interface
1 Power Supply
2 USB interface
3 Graphic and image interface
4 Fault diagnosis interface
5 Reserved extensive module interface
6 USB interface
7 Ethernet interface
8 CAN interface

18
 CONTROL UNIT

4.3. Notes
The dimension of the controll unit is shown below.

1206

270

101

Fig 4.2 Dimension of Control Unit

19
 SERVO UNIT

5. SERVO UNIT
(1) Do not connect the servomotor directly to the local electrical network.
Failure to observe this may result in damage to servomotor. Servo motor cannot run properly without servo driver.
(2) Do not plug or unplug connectors from servo drive when power is on.
Failure to observe this may result in damage to servo drive and servomotor.
(3) Wait at least 5 minutes before inspections.
Please note that even after power is removed, residual voltage still remains in the capacitor inside the servo drive. If
inspection is to be performed after power is removed, please wait 5 minutes to avoid risk of electrical shock.
(4) Keep servo drives and other devices separated by at least 10mm.
The servo drive generates heat. Install the servo drive so that it can radiate heat freely. When installing servo drives with other
devices in a control panel, provide at least 10mm space between them and 50mm space above and below them. Please install servo
drives in an environment free from condensation, vibration and shock.
(5) Perform noise reduction and grounding properly.
Please comply with the following instructions to avoid noise generated by signal lines.
1. Separate high-voltage cables from low-voltage cables.
2. Use cables as short as possible.
3. Single point grounding is required for the servomotor and servo drive (grounding resistance 100Ω or below).
4. Never use a line filter for the motor's power supply in the circuit
(6) Conduct a voltage resistance test for the servo drive under the following conditions:
1. Input voltage: AC 1500Vrms, 1 minute
2. Braking current: 100mA
3. Frequency: 50/60Hz
4. Voltage applied point: Between L1, L2,L3 terminals and frame ground.
(7) Use a fast-response type ground-fault interrupter.
For a ground-fault interrupter, always use a fast-response type or one designed for PWM inverters. Do not use a time-delay
type.
(8) Do not make any extreme adjustments or setting changes of parameters.
Failure to observe this caution may result in injury or damage to the product due to unstable operation.
(9) The servomotor cannot be operated by turning the power on and off.
Frequently turning the power ON and OFF causes the internal circuit elements to deteriorate, resulting in unexpected
problems. Always start or stop the servomotor by using reference pulses.
Display of normal operation is shown in the following figure.

Fig 5.1 Controller Display

20
 SERVO UNIT

Charge indicator
Lights when the main circuit
power supply is ON and Power-on indicator
stays lit as long as the main CHARGE Lights when the controller is
POWER
circuit power supply turned ON.

N3
capacitor remains charged.

C
L1 Connector for
Main circuit power supply L2 communication

N4
C
L3
terminals Connecting

＋1
I/O signal connector
Connecting terminal of ＋2
Used for reference input

N1
C
DC reactor
－ signals and sequence I/O
Control power supply L1C
signals.
terminals
L2C

B1 Encoder connector

N2
C
B2
Regenerative resistor B3
Connects to the encoder in the
connecting terminals servomotor.

Servomotor terminals V

Ground terminal

Fig 5.2 Driver Terminal and Description

The servo motor and redactor generate heat, especially in high-temperature environment. Do not touch the heated parts to
avoid injury.

21
 INPUT AND OUTPUT UNIT

6. INPUT AND OUTPUT UNIT

6.1. Interface Definition

Fig 6.1 Input and Output Unit Interface

Tab 6.1 Input and Output Unit Interface Definition

No. Interface
1 Power supply
2 Digital output interface
3 Digital input interface

The wiring diagram is shown as below.

22
 INPUT AND OUTPUT UNIT

Fig 6.2 Input Module Wiring Diagram

Fig 6.3 Output Module Wiring Diagram

23
 INPUT AND OUTPUT UNIT

6.2. Technical Parameters

Technical parameters of digital input and output module are show in the following table.

Tab 6.2 Technical parameters (In general)

Parameter Description
24V DC from the front (19.2V to 30V, acc. to IEC61131-2)
Power supply voltage 24V DC from K-Bus
5V from K-Bus
Overvoltage category Ⅱ
Equipment class Ⅲ according to IEC61131-2:2007
Addressing at K-Bus Via 16-digit address switch, on the side
Connection terminals Open terminals, grid dimensions 5.08 mm
Max. power consumption K-Bus 24 V 1.9W
Max. power consumption K-Bus 5 V 0.4W
Height 120mm
Width (with / without K-Bus plug) 32.5mm/22.5mm
Depth 100mm
Weight 135 g
Operating temperature +5℃～+55℃
Storage temperature -40℃～+70℃
Relative humidity of air 10％～95％ (not condensing)
Vibration / Shock resistance According to EN 61131-2:2007
System bus interface Parallel bus interfaces, plug-in on side

表 6.1 Technical parameters of digital inputs

Parameter Description
Number of inputs 8
Input type Type 1 (according to EN 61131-2:2007)
Voltage range for LOW ≥-3V, ≤+5V
Voltage range for HIGH ≥+15V, ≤+30V
Status display Green LED
Cycle time 1ms
Debouncing Configurable 1 ms, 100 ms

表 6.2 Technical parameters of interrupt inputs

Parameter Description
Number of inputs 2 (DI0, DI1) of the digital inputs
Input type Type 1 (according to EN 61131-2:2007)
Voltage range for LOW ≥-3V, ≤+5V
Voltage range for HIGH ≥+15V, ≤+30V
Status display Green LED
Response time of the K-Bus Interrupt 50μs
Galvanic insulation yes

24

Tab 6.3 Technical parameters of digital outputs
Parameter
Number of outputs
Rated voltage
Processing time
Rated current
Protection device
Max. inductive load
Status display
Galvanic insulation
INPUT AND OUTPUT UNIT
Description
8
24V DC
1ms
2A at 50% coincidence
Short circuit protection
1 J at max. 0.2 Hz
Orange LED
Yes, to selection electronics and to inputs
Electric strength 707 V

25
 RELAY MODULE UNIT

7. RELAY MODULE UNIT

Relay module (type: 11261100001) is integrated with 18 LED indicators to indicate current condition, which is important to
protect the internal circuit.

Fig 7.1 Relay Module Diagram

Indicator 1: Servo driver power supply indicator. Light on: Power on. Light off: Power off
Indicator 2: Chief servo alarm indicator. Light on: No alarm. Light off: There is an alarm.
Indicator 3,4: Emergency stop indicator. Light on: No emergency stop. Light off: There is an emergency stop.
Indicator 5: Teach pendant indicator. Light on: No teach pendant. Light off: There is a teach pendant.
Indicator 6: Servo driver power supply indicator. Light on: Power on. Light off: Power off

2 1 2 3 4 5 6

Brake indicato r. 3
From top to down, each indicates the
brake of one of the 6 servo motors.
Light on: Brake released. 4
Light off: Brake closed. Servo alarm indicator.
From left to right, each indicates the
5 1 2 3 4 5 6 alarm of one of the 6 servo drivers.
Light on: No alarm.
Light off: There is an alarm.
6

Fig 7.2 Relay Module Indicators

26
 REPLACING

8. REPLACING

8.1. Replacing Fuses

！ Power supply must be turned off before replacing fuses.

CAUTION

Replacement procedure:
（1） Open the fuse slot and take out the fuse.
（2） Install the new fuse of same type.
（3） Close the slot firmly.

27
 BLOCK DIAGRAM

9. BLOCK DIAGRAM
The following figure shows the block diagram of electric interface of the cabinet.

Factory Monitor

Extensive device
(PLC, sensors, etc.)

ESTUN
Teach pendant
KEBA (option)
Cabinet 1.Palletizing
Manipulator 2.Arc welding
3.Bending
(DEG) 4.Die-casting
5.Other applicaitons
Power Supply
(AC 380V)

Fig 9.1 Block Diagram

28
 COMMUNICATION CONNECTION

10. COMMUNICATION CONNECTION

EC Interface
DIAG

USB1
EC Interface
PANEL / SIO
EC Interface
EC Interface
JB001/A SET

WiFi
Teach pendant
terminal box

3G/4G
shoule be fixxed.

3G/4G and
WiFi antenna

VPN Router

Fig 10.1 Communication connection between controller and servo motors (ER180-K6B-P-D)

29
COMMUNICATION CONNECTION

Fig 10.2 Communication connection between controller and servo motors (Other models)
LAN
VPN Router
WiFi 3G/4G
3G/4G and
WiFi antenna
shoule be fixxed.

30
J1 J2 J3 J4 J5 J6
CN3 CN4 CN3 CN4 CN3 CN4 CN3 CN4 CN3 CN4 CN3 CN4 Teach pendant
terminal box
JB001/A SET
 PERIPFIRAL DEVICE INTERFACE

11. PERIPFIRAL DEVICE INTERFACE

11.1. Input and Output Module Wiring

(Default) (Default)

Sy stem
Alarm ES
20 20

M D1
S4 Relay Mo d u le S10

SB2

19 19
501

502

504
00 01 02 03 04 05 06 07 08 09

0V 24V DO0 DO1 DO2 DO3 DO4 DO5 DO6 DO7

DM1 DM2
DM 2 7 2 /A

DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7

10 11 12 13 14 15 16 17
200

201

203

204

207
MD1
XT2
8 10 S11 SA1
JB0 0 1 /A
Teach Pen d an t
Relay Mo d u le

Pau se Safe d o o r ES Op eratio n Alarm Lo cal/Remo te

Reset
(Default) (Default)

Fig 11.1 Input and Output Module Wiring (1)

31
 PERIPFIRAL DEVICE INTERFACE

20

19

09 00 01 02 03 04 05 06 07 08 09

DO7 0V 24V DO0 DO1 DO2 DO3 DO4 DO5 DO6 DO7

DM2
DM 2 7 2 /A

DI7 DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7

17 10 11 12 13 14 15 16 17
207

o cal/Remo te

Fig 11.2 Input and Output Module Wiring (2)

11.2. Terminal Wiring

XT1
Four-cable Four-cable
plug-in terminal Four-cable
plug-in terminal plug-in terminal

Dual-cable plug-in terminal

Terminal Isolation

Four-cable
plug-in terminal

Dual-cable
plug-in terminal

Fig 11.3 Terminal Wiring (ER6A-K6B-P-D、ER16-K6B-P-D)

32
 PERIPFIRAL DEVICE INTERFACE
XT1
Four-cable Four-cable
plug-in terminal Four-cable
Four-cable plug-in terminal Four-cable plug-in terminal Four-cable
plug-in terminal plug-in terminal plug-in terminal

Dual-cable plug-in terminal

Dual-cable plug-in terminal
Terminal Isolation
Terminal Isolation

Four-cable
plug-in terminal
Four-cable
plug-in terminal

Dual-cable
plug-in terminal

Dual-cable
plug-in terminal

Fig 11.4 Terminal Wiring (ER20-K6B-P-D)

Four-cable Four-cable Four-cable

plug-in terminal plug-in terminal plug-in terminal

Terminal Isolation Dual-cable plug-in terminal

Four-cable
plug-in terminal

Dual-cable
plug-in terminal

Fig 11.5 Terminal Wiring (ER30-K6B-P-D)

Four-cable Four-cable Four-cable

plug-in terminal plug-in terminal plug-in terminal

Four-cable Four-cable Four-cable

Terminal Isolation Dual-cable plug-in terminal plug-in terminal
plug-in terminal plug-in terminal

Terminal Isolation

Four-cable
plug-in terminal
Four-cable
plug-in terminal

Dual-cable
plug-in terminal
Dual-cable
plug-in terminal

Fig 11.6 Terminal Wiring (ER50-K6B-P-D、ER100-K6B-P-D)

Baffle Baffle Baffle 33

 Dual-cable
plug-in terminal

PERIPFIRAL DEVICE INTERFACE

Baffle Baffle Baffle

Fig 11.7 Terminal Wiring (ER80-K6B-P-D)

Four-cable Four-cable Four-cable

plug-in terminal plug-in terminal plug-in terminal

nal Terminal Isolation Dual-cable plug-in terminal

Four-cable
plug-in terminal

Dual-cable
plug-in terminal

Fig 11.8 Terminal Wiring (ER170-K6B-P-D、ER180-K6B-P-D)

Pin 19 may connect to an external safe door signal.

INFO An external emergency stop signal can be connected between pin E002 and E004.
An external emergency stop signal can be connected between pin E006 and E008.

34
 11.3. Plug Wiring
动力航插 PERIPFIRAL DEVICE INTERFACE

Plug Pin Definition Previous: 24

Pin Line Number 25 U6
1 U1 26 V6
Connect to cable Connect to cable
shielding layer shielding layer 2 V1 27 W6
3 W1 28 6PE
4 1PE 29 41

30 1 1 30 5 30 42

36 25 16 7 7 16 25 36 6 31 43

31 21 12 2 2 12 21 31 7 U2 32 44

37 26 17 8 8 17 26 37 8 V2 33 45

32 22 13 3 3 13 22 32 9 W2 34 46

38 27 18 9 9 18 27 38 10 2PE 35 30

33 23 14 4 4 14 23 33 11 36 30

39 28 19 10 10 19 28 39 12 U3 37 30

34 24 15 5 5 15 24 34 13 V3 38 30

40 29 20 11 11 20 29 40 14 W3 39 30

35 6 6 35 15 3PE 40 30
16 U4
17 V4

D
18 W4
19 4PE
20
Male plug Han 40 EEE-M-C Femal plug Han 40 EEE-F-C
21 U5
22 V5
23 W5
24 5PE
Next: 25

Fig 11.9 Power Plug Wiring (ER6A、ER16、ER30、ER80)

35
 PERIPFIRAL DEVICE INTERFACE

Plug Pin Definition Previous: 24

Pin Line Number 25 V4

34 1 1 34 1 U1 26 W4
24 14 14 24 2 V1 27 4PE
35 2 2 35 3 W1 28
25 15 15 25 4 1PE 29
36 3 3 36
5 U2 30
37 26 16 4 4 16 26 37 6 V2 31 30

38 5 5 38 7 W2 32 30
27 17 17 27 8 2PE 33 30
39 6 6 39 9 34 U5
28 18 18 28
10 35 V5

D
40 7 7 40
11 41 36 W5
41 29 19 8 8 19 29 41 12 42 37 5PE

42 9 9 42 13 43 38 U6
30 20 20 30
14 U3 39 V6
43 10 10 43 15 V3 40 W6
31 21 21 31
44 11 11 44 16 W3 41 6PE

D 45

46
32

33
22

23
12

13
12

13
22

23
32

33
45

46
17
18
19
20
21
3PE

30
42
43
44
45
46
44
45
46
22 30

D
Male plug Han 46 EEE-M-C Femal plug Han 46 EEE-F-C
23 30
24 U4
Next: 25

Fig 11.10 Power Plug Wiring (ER20、ER50、ER100、ER170)

Plug Pin Definition Previous: 24

Pin Line Number 25 U6
1 U1 26 V6
Connect to cable Connect to cable
shielding layer shielding layer 2 V1 27 W6
3 W1 28 6PE
4 1PE 29

30 1 1 30 5 30 41

36 25 16 7 7 16 25 36 6 30 31 42

31 21 12 2 2 12 21 31 7 U2 32 43

37 26 17 8 8 17 26 37 8 V2 33 44

32 22 13 3 3 13 22 32 9 W2 34 45

38 27 18 9 9 18 27 38 10 2PE 35 46

33 23 14 4 4 14 23 33 11 36 30

39 28 19 10 10 19 28 39 12 U3 37 30

34 24 15 5 5 15 24 34 13 V3 38 30

40 29 20 11 11 20 29 40 14 W3 39 30

35 6 6 35 15 3PE 40 30
16 U4
17 V4
18 W4
19 4PE
20
Male plug Han 40 EEE-M-C Femal plug Han 40 EEE-F-C
21 U5
22 V5
23 W5
24 5PE
Next: 25

Fig 11.11 Power Plug Wiring (ER80)

36
 PERIPFIRAL DEVICE INTERFACE

Plug Pin Definition Previous: 24

Pin Line Number 25 V3

34 1 1 34 1 U1 26 W3
24 14 14 24 2 V1 27 3PE
35 2 2 35 3 W1 28 43
25 15 15 25 4 1PE 29 30
36 3 3 36

D
5 41 30
37 26 16 4 4 16 26 37 6 30 31 L09

38 5 5 38 7 32 L10
27 17 17 27 8 33 L11
39 6 6 39 9 L01 34 U4
28 18 18 28
40 7 7 40 10 L02 35 V4
11 L03 36 W4
41 29 19 8 8 19 29 41 12 L04 37 4PE

42 9 9 42 13 L05 38 44
30 20 20 30
14 U2 39 30
43 10 10 43 15 V2 40
31 21 21 31
44 11 11 44 16 W2 41
17 2PE 42 L12
32 22 22 32
45 12 12 45 18 42 43 L13

46 33 23 13 13 23 33 46 19 30 44 L14

编码器航插 一样的
20 45 L15
21 L06 46 L16
22 L07
Male plug Han 46 EE-M-C Femal plug Han 46 EE-F-C
23 L08
24 U3
Next: 25

Fig 11.12 Power Plug Wiring (ER180)

Encoder Plug Pin Definition Previous:24

Pin Line Number 25 5V-4
1 1S+ 26 0V-4
Connect to cable Connect to cable
shielding layer shielding layer 2 1S- 27 5S+
3 28 5S-
4 29

30 1 1 30 5 5V-1 30

36 25 16 7 7 16 25 36 6 0V-1 31

31 21 12 2 2 12 21 31 7 2S+ 32 5V-5

37 26 17 8 8 17 26 37 8 2S- 33 0V-5

32 22 13 3 3 13 22 32 9 34 6S+

38 27 18 9 9 18 27 38 10 35 6S-

33 23 14 4 4 14 23 33 11 36

39 28 19 10 10 19 28 39 12 5V-2 37

34 24 15 5 5 15 24 34 13 0V-2 38 5V-6

40 29 20 11 11 20 29 40 14 3S+ 39 0V-6

35 6 6 35 15 3S- 40
16
17
18 5V-3
Connect to cable Connect to cable
shielding layer shielding layer 19 0V-3
20
Male plug Han 40EEE-M-C Femal plug Han 40EEE-F-C
21 4S+
22 4S-
23
24
Next: 25

Fig 11.13 Encoder Plug Wiring

37
 IO航插 一样的 PERIPFIRAL DEVICE INTERFACE

IO Plug Pin Definition

Pin Line Number
1 01
2 02
3 03
4 04
5 05
21 17 13 9 5 1 1 5 9 13 17 21 6 06
7 07
22 18 14 10 6 2 2 6 10 14 18 22
8 08

23 19 15 11 7 3 3 7 11 15 19 23 9 09
10 10
24 20 16 12 8 4 4 8 12 16 20 24 11 11
12 12
13 13
14 14
15 15
16 16
Male plug Han 24DD-M-C Femal plug Han 24DDE-F-C
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24

Fig 11.14 IO Plug Wiring

38
 HANDLING AND INSTALLATION

12. HANDLING AND INSTALLATION

12.1. Handling Procedure

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

12.1.1. Using a Crane to Move the Cabinet

Check the following before handling the cabinet:

 Confirm the weight of the cabinet before handling, and use a wire rope with a rating that is greater than the weight of the
cabinet.
 Install eyebolts for handling and confirm they are securely fastened before hoisting.

12.1.2. Using a Forklift to Move the Cabinet

Observe the following precautions when using a forklift to handle the cabinet:
 Confirm that there is a safe work environment and that the cabinet can be transported safely to the installation site.
 Inform people along the forklift route that equipment is being moved in their area.
 Secure the controller so it cannot shift or fall during handling.
 Transport the cabinet at lowest possible height.
 Avoid jarring, dropping, or hitting the cabinet during handling.

12.2. Place of Installation

The conditions listed below must be met before installing the cabinet:
 Ambient temperature must be 0 to 45°C (32 to 113°F) during operation and -10 to 60°C (14 to 140°F) during
transportation and maintenance.
 Humidity must be low with no condensation (under 10%RH).
 It must be a place with little dirt, dust, or water.
 No flammable or corrosive liquids or gases, etc. in the area.
 Little jarring or potential for striking of the cabinet (under 0.5 oscillation).
 No large electric noise source (such as a TIG welding device, etc.) nearby.
 No potential for collision with moving equipment such as forklifts.

12.3. Location
Observe the following precautions when locating the cabinet:
 The cabinet must be installed in a location from which the robot is easily visible.
 The cabinet must be installed outside the safeguarding.

39
 HANDLING AND INSTALLATION
 The cabinet must be installed in a location from which you can easily inspect it when the door is open.
 The cabinet must be installed at least 500mm from the nearest wall to allow maintenance access.

12.4. Connection

The system must be grounded. Failure to ground equipment may result in injury from fire or electric
shock.
Before grounding the system, turn off the power supply and lock the main power switch. Failure to
observe this caution may result in injury and electric shock.
Do not touch any unit inside the controller for five minutes after turning off the power supply.

！ Capacitors inside the controller store electricity after power is turned off. Exercise caution whenever
handling circuit boards. Failure to observe this caution may cause electric shock.
WARNING
Power cannot be turned on unless the door is closed. Interlocks prevent power from being turned on.
Failure to observe this caution may result in fire and electric shock.
Any occurrence during wiring while the cabinet is in the emergency stop mode is the user’s
responsibility. Do an operation check once the wiring is completed. Failure to observe this caution
could lead to injury or mechanical failure.

Wiring must be performed only by authorized personnel. Incorrect wiring may cause fire and electric
shock.

！ Perform wiring in accordance with the rated capacity as specified in the Manuals. Incorrect wiring
may cause fire or mechanical breakdown.
CAUTION
Be sure the power circuit screws are securely tightened. Loose power circuit wires can cause fire and
electric shock.

12.4.1. Notes on Cable Junctions

The cables that connect the controller to peripheral device are low voltage circuits. Keep controller signal cables away from
the primary power circuit. High voltage power lines should not be run in parallel to controller signal cables. If running parallel
cabled is unavoidable, use metal ducts or conduit to isolate electrical signal interference. If cables must be crossed, run the power
cables perpendicular across the signal cables.
Confirm the connector and cable numbers to prevent misconnection and equipment damage. One connects the manipulator
and the cabinet. Another connects the cabinet and peripheral device. A wrong connection can cause damage to electronic
equipment.
Clear the area of all unauthorized personnel while making cable connections. Place all cables in a covered cable channel in
the floor.

Piping Cable Lead

channel

Fig 12.1 Cable Junction Diagram

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 HANDLING AND INSTALLATION

12.4.2. Connection Methods

（1）Connect power cables

 Remove the package, and take out the power cables. Connect the cable to the connectors on each side of the cabinet
 Connect the manipulator to the cabinet.
Confirm the shape and size of the cable connector, the key fitting, and the position of the pins of the manipulator. Push the
cable connector into the manipulator side connector firmly, and tighten securely.
（2）Connecting the teach pendant
Connect the teach pendant cable to the connector on the door right side of the controller cabinet.

Alignment mark

Fig 12.2 Connect teach pendant and controller

12.5. Adjustment and Confirmation

Adjustment procedures are shown as follows:

Item Content
1 Check the appearance of the cabinet.
2 Confirm that the bolts have been fastened firmly.
3 Confirm that the connector and all units of the controller are in proper condition.
4 Connect controller and robot with cables.
5 Turn off the breaker, and connect input power supply cables.
6 Confirm the voltage of input power supply.
7 Press emergency stop button on the panel. Switch on the power.
8 Confirm the interface signal between controller and robot.
9 Confirm and set parameters.
10 Touch emergency stop button on the panel.
11 Confirm the motion condition of each axis on manual mode.
12 Confirm the condition of each port signal.
13 Confirm the motion condition of each control interface of peripheral device.

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 APPENDIX

APPENDIX ALARM DISPLAY

Alarm Alarm
Alarm Name Meaning
Display Output
A.01 ╳ Parameter breakdown The checksum results of parameters are abnormal.
A.02 ╳ AD shift channels breakdown AD related electrical circuit is faulty.
Overspeed The servomotor speed is excessively high and the
A.03 ╳
servomotor is out of control.
Overload The servomotor is operating continuously under a torque
A.04 ╳
largely exceeding ratings.
A.05 ╳ Position error counter overflow Internal counter overflow.
A.06 ╳ Position error pulse overflow Position error pulse exceeded parameter (Pn504).
The setting of electronic gear or given The setting of electronic gear is not reasonable or the given
A.07 ╳
pulse frequency is not reasonable. pulse frequency is too high.
The 1st channel of current detection is Something wrong with the inside chip of the 1st channel.
A.08 ╳
wrong.
The 2nd channel of current detection is Something wrong with the inside chip of the 2nd channel.
A.09 ╳
wrong.
A.10 ╳ Incremental encoder disconnection At least one phase shortage occurs in PA、PB、PC.
A.12 ╳ Overcurrent An overcurrent flowed through the IPM.
Overvoltage Main circuit voltage for servomotor rotation is excessively
A.13 ╳
high.
Undervoltage Main circuit voltage for servomotor rotation is excessively
A.14 ╳
low.
A.15 ╳ Bleeder resistor error Bleeder resistor is faulty.
A.16 ╳ Regeneration error Regenerative circuit error.
A.17 ╳ Rotate transformer abnormal Rotate transformer communication is abnormal.
A.18 ╳ IGBT superheat alarm IGBT temperature is too high.
A.19 ╳ Motor overheat alarm Motor temperature is too high.
A.20 ╳ Power line phase shortage One phase does not bring into main circuit power supply.
A.21 ╳ Instantaneous power off alarm An power off for more than one period is occurred in AC.
Motor temperature detection sensor is Encoder cable is error.
A.22 ╳
break off.
A.23 ╳ Brake overcurrent alarm Bleeder resistor is too small, or bleeder module is faulty.
A.25/26 Motor power line U/V/W over current Mechanical stuck or motor power line UVW phase
╳
/27 sequence is wrong.
A.28 ╳ Nikon encoder temperature is too high Nikon Encode internal Temperature (unit: ℃) is too high.
A.41 ╳ Reserved Reserved
Servomotor type error The parameter setting of servo drive does not match the
A.42 ╳
servomotor.
Servo drive type error The parameter setting of servo drive does not match the
A.43 ╳
servomotor.
A.44 ╳ Reserved Reserved

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 APPENDIX
Absolute encoder multiturn information Absolute encoder multiturn information is faulty.
A.45 ╳
error
Absolute encoder multiturn Absolute encoder multiturn information overflow.
A.46 ╳
information overflow
A.47 ╳ Battery voltage below 2.5V Absolute encoder multiturn information is lost.
A.48 ╳ Battery voltage below 3.1V Battery voltage is too low.
Serial encoder communication overtime Encoder disconnected; encoder signal disturbed; encoder
A.50 ╳
error or encoder decoding circuit error.
Absolute encoder overspeed alarm Absolute encoder multiturn information may be faulty.
detected Error reasons:
1. The battery is not connected or the battery voltage is
A.51 ╳ insufficient.
2. The power supply to servo drive is not turned ON when
the battery voltage is normal, or the servomotor running
acceleration is too high due to external reason.
A.52 ╳ Absolute state of serial encoder error Encoder or the encoder decoding circuit is faulty.
A.53 ╳ Serial encoder calculation error Encoder or the encoder decoding circuit is faulty.
Parity bit or end bit in serial encoder Encoder signal is disturbed or the encoder decoding circuit
A.54 ╳
control domain error is faulty.
Serial encoder communication data Encoder signal is disturbed or the encoder decoding circuit
A.55 ╳
checking error is faulty.
End bit in serial encoder control domain Encoder signal is disturbed or the encoder decoding circuit
A.56 ╳
error is faulty.
A.58 ╳ Serial encoder data empty The EEPROM data of serial encoder is empty.
A.59 ╳ Serial encoder data format error The EEPROM data format of serial encoder is incorrect.
Communication module cannot be The communication module is not fixed, or it is incorrect.
A.60 ╳
detected
Handshake with communication Communication module CPU is in abnormal status.
A.61 ╳
module failure
Servo drive cannot receive periodic Data receiving channel or sending channel is incorrect.
A.62 ╳
data from communication module
Communication module cannot receive Communication module is incorrect.
A.63 ╳
response data from servo drive
Disconnection between communication BUS communication is abnormal.
A.64 ╳
module with BUS.
CAN communication abnormal CAN communication is faulty because of abnormal
A.66 ╳
communication connection or disturbance.
A.67 ╳ Receiving heartbeat timeout The master station sends heartbeat time timeout.
Synchronization signal monitoring The filling time and the cycle of the synchronous signal
A.69 ╳
cycle is longer than setting does not match.
A.00 〇 Not an error Normal operation status.
〇：Output transistor is ON ╳：Output transistor is OFF
A.45、A.46、A.47、A.48、A.51 only can be reset when the absolute encoder related alarm is cleared.
The multiturn data should be cleared because of the multiturn information is incorrect.

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 REVISION RECORD

REVISION RECORD

Revision Date Contents

01 2017.12

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