Enable everyfactorytousegoodrobot 1

ContentContent ............................................................................................................. 2
Chapter1.Usinginstructions ................................................................................... 5
1.1. SafetyPrecautions............................................................................................................... 5
1.1.1. Applicablecriteria...........................................................................................................................5
1.1.2. Safetyterminology .........................................................................................................................5

1.2. Safety-relatedinstructions .................................................................................................. 6

1.2.1. Danger............................................................................................................................................6
1.2.2. Attention .........................................................................................................................................6
1.2.3. Compulsion....................................................................................................................................7
1.2.4. Prohibition ......................................................................................................................................7

1.3. Safetylabels ......................................................................................................................... 8

1.4. Casesunpacking check .................................................................................................... 10
1.5. Useenvironment ................................................................................................................ 10

Chapter2.Weldingrobotoverview ........................................................................ 11
2.1. Preface ............................................................................................................................... 11
2.2. Robotbodycomposition .................................................................................................... 11
2.3. Rrobotmechanicalparameters ......................................................................................... 13
2.4. Robotpartsinstallation payload ........................................................................................ 14
BR-1510A Wristflange ......................................................................................................................... 16
BR-1810A Wristflange ......................................................................................................................... 19
BR-2010A Wristflange ......................................................................................................................... 21

2.5. Jointmovementdirections ................................................................................................. 23

2.6. Robotmotion rangeand specification ............................................................................. 23
2.7 Limitation ofthemotion range ............................................................................................ 30

Chapter3.Transportingandinstallation .............................................................. 31
3.1. Preface ............................................................................................................................... 31
3.2. Precautions ........................................................................................................................ 31
3.2.1. Precautionsfortransporting, installationand storage ............................................................. 31
3.2.2. Robot arminstallationenvironment........................................................................................... 32

3.3. Safety fence....................................................................................................................... 33

3.4. Transporting ...................................................................................................................... 34
3.5. Installation .......................................................................................................................... 38

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 3.5.1. Fixingtherobotto thebase .......................................................................................................... 38
3.5.2. Installationmethod ofthebaseandtheground ........................................................................... 41
3.5.3. The basementpayload............................................................................................................... 41

Chapter4.Connection ............................................................................................. 42
4.1. Preface ............................................................................................................................... 42
4.2. Equipmentdetails .............................................................................................................. 43
4.3. Installationand connectionprocess ................................................................................. 45
4.3.1. Wire feedingplateinstallation .................................................................................................... 45
4.3.2. Externalwirefeedtubeconnection.............................................................................................. 45
4.3.3. Weldingmachinetubeandcables connection........................................................................... 45
4.3.4. Controlcabinetpowerconnection .............................................................................................. 48
4.3.5. Robot servomotor cablesconnection ...................................................................................... 49

4.4. Debuggingand testing process ....................................................................................... 50

Chapter5.Inspectionandmaintenance ................................................................. 51
5.1.Preface ................................................................................................................................ 51
5.2. Precautions ........................................................................................................................ 51
5.3. Robotinspection ................................................................................................................ 53
5.3.1. Dailyinspection ........................................................................................................................... 53
5.3.2. Monthlyinspection ...................................................................................................................... 54

5.4. Robotmaintenance ........................................................................................................... 54

5.4.1. Synchronous belttension adjustment ....................................................................................... 54
5.4.2. Maintenanceplan ....................................................................................................................... 57

5.5. Battery ................................................................................................................................ 59

5.5.1. Precautionsfor batteryuse......................................................................................................... 59
5.5.2. Batteryreplacement .................................................................................................................... 59

5.6. Lubricating grease ............................................................................................................ 59

5.6.1. J1-J3jointsgrease replenishment............................................................................................. 59

5.7. Zeroposition calibration .................................................................................................... 63

5.8.Warranty .............................................................................................................................. 63

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Thank youverymuchfor choosingour products!

 Beforeusingtherobot,
pleasereadthismanualindetailandfollowallinstructionsonsafetymattersandthe body.

 Asforthe installation, operationandmaintenanceof robots,

onlythosewhohavereceived relevanttrainingandassessmentfrom our
companyarerequiredtodoso.

 Whenusingthisrobot, wemust abidebythe

lawsandregulationsofvariouscountriesconcerning
industrialrobotsandsafety.

 Besureto deliver thisinstruction totheactualoperator.

 The relevantmanualsof thissystem shouldbeproperlykept

sothattheycanbeconsultedwhenneeded.

 Iftheequipmentneedstobehandedover,pleaseforwardthe
relevantinformationtotheother party!

Content description:
Thecontentof thismanualwillbesupplementedand
modified.Pleaseobtainthelatestmanualfrom thetechniciansof

Enable everyfactorytousegoodrobot 4
Chapter 1.Using instructions

1.1. SafetyPrecautions
1.1.1. Applicablecriteria
Robot system designmeetsthe followingrequirements：

Standard Describe
MechanicalSafety,MechanicalSafety,MechanicalSafety,ElectricalEquipmentPart
GB5226.1-2002
1:GeneralTechnicalConditions(IEC60204-1：2000，IDT)

GB1129l-1997 IndustrialRobot,SafetySpecification(eqvISO10218：1992)

GB/T12644-2001 IndustrialRobot,Characteristic
Representation(eqvISO9946：199
9)
GB14048(Allparts) LowVoltageSwitchgearandControlEquipment
MechanicalSafety,BasicConceptsandDesignPrinciples,Part1:BasicTermi
GB/T15706.1-1995
nology,Methodology(eqvISO/TR12100-1：1992)

MechanicalSafety,BasicConceptsandDesignPrinciplesPart2:TechnicalPrinci
GB/T15706.2-1995
plesandSpecifications(eqvISO/TR12100-2：1992)

GB/T16856-1997 MechanicalSafety,PrinciplesofRiskAssessment(eq
vPREN1050：1994)

1.1.2. Safety terminology

Usethe followingsignstorecordsafetyprecautions. Besuretoreadthem.

Sign Explain

Indicatesthatifthelogoisignoredandmisused,it
Danger canleadtodeathorseriousinjury,etc.

Misoperationisdangerousandmaycausemoderateinjuryor
Attention minor injuryaccidentsandequipment failure.

Compulsion Mattersthatmustbeobserved.

Prohibition Prohibitedmatters.

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  Eventhecontentsrecordedin"Attention"willhaveseriousconsequencesbecauseofdifferen
tsituations.Therefore,
anyprecautionsareextremelyimportant.Pleasestrictlyabidebythem.
 Evenwhere"attention" or "danger" isnot marked,itissomethingthatusersmuststrictly
observe.

1.2. Safety-relatedinstructions

1.2.1. Danger
Theelectricalor mechanicaldebuggingandmaintenanceof industrialrobotsareonlyallowed
tobecarriedout byprofessionalpersonnel,andallpersonnelworkingontherobotmusthaveaccepted
trainingintheuseof therobot.

Wrong installation(suchas overload)ormechanicaldamage(suchasbrakefailure) cancausetherobot

or theadditionalaxistosink.Ifyouareworkingona robot systemthathasbeenturnedoff,youmust
firstdrivetherobotandtheadditionalaxistoa statewhereit willnot moveonitsownregardlessof loador
noload. If thereisnosuchpossibility,therobotandadditionalaxismustbeprotectedaccordingly.

Duringmaintenance, especiallyafter
operationssuchasreplacingmotors,drives,andbatteries,therobot mustbereset tozerobeforeit can
automaticallyruntheprogram,otherwiseaccidentsmayoccur.

1.2.2. Attention
Pleasepayattentiontotherotationaxisoftherobot body. Keep adistancefrom theaxistoprevent hair
or clothingfrom beingstalked.At thesametime,pleasebeawareof
anyhazardsthatmaybecausedbyrotatingtoolsorother devicesinstalledontherobot or intheunit.

Under no circumstancesshould youstandunder anyaxisof therobot.

Protectiveglovesmustbewornif thedisassemblyandother operationsareperformedimmediately

after thecontrolsystemispoweredoff andstopped,soasto avoidscaldscausedbythehightemperatureof
theradiatorsurfaceor motor.

Whenreplacingthebatteryontherobotbody,payattentiontotheoccurrenceof short-
circuitbetweenthepositiveand negativeelectrodesof thebattery.

Visuallyinspecttherobot tomakesureit isnot damaged. Donotinstallrobotsthat aredamagedor

missingparts,otherwisethereisa danger ofseriousaccidentsandpersonalinjury.

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 Before movingtherobot, pleasecheckthestabilityof therobottoavoidthedanger oftilting.

1.2.3. Compulsion

Theemergencyshutdownbuttonisa safety deviceusedinemergencysituations.It

isstrictlyforbiddentouseitfrequentlywithout purpose,whichwillaffectthe servicelifeof therobot-
relatedcomponents(motor brakes,etc.).Inparticular, it isforbidden torepeatedlyturnoff
therobotduringhigh-speedoperation.

Temporaryshort-circuitingisallowedduringswitchinspectionandmaintenance, but atthistime,it

isstrictlyforbidden toworkon livepartsof thecontrolsystemtoavoidaccidents.

Operatorsof allroboticsystemsshouldparticipateinthe trainingof

thesystem,learnsafetymeasuresandusethefunctionsofrobots.

Beforestartingtheoperationof therobot, makesurethat therearenoabnormalor

dangerousconditionsaroundtherobotandperipheralequipment.

Turnoffthepower supplyorpresstheemergencybuttonbeforeenteringtheoperationarea,evenif
therobotisnot running.

Whenprogrammingintheworkingrangeof therobot, set

upcorrespondingguardstoensurethattherobotcanstop quicklyinan emergency.Donot
operatewithgloveswhenteachingrobots,trytooperateat lowspeedwhenteachingrobots, and
effectivelycontroltherobottostopincaseofabnormalcircumstances.

Itisnecessarytorememberthepositionoftheemergencystopbuttonsontherobot
controllerandperipheralcontrolequipmentsothattheycanbepressedaccuratelyinan emergency.

Neverassumethat arobot'sprogram hasbeencompletedwhenitisin astopstate. Becausetherobot

isprobablywaitingfortheinput signaltokeepitmoving.

1.2.4. Prohibition

Whenthe powerof therobotisconnected, it isforbiddentounpluganyelectricalconnector.

Itisforbidden touseanymethodtoconnect safety devices.

Itisforbidden tooperateanduserobotsbypersonnelwhohavenot passedsafety trainingandsafety

assessment.

Nodrunkenwork.

Dis-assembly andmodificationofanypartsof the controller isprohibited.If any

unauthorizedmodification resultsindamagetoanyequipmentandpersonnel, willnot bear any

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responsibility.

Theoperationof therobotcontroller must designatea dedicatedoperator,

andtheoperatormustundergosafety trainingandpassthe examinationbeforehecantakeuphispost.

Safetyfenceshouldbeset aroundtherangeofmotionof therobot.

Man-machineseparation: Intheprocessof robotmovement (automatic, manual),

nooneisallowed toenterthescopedefinedbythesafetyfenceoftherobot.

Ifthereareseveraloperatorsworkingtogether
intherobotapplicationsystem,itisnecessaryforalloperatorsandtheir
relatedpersontoknowthattherobot hasbeenenabledbeforestartingtherobot.

1.3. Safetylabels
Inthismanual,thecontentsof the followingsymbolsshouldbegivenspecialattention.
Toensureproperandsafeoperationof therobot, toprevent
personalinjuryandpropertydamage,pleaseobservethesafetyinformation showsonthesafety
labelsinthetable below:

Warning
❖ Donot entertherobot
workingrangeasmainpower
on.Pleasereadthemanualcarefully.

Warning
❖ Pleasereadthe carefullywhen
handlingorinstallingtheequipment.Improper
operationmayresult indamagetotheequipment or
accidents.
❖ Overturningcouldhappenwhenremovingorinst
allingtheset screws,which
maycauseseriousinjure.Pleasefixtheequipment
beforeoperation.

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 Warning
❖ Donot entertherobot
workingrangeasmainpower
on.Pleasereadthemanualcarefully.

Warning
❖ Pleaseturnoffthe powerbeforeopeningthebox.
Unauthorizedmodification
maycausefireorproductfailurethenresult
inpersonalinquiryorequipment damage.
❖ Themodifiedproductisnotcoveredbythewarr
anty.
Keephands,fingers,hair or
clothingawayfromtherotatingpartsofthe
coolingfanandwirefeeder.
❖ Donot touch
electricalcomponentsinoneminuteafter
poweroff,otherwisecancausefatalshocksor
burns.
❖ Pleaseuseappropriateexternalprotectionde
viceandwireitcorrectly.

Warning
❖ Thepower supplymust begrounded.
❖ Inputpower:220v

Attention
❖ Caution,hightemperature.

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 CAREFUL
❖ Astherobotmovesinhigh-
speed,becarefultoremoveor release abrake.

1.4. Casesunpackingcheck

 Visuallyinspect therobottomakesureit isnot damaged.Robotsthat

aredamagedorlackpartsmustnot be
installed,otherwiseheavydamageandpersonalinjurymayoccur.
 Before movingtherobot, pleasecheckthestabilityof therobot
toavoidthedangeroftilting.
 Cable packagingissusceptible tomechanicaldamage.
Thecablepackaging,especiallytheconnector, mustbehandledcarefullytoavoid
damage.Otherwise,therobotcannot operate normally.

Whenunpacking,please carefullyconfirm:Whether
thereisanydamageduringtransportation;whetherthemodelandspecificationsofthenameplateof the
machineare consistent withtheorderrequirements. Ifyoufindthatthemodeldoesnot matchor
thedeviceismissing, pleasecontactthemanufactureror supplierassoonas possible.

1.5. Useenvironment.
Theworkingenvironment of therobot is 0°C~45°Candnodirectsunlight.

Note:
 Robot productscanbeusednormallyintheenvironment of 13℃~45℃;
intheenvironmentof0℃~13℃, therobotcanbeused normallyafter preheating.It isnot
recommendedtousetherobotintheenvironment below0℃and above45℃;otherwise,
itmaycauseequipmentdamage;
 Robot productspreheatingmethod:whenrunning between10℃~13℃,
theJ3axisneedstobepreheatedat a speedbelow60% formorethan5minutes; whenrunning
between5℃
~10℃, theJ3axisneedstobepreheatedat a speedbelow50% formorethan5 minutes; whenoperating
between0℃and5℃,theJ3axisneedtobepreheatedat aspeedbelow20% for 5

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minutes, andthenpreheatat a speedof 40%for morethan5 minutes, at
thesametime,maketheJ2axistobepreheatedat a speedof 60%or lessthan5minutes.

Chapter2.Welding robotoverview

2.1. Preface
Thischapterdescribestechnicalspecifications,dimensions andmotionrangesof our
BRseriesweldingrobot(BR-1510A/BR-1810A/BR-2010A).

2.2. Robotbodycomposition
TheBRseriesrobotiscompact,smallinsizeandlight inweight. Itisadedicatedarc weldingrobotthatcan
achievestablewelding,obtain ahighlyaccurate weldingpath, shortenthe
weldingcycle,andextendthelifeof pipefittingsandcables. At thesametime,
theBRseriesrobotscanflexiblyperformweldingoperationsin asmallspace,andthe
installationmethodcanbeselectedasground installation,verticalinstallation, or hoisting installation.
BR-1510A:Themaximumworkingradiusis1472mm,theratedloadofthewrist
is6kg.Therobotbodycomposition isshowninFigure2.2.1.

Transposition

Forearm

Bigarm Waist

Fixed
seat
Transposition

Figure2.2.1. BR-1510A robotbodycomposition

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BR-1810A:Themaximumworkingradiusis1799mm,theratedloadofthewrist
is6kg.Therobotbodycomposition isshowninFigure2.2.2.

Transposition

Forearm

Forearm
Bigarm

Waist

Transposition

Fixedseat

Figure2.2.2BR-1810A robot body composition

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BR-2010A:Themaximumworkingradiusis1990mm,theratedloadofthewrist
is6kg.Therobotbodycomposition isshowninFigure2.2.3.

Transposition

Waist
Bigarm

Transposition Forearm
extension Forearm

Fixedseat

Figure2.2.3.BR-2010Arobotbody composition

2.3. Robotmechanicalparameters
Themechanicalparametersof BR-1510A, BR-1810A, BR-2010Arobotsare showninTable2.3.1.

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 Table2.3.1.Themechanicalparameters ofBR-1510A,BR-1810A,BR-2010A

Model
BR-1510A BR-1810A BR-2010A

Axis 6 6 6

Payload 6kg 6kg 6kg

Repeat-ability ±0.08mm ±0.08mm ±0.08mm

Reach 1472mm 1799mm 1990mm

Weight 172kg 200kg 230kg

Protection
IP65
Class

IOdescription 23DI/23DO

Input Voltage Single-phase220V±10% 50/60Hz

UseEnvi
0-45℃,20-80% RH(Nocondensation)
ronment

*Measuringcondition
Therobotmustbefirmly fixed toa flat
surface.Noise levelchanges according
toconditions.

2.4. Robotpartsinstallationpayload
 BR-1510A
BR-1510Arobotpayloadparametersare showninTable2.4.1.

Table2.4.1.Thepayloadparameters of BR-1510A

Wirefeederinstalla Wirefeedingplateinsta
Robotmodel Waistpayload
tion(maxpayload) llation(maxpayload)

BR-1510A 6kg 15kg 20kg

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BR-1510Aparts installationpositionsasthefigure 2.4.1.shownbelow:

Figure2.4.1.B-1510A partsinstallationpositions

Therelationship betweentheloadcenterof gravityof theBR-1510Awrist

anditsloadqualityisshowninFigure2.4.2.

Figure2.4.2.wristaxis loadgravity andquality

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 Inordertoavoiddamage tothemotor or reducerdue to overload, pleasebecarefulnot
toexceedtheallowableloadof thewrist shaft.

BR-1510A Wristflange

Wheninstallingthearm andothertools, pleasebesuretodisconnect thepower

supplyofthecontrollerandtheexternalpowerswitch,set up
astrikingsign"intheprocessofinstallation",andlockor hangthesignof
theexternalpowersupplyswitchtoprevent theoperationpersonnelor other peoplefrom
accidentally turningonthe powersupplytoavoidtheoccurrenceof
unpredictableelectricshockandother accidents.

Thedimensionsof theend executionflangeare showninFigure2.4.3.

Installa toolsuitablefortheouterdiameter(68H7) or inner diameter (45H7)of theflangesize
tomakeitaccuratelypositioned. Use 6-M4screwtorque = 4.9Nm(defaultscrewgrade12.9) tofixthetool.
Thelengthof theselectedM4bolt mustnot exceedthedepthof thethreadedholeontheflange(8mm).

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 Figure2.4.3 BR-1510Awaistflangedimensions

 BR-1810A
BR-1810Arobotpayloadparametersare showninTable2.4.2.

Table2.4.2.Thepayloadparameters ofBR-1810A

Wirefeederinstalla Wirefeedingplateinsta
Robotmodel Waistpayload
tion(maxpayload) llation(maxpayload)

BR-1810A 6kg 20kg 20kg

Installequipment at theendoftheforearmholder
Wirefeeder,shieldinggas solenoidvalveandotherequipment canbe installedat
thetailofthearmholder. Wheninstalling,useM8screwstofixthedevice. Thecenterofgravityof the
deviceinstalledonthearmmountmustbewithinthe110mm apertureofthe 4-M8screwhole.

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BR-1810Aparts installationpositionsasthefigure 2.4.4.shownbelow:

Figure2.4.4BR-1810Aparts installationpositions

Therelationship betweentheloadcenterof gravityof theBR-1510Awrist

anditsloadqualityisshowninFigure2.4.5.

Figure2.4.5.wristaxis loadgravity andqualitychangediagram

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 Inordertoavoiddamage tothemotor or reducerdue to overload, pleasebecarefulnot
toexceedtheallowableloadof thewrist shaft.

BR-1810A Wristflange

Wheninstallingthearm andothertools, pleasebesuretodisconnect thepower

supplyofthecontrollerandtheexternalpowerswitch,set up
astrikingsign"intheprocessofinstallation",andlockor hangthesignof
theexternalpowersupplyswitchtoprevent theoperationpersonnelor other peoplefrom
accidentally turningonthe powersupplytoavoidtheoccurrenceof
unpredictableelectricshockandother accidents.

Thedimensionsof theend executionflangeare showninFigure2.4.6.

Figure2.4.6 BR-1810Awaistflangedimensions

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Installequipment at theendoftheforearmholder
Wirefeeder,shieldinggas solenoidvalveandotherequipment canbe installedat
thetailofthearmholder. Wheninstalling,useM8screwstofixthedevice. Thecenterofgravityof the
deviceinstalledonthearmmountmustbewithinthe110mm apertureofthe 4-M8screwhole.

 BR-2010A
BR-2010Arobotloadparametersare showninTable2.4.3.

Table2.4.3.Thepayloadparameters ofBR-2010A

Wirefeederinstalla Wirefeedingplateinsta
Robotmodel Waistpayload
tion(maxpayload) llation(maxpayload)

BR-2010A 6kg 20kg 20kg

BR-2010Aparts installationpositionsasthefigure 2.4.7.shownbelow:

Figure2.4.7BR-2010Aparts installationpositions

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Therelationship betweentheloadcenterof gravityof the BR-2010Awrist
anditsloadqualityisshowninFigure2.4.8.

Figure2.4.8.BR-2010Awristaxisloadgravity andquality changediagram

Inordertoavoiddamage tothemotor or reducerdue to overload, pleasebecarefulnot

toexceedtheallowableloadof thewrist shaft.

BR-2010AWristflange

Wheninstallingthearm andothertools, pleasebesuretodisconnect thepower

supplyofthecontrollerandtheexternalpowerswitch,set up
astrikingsign"intheprocessofinstallation",andlockor hangthesignof
theexternalpowersupplyswitchtoprevent theoperationpersonnelor other peoplefrom
accidentally turningonthe powersupplytoavoidtheoccurrenceof
unpredictableelectricshockandother accidents.

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Thedimensionsof theend executionflangeare showninFigure2.4.9.
Installa toolsuitablefortheouterdiameter(68H7) or inner diameter (45H7)of theflangesize
tomakeitaccuratelypositioned. Use 6-M4screwtorque = 4.9Nm(defaultscrewgrade12.9) tofixthetool.
Thelengthof theselectedM4bolt mustnot exceedthedepthof thethreadedholeontheflange(8mm).

Figure2.4.9 BR-2010Awaistflangedimensions

Installequipment at theendoftheforearmholder
Wirefeeder,shieldinggas solenoidvalveandotherequipment canbe installedat
thetailofthearmholder. Wheninstalling,useM8screwstofixthedevice. Thecenterofgravityof the
deviceinstalledonthearmmountmustbewithinthe110mm apertureofthe 4-M8screwhole.

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 2.5. Jointmovementdirections
Themotionof eachjoint oftheBRseriesrobotisshowninFigure2.4.1

Figure2.5.1robotjointsmovementdirections

2.6. Robotmotionrangeandspecification

Thisworkspacereflectsthezeropointandoperatingrangeof themechanicalsystem,whichisslightly
different from thedefinitioninthecontrolsystemmanual.
Whentheusermanipulatestherobot,thedefinitioninthecontrolsystem manualmustprevail,
otherwisethesystem willreportanerror.
Themotionparametersof eachjointof theBRseriesrobots BR-1510A, BR-1810A, BR-
2010Aareshowninthetable
As showninTable2.6.1.
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 Table2.6.1.Themechanicalparameters of BR-1510A,BR-1810A,BR-2010A

Model BR-1510A BR-1810A BR-2010A

J1 ±170° ±175° ±175°

J2 +64°~-130° +85°~-150° +85°~-150°

J3 ±75° ±80° ±80°

Motion
range
J4 ±150° ±150° ±150°

J5 +130°~-105° +130°~-105° +130°~-105°

J6 ±220° ±220° ±220°

J1 259.3°/s 172.1°/s 172.1°/s

J2 160°/s 138.8°/s 135.1°/s

J3 296.3°/s 259.3°/s 259.3°/s

Motion
speed
J4 294.1°/s 294.1°/s 294.1°/s

J5 294.1°/s 294.1°/s 294.1°/s

J6 426.7°/s 426.7°/s 426.7°/s

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 BR-1510Arobotmotionrangeanddimensions

Figure2.6.1.BR-1510A robotmotionrangeleft view

Figure2.6.2.BR-1510A robotmotionrangetopview

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 Figure2.6.3.Theanglereferencepositionof eachjointof BR-1510Aintheactionarea

J1：0degrees, front

positionJ2:0 degrees,
verticalposition
J3:Definedas0degreewhentheforearmisparallel totheground
J4:0 degreeisthepositionwhentheJ3axisandJ4axisarein astraightlineJ5:0
degreeisthepositionwhentheJ4axisandJ5axisarein astraightlineJ6:0
degrees,front position

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 BR-1810robot motionrangeanddimensions

Figure2.6.4.BR-1810Arobotmotionrangeleftview

Figure2.6.5.BR-1810Arobotmotionrangetopview

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 Figure2.6.6.TheanglereferencepositionofeachjointofBR-1810Aintheactionarea

J1：0 degrees, front

positionJ2:0degrees,verticalpo
sition
J3:Definedas0 degreewhentheforearmisparallel totheground
J4:0degreeisthepositionwhentheJ3axisandJ4axisareinastraight
lineJ5:0degreeisthepositionwhentheJ4axisandJ5axisareinastraight lineJ6:0
degrees,front position

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 BR-2010robotmotionrangeanddimension

Figure2.6.7.BR-2010Arobotmotionrangeleftview

Figure2.6.8.BR-2010Arobotmotionrangetopview

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 Figure2.6.9.TheanglereferencepositionofeachjointofBR-2010Aintheactionarea

2.7Limitationofthemotionrange
Boththerobot andits controller areequippedwithfunctionsto limit themotionrangeof each
axis.Whenthe limitof themotionrangeisset bytheprogram intherobot controller, it
iscalled"softlimit".Incasetherobotexceedsthemotionrangeof thesoft limit, mechanicallimit isalso
provided.
Theoperatingrangelimitsare showninTable2.3.5.1 below.

Softlimit Mechanicallimit

J1 ● ●
J2 ● ●
J3 ● ●
J4 ● ×
J5 ● ×

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 J6 ● ×

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Chapter 3.Transporting and installation

3.1. Preface

Thischapterdescribesthetransportingand installationof theBRseriesrobot.

Please readandfullyunderstandthecontentsof
thismanualandthesafetymanualbeforeproceedingwithanyoperation,andpleasestrictlyabidebyallsafet
yregulations. Thismanualonlydescribesthe installationandconnectionof therobotarm. For
operating,programmingof therobot,pleaserefer toother relatedmanuals.
Itisemphasized herethatyoushouldnot do anythingbeforeyou
fullyunderstandtheentirecontentsofthisbook.TThabelec2o.m
3.5p.a
1 nliy
miw
taitlilon
nootftbhe
emliaob
tiole
nrfaonrga
enoyfeaaccc
hid
axeisntor
damagecausedbyonly operatinginaccordancewitha partof thismanual.

3.2. Precautions

3.2.1. Precautions fortransporting,installation and storage

Whentransportingtherobot toits installationlocation, the

followingprecautionsmustbestrictlyobservedfor handlingand installation.

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  Whentransportinga robotusing acraneor forklift,itisabsolutelyimpossible
tomanuallysupporttherobotbody.Never carryontherobotor under
theliftedrobotduringtransport.
 Besuretodisconnect the controller powerandmainpower
beforestartingtheinstallation. Set an„installing‟eye-catchingsign, lockor
hangtheexternalpowerswitchtoprevent theoperator or othersfrom accidentally
turningonthe powertoavoidaccidentssuchasunpredictableelectricshock.
 When startingtherobot, besuretoturnonthemotor power after confirmingthatthe
installation statusisnormal, etc, andadjustthearmof therobottothespecifiedposture.
Becarefulnot toapproachthearmandsqueezeit.

 Becausetherobotbodyismadeupof precisionparts, it isimportant

toavoidexcessiveshockandvibrationof therobotduringtransporting.
 Whentransportingtherobotwith acraneor aforklift, removeobstaclesfirst
toensuresafetransportationtothe installationposition.
 Avoid excessivevibrationandshock.

3.2.2. Robotarminstallation environment

 Please installtherobotarm in aplacethatmeetsthe followingconditions.

 Wheninstallingontheground, pleaseensurethatthelevelof thegroundis within±5°.
 Ensurethatthefloor andthemountare sufficientlyrigid.
 Ensureflatnesstoavoidextraforceonthebaseof therobot.(If theflatnessisnot achieved,useapad
toadjusttheflatness.)
 Theworkingenvironment temperaturemustbebetween 0°Cand45°C. (If start-
upwithlowtemperature,greaseandgear oilaretooviscous,andthere
willbeabnormaldeviationoroverload.Inthiscase, pleaseperform low-
speed(abouthalfofthenormalstartingspeed)warm-upoperation(5-10minutes).
 The relativehumiditymust be between 20%and80% RHwithout condensation.

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 Ensurethatthe installation locationisrarely exposed todust, smokeandwater.
 Ensurethattherearenoflammable,corrosiveliquidsor gasesinthe installationlocation.
 Ensurethatthe installation locationisnot affectedby excessivevibration. (0.5Gor less)
 Ensurethatthe installation locationisminimalelectromagnetic interference.
 Makesurethereisenoughspaceforrobotmovement inthe installation location.
 Set asafetyfencearoundtherobottoensurethattherobot'smaximum movement space,evenif
the weldingtorchareattachedtothearm,willnot interferewiththesurroundingmachines.
 Set up servicedoor witha safetypinatthesafetyfence(if possible, set uponlyoneservicedoor
andgoinandout thesafetyfence).

3.3. Safetyfence
Duringautomaticrunningof industrialrobot,operatorsandthesurroundingstaffmayget
injuredbytouchingtherobot. Toavoidstaffinjuryandequipment damageinrobot operation,
pleasebesuretoset safetyfenceor relevantprotections.

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 3.4. Transporting

Whenunpackingor installingtherobot, aforkliftor hydrauliccarmustbeused.Theoriginalposturefrom

itsfactorymustbemaintainedduringtransportation,asshowninFigure3.4.1to3.4.4
Whenusing a forklift totransport, therobotisfixedonthe palletshowninFigure3.4.1to3.4.4 toprevent it
from tippingover.
Inaddition, themonomerweightofBR-1510is172Kg; themonomer weightof BR-
1810is200Kg;themonomer weight ofBR-2010Ais230Kg.
A palletthatcanwithstandtheseweightsshouldbeused.
ThetransferpostureofBR-1510robotisshowninFigure3.4.1andFigure3.4.2.Thetransferpostureof BR-
1810robotisshowninFigure3.4.3. Thetransferpostureof theBR-2010robotisshowninFigure3.4.4.

Figure3.4.1BR-1510transferposture Figure3.4.2BR-1510transferposture

Figure3.4.3BR-1810transferposture Figure3.4.4BR-2010transferposture

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WhentheBR-1510A,BR-1810A, BR-2010Arobotsareinthetransfer posture,theangleof
eachjointisshowninthetable3.4.1 below:

Table3.4.1.Transferpostureangleof BR-1510A/BR-1810A/BR2010A

Angle（°）

BR-1510A BR-1810A BR-2010A

J1 0 0 0

J2 +60 +64.7 +65.5

J3 -53.4 -63.2 -62.7

J4 0 0 0

J5 +101 +78.3 +94.6

J6 0 0 0

 Forklifttransporting

Figure3.4.5BR-1510forklifttransportingway

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 Figure3.4.6BR-1810forklifttransportingway

Figure3.4.7BR-2010forklifttransportingway

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 Hydrauliccar transporting

Figure3.4.8BR-1510hydraulic cartransportingway

Figure3.4.9BR-1810hydraulic cartransportingway

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 Figure3.4.10BR-2010hydrauliccar transporting

3.5. Installation
3.5.1. Fixing therobottothebase
Whentherobot adjustsitsspeedandmoves,therotatingbase willreceivehugereactionforcesfrom
alldirections. Thebasenotonlyneedstowithstandthestaticload, but
alsoneedstowithstandthereactionforcegeneratedunder theadjustedspeed. Therefore,therobot
andits
mountingbaseshouldbestable.

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 A

Figure3.5.1.1Mountingholesizeofrobotbase

Becausetherobotinoperationwillgeneratehugeinertialforce,thebaseforinstallationmust beverystrong.
Therefore,whentherobotandthefixturearetobe installedonthesamebase,thethicknessof
thebasemustexceed20mm,and4 hexagonsocketheadscrews (M16)andflatwashersmust
beusedtosecurelyfixtherobotwith atorqueof 216Nm.
The installationmethodof therobotbaseis showninFigure3.5.1.1

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 Ф

Figure3.5.1.2Installationdiagram oftherobotbase

Figure3.5.1.3BR-1510A/BR-1810A/BR-2010Abasemountingdimensions

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3.5.2. Installation method ofthebaseand the ground

Becausetherobotinoperationwillgeneratehugeinertialforce,thebaseforinstallationmust beverystrong.
Becausetherobotinoperationwillgeneratehugeinertialforce,the installationfloor must
beverystrong.Whenthethicknessof theconcretefloor exceeds 200mm,
useM14*130expansionscrewsforinstallationas showninFigure3.5.2.1
Ifthethicknessof theconcretefloor islessthan200mm,
thefoundationshallbeconstructedinadvanceafter thorough examination.

Figure3.5.2.1Installationmethodof robotbaseandground

3.5.3. The basementpayload

Therearethreeinstallationmethodsfortherobot: ground installation, verticalinstallation

andhoisting installation.
Figure3.5.3.1 showsthedirectionof robotstress, which isvalidfor allground-
mountedandhangingrobots.

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 Figure3.5.3.1Thedirectionofrobotstress

Amongthem:F1--forceintheverticaldirectionofthebase;F2--forceinthehorizontaldirection;M1--
inclinedbendingmoment;M2--torquearoundtheA1axis.

Note:Thefollowingextreme valuesrarelyappearduringtherobotoperation,
andthesevaluescannotreachthemaximum at thesametime:

F1=2200N;F2=1500N; M1=2300Nm;M2=1600Nm

Chapter4. Connection

4.1. Preface
Thischapterintroducesthe installation andconnectionof
standardseriesrobot(withMegmeetEhaveCM350weldingmachine).Other seriesareforreferenceonly,
pleaseconnectaccordingtotheactualconfigurationor consult thesupplier.
Besuretoreadandunderstandthisandthesafetysectionthoroughlybeforedoinganything,
andfollowallsafetyrules.Inaddition, pleaserefer tothe relevantmanualif necessary.
Inparticular, don't do anythinguntilyoufullyunderstandthecontentofthisarticle.Thecompanyshallnot
beliableforanyaccident or damagecausedbytheoperationof thecompanyonlyin
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accordancewitha limitedpart ofthisarticle.

Suitableor BR-1510A/BR-1810A/BR-2010ASTANDARDSERIESrobotconnection

4.2. Equipmentdetails
Table4.2.1Packinglistfor theweldingrobot setandrelatedequipment

No. Item Model QTY Remark

Weldingrobot set(BR-1510A)

1 Robot body BR-1510A 1

2 Wirefeeder 1

3 Wirefeedingplate 1

4 Weldingtorch 1

5 Controlcabinet 1

6 Teachpendant 1

7 Reservationbox 2

8 Externalwirefeedtube 1

9 Robot basement 1

10 Integrated powerline 1

11 Integratedcodingline 1

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Picturesexample:

Pic.1robotbody Pic2. welder(weldingmachine) Pic.4wirefeedingplate

Pic3. wirefeeder

Pic.5weldingtorch Pic.6control cabinet Pic.7teachpendant Pic.8reservationbox

Pic.9welderpowercable Pic.10positivepowercable Pic.11negativepowercable Pic.12weldercontrolcable1

pic.3weldercommunicationc
able1

Pic.13weldercontrol cable2 Pic.14wirefeedtube Pic.15integratedpowerli Pic.16integratedcodingli

ne ne

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 4.3. Installationandconnectionprocess
4.3.1. Wirefeeding plate installation

4.3.2. Externalwire feed tube connection.

Onesidescrewtothewirefeedingplatebracket,anothersidescrew tothewirefeederinterface.

4.3.3. Welding machinetubeand cables connection

The weldercablebundleconsistsofthepower cable,7-corecontrolcable,
andgastube.Whenpreparingthecablebundle, makesurethat the7-corecontrolcableis0.3m
longerthanthepowercableandthegastubeis1.5m longerthanthepower cable.
(1) Weldingmachinepower lineconnection
Table4.3.3.1 providesthe powersupplyspecifications.

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 Table4.3.3.1Weldingmachinepowersupply specifications.

Description

Item
EhaveCM250/350/350AR EhaveCM500/500H/500AR

Power supplyfeature Three-phase380VAC50Hz/60Hz Three-phase380V AC 50Hz/60Hz

Grid 20kVAorgreater 30kVAor greater

Power
devicecapaci Generator 30kVAorgreater 50kVAor greater
ty
Inputprotection
device(distribut
Air
ionbox)
circuitbre GradeC and40A orgreater GradeC and63A or greater
aker

Inputonthe
welder side 10mm2orgreater 16mm2or greater

Outputont
hewelders
ide 35mm2orgreater 50mm2or greater
Power cable

Housinggr
oundingc
able ≥ powersupplycable ≥ powersupply cable

(2) Positivepower cableconnection

For thepositivepowercable,fastenoneside tothe positiveoutputterminalof the
weldingmachineandtheothersidemustbefasten totheinputterminalof therobot.

(3) Negativepower cableconnection

For thenegativepower cable,fastenonesidetothe negativeoutput terminalof
weldingmachine.anothersidebefastentothebasemetal.

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(4) Weldertowirefeederconnection
Connect the7-coreaviationplugof thecontrolcable1 tothe7-corejackonthe welder frontside;
connectthe14-coreaviationplugof thecontrolcable1 tothe14-corejackontherobotbackside.

(5) Weldertocontrolcabinet connection

Forthecommunicationcablebetweenwelder
andcontrolcabinet,oneendsidebeconnectedtothecontrolcabinet jack,another
endsidebeconnectedtothebacksidejackof the welderwithblackcover.

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(6) Protectivegastube
(Protective gastubeandgascylinder needtobepreparedbycustomer.)
Onesideof the protectivetubebeconnectedthebacksideofrobot,
anothersidebeconnectedtotheholeofgascylinder.

(7) Reservationboxconnection
Theendofthe reservationboxbeconnectedtothecontrolcabinet jackwithbluecover.

4.3.4. Controlcabinetpower connection.

Controlcabinet power cableconnection:

Electroniccontrolsystem ispoweredbyvoltageAC220V±10%,50-60Hz

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4.3.5. Robotservomotor cables connection.

(1) Theintegratedpowerlineconnection.
Onesidebeconnectedto thebacksidejackof therobot. Another
sidebeconnectedtothejackonthecontrolcabinet.

(2) Integratedcodinglineconnection.

Onesidebeconnectedto thebacksidejackof therobot. Another

sidebeconnectedtothejackonthecontrolcabinet.

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4.4. Debuggingandtestingprocess

(1) Theweldinggasandweldingtableneed tobepreparedbeforedebugging;

(2) Turnonthe powerof therobotcontrolcabinet;

(3) Turnonthe powerof the weldingmachine;

(4) Openthe weldinggaspressurereducingvalveandflowmeter,andpressthe"gascheck"ontherobot

teachpendant todetect theoutflowof gas;

(5) Pressthe SENDand RETRACTbuttonof therobotteachpendant

tocheckthewirefeedingofthewirefeeder;

(6) Fixthetestworkpieceontheweldingtable,adjust the

weldingtorchangleandthewirelengthstickingout of nozzle(about10timesasthediameterof
thewire),set asafeworkingpoint andteacha linear program alongtheworkpiece;

(7) Aftertheteachingworkiscompleted,
inthe"Teachmode",simulatetheworkpathtocheckifthereisanyinterferenceor collisionor other
situations;

(8) Inthe weldingsettingsof theteachpendant, modifythe weldingparameters;

(9) Addweldinginstructionsafter the"arcon" point andbeforethe"arcoff"point;

(10) Switch tothe"automaticmode"of therobot, executea

singlecycle,press"Start"onthereservationbox, andcompletetheautomaticarc weldingwork;

(11) Shakethe anti-collision sensor of the weldingtorchtotestwhether

therobothasanemergencystopandwhether theteachpendant screenappearsthealarm;

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Chapter 5.Inspection and maintenance

5.1.Preface
Thischaptermainlyintroducesabout themethods, plansandprecautionsof
therobot'sregularinspectionandmaintenance.

5.2. Precautions

WARNING！

1.Beforemaintenance,pleaseensurethattherobothascompletelystoppedrunningandthereisnointerf
erencewithinthemovement rangeoftherobot thatmaycausedanger.
2.Duringthemaintenance, exceptforthemaintenancepersonnel,
nooneshallentertheworkingrangeoftherobot.
3.Inordertoensurethesafetyof themaintenancepersonnel,
pleasetakepersonalprotectionmeasuresandwear a helmetduringthemaintenance.
4.Beforeperformingeachstepof theoperation,
pleasecarefullychecktherobotforsafetyhazardssuchastipping,swingingjoints, etc.

(1) Besuretowear
helmets,safetyshoes,glovesandothersafetyprotectionmeasuresnecessarytoperformrobotinspection,
maintenance, adjustment,repair or
othersimilaroperationsinaccordancewithlegalrequirements.Makesuretowear
clothingsuitableforthejob.
(2) Beforestartingwork,pressthe"emergencystop" buttonor stopbutton tocheck whether
therobotsystem stopsimmediately.Inaddition, if therobot system
isalsoequippedwithsafetypins,safetyswitchesor other protectivedevices,it must becheckedwhether
theyareoperatingnormally.Ifanyfailureisdetected,
stoptheinspectionwork,immediatelyturnoffthemainpowersupply,
checkthecauseof thefailureandtakenecessarycountermeasures accordingly.
(3) Beforestartingwork,place a“maintenance”signin
aconspicuouslocationsothatpeoplearoundtherobotsystem knowthat theinspectionisinprogress.
(4) Donot useanyequipment thatmaygenerate electromagneticnoiseinor
aroundtheplacewheretheinspectionisperformed.
(5) Inspectionormaintenanceworkshouldbeperformedbyat leasttwo workers,oneof
whomperformstheactualworkandtheotheractsasasupervisor.
(6) Personnelwhowillperformrobotinspection, maintenance, adjustment and/orrepair
operationsshould receiveguidanceand trainingonrobotfunctions, operationandmaintenance.
Inaddition, iftherobot system isequippedwithspecialequipmentor facilities, the relevant
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personnelmust fullyunderstandtheentireorganization.
(7) Onlyqualifiedpersonnelwhohavereceivedspecialtrainingcanperformrobot inspection,

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maintenance,adjustment andrepair operations. Inaddition, evenif personnelhavereceived
suchspecialtraining, theyarenot allowed toperforminspection, maintenance,
adjustmentorrepairoperationsonothermachinesthattheyarenot fully familiarwith.
(8) Anyidentification provided toworkers,supervisorsand/oroperatorsof related machines
mustcomplywiththecustomer'ssafetymanagementstandards.
(9) Supervisorsmust complywiththe followingrequirements. Heshould:
(A) Standin a
positionthatoverlookstheentirerobot'sworkingrangeandconcentrateonthejobofsupervisingthe
workresponsibility.
(B) Alwayskeep yourhandonthe"emergencystop" button,andimmediately incaseof
anyabnormalitypressthebutton.
(C) Ensurethat peopleother thanworkers involvedininspectionsarenot
closetotherobot'sworkingarea.
(10) Workers involvedininspectionsor other operationsmust comply withthe
followingrequirements.
(A) If
thejobcanbeperformedoutsidetherobot'sworkingrange,determinethejobdetailsbeforestartingthejob.
Inanycase, besuretoperformtasksoutsidetherobot'soperatingrange.
(B) In principle,performinspectionsandother taskswhiletherobotisstopped.However,
ifinspectionsor othertasksareunavoidableduringtheoperation, the situationmust
bereportedtotheresponsiblesafetymanager.After permission isobtained,
theoperationwillbeperformedoutsidetherobot'sworkingrange.
(C) If therobotisrequiredto beinanoperablestatewhenperforminginspectionsor similaroperations,
determinethedetailsof theoperatingproceduresinadvance toeffectivelyperformsafeoperations.
Inaddition, if thereisnospecialrequirement fortherobottobeinanoperablestate,
theworkisperformedwiththerobotcontroller, weldingpowersupply, or other input power
suppliesturnedoff.Ifthereisnospecialsafetyprogramrequirement, besuretoturnoffthepower
supplyoftheinputsideof thefixtureandperipheralequipmentor leavethemin astoppedstate.
(D) Whenperformingtaskswithintheworkingrangeof therobot, makesurethat youare
alwaysinthe"alwaysready" posture, and youcan immediately
pressthe"emergencystop"buttonwhentherobotmalfunctions.
(E) Beforestartingwork,carefullycheck yourfooting.Besuretoavoidunstable
scaffoldingorscaffolding that iselevated(over1.5metershigh).
(F) When youare withintheworkingrangeof therobot, donot perform taskswithyour backtotherobot.
(G) Whenreplacingtheprintedcircuitboardintherobotcontrolleror teaching box,take anti-
staticmeasures,includinganti-staticboards.
(11) Ifthereisanyabnormalityduringtheoperation,perform the followingprocedures carefully.
(A) If anymalfunctionisfoundintherobot system,immediatelypressthe"emergencystop" button.
(B) Report the situation tothe supervisorimmediately andclosethepower supplyof
thecontroller,andthenplacethe"powersupplynot allowed"sign.
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(C) Besuretocheckthatallrelatedmachines havestopped.
Donot turnonthepower
(D) Whenitisnecessarytoenter the guardrail, thepersonwhoisabout toentermustpersonallypullout
thesafetyplug, carryit withthem, andthenperformrelatedoperations.
(E) Evenwhentherobot stops automaticallyduetoapowersupplyvoltagefailureof
therobotsystem,hydraulicpressureor air pressureof relatedequipment, makesurethatitisin a
completelystoppedstate,andtheninvestigatethecausetotakenecessarycountermeasures.
(F) If the"emergencystop"buttonswitchor other safetyequipmentfailstooperate,
immediatelyturnoffthemainpowersupply,investigate thecauseandtakenecessarycountermeasures.
(G) After pressingthe"emergencystop"buttonto stoptherobot, if youwanttorestart
therobot,investigatethecause, takenecessary countermeasures,
returnthesafetylatchtoitsoriginalposition, andrestarttherobotfrom outsidethe guardrail.
(12) Attheendof
theoperation,carefullycheckthatthenecessaryconnectors,shields,panels,etc.havebeen
installedandconnected correctly.

5.3. Robotinspection

Inordertocontinuouslyoperatetherobot in asafeand effectivemanner, regular

inspectionsareessential.
Theproducthasbeendeliveredfor 6yearsor theoperationtimereaches30,000hours
(whicheverisshorter),and athoroughinspectionmust becarriedout.
Theinspectionandmaintenance cycleisestimatedbasedontheassumptionthattherobotisonlyusedfor
arcwelding. For higherfrequencyof use, suchas handlingwork,the
aboveperiodisshorter.Pleasecontact our companyfordetails.

5.3.1. Daily inspection

1. Aftertherobot stopsworking, checkwhether

therobotreturnstothezeropointpositionandwhetheralljointsof therobotmovenormally.
2. Clean thedust onthesurfaceof theequipment after normalshutdown.
3. Check whether the positiveandnegativecablesof thepower supplyareloose. Ifso,
tightenthemwitha wrench.
4. Check whether thewirefeedingwheelof thewirefeedingmachineisclean. Ifnot
clean,pleasecleanitup.
5. Check whether theconnectionof externalwirefeedingpipeisloose.
6. Check whether the conductivenozzleisseriouslywornor not. Ifso, pleasereplaceitintime.

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7. Check whether theconnection linesof theequipmentaresafeandprotected.

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8. Ensurethatthesurroundingenvironment oftheequipment
meetstheoperationrequirementsoftheequipment(norain, no corrosivegas, non-
hightemperatureenvironment)

5.3.2. Monthlyinspection

1. Duringregular inspection, stoptheoperationandcut offthepower supply.

2. Check whether thevoltageof power supplyiswithinthe allowedrange.
3. Clean thedust onthe driveandcontrolboard.
4. Inspectthe insulationof thecable. Ifthereisanydamage, stopusingit
andreplaceitimmediately.
5. Ifanyconnectorpartsareloose, tightenthembeforeuse.
6. thecontrollineandelectricalcomponents,if
thereisdamageandaffectthenormaloperationorbecometroubleinthefuture, mustberepaired.
7. Check whether thecopper columnof the conductivedeviceisingoodcontact
withtheworkingtableandwhether thespringiseffective.
8. Check whether thewirefeedingissmooth. Ifnot,
checktheinternalwirefeedingpipeandtheexternalwirefeedingpipe,theinternalwirefeedtubeisreplac
edeverythreemonths.

5.4. Robotmaintenance

5.4.1. Synchronous belttension adjustment

Correct andreasonableuseofthesynchronousbeltcannot onlyensurethesmoothprogressof

productionandtransmission, but alsoreducethefailurerateof thedeviceandextendtheservicelifeof
thesynchronousbelt.

Thesynchronousbeltislocated betweenthemotor andthereducer andisusedto drivetheJ4,

J5,andJ6shafts. Thesynchronousbeltmustbeloadedwithpropertensionto achievetherequirementsof
smoothtransmission. Followtheinstructionsbelow toproperlyadjustthetensionbetweentheshafts.
Whenmakingadjustments,becarefulnot tolet thetransmission
pulleyidle,becauseinthiscase,theoriginmayshift andneed tobere-adjusted.
Themotor belt generallyneedstobereplacedonceevery3 years

 J4axissynchronousbelttensionadjustment

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(1) Removethe sealingplateat thetailofthearm holder (viewedfrom therearoftherobot) and

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youcanseethesynchronousbeltinFigure5.1.1.1.
(2) Loosenthe fixedbolt(M5×15) andloosenut ontheservomotor,andusethebolt
(M4)toadjustthetensionof the timingbelt untilthetensionreachestheestimated value.
(3) Afteradjustment, usean Allenwrench totightenthemotor fixingbolts, torque= 9.3Nm
(boltgradedefault is12.9), andapplythreadglueontheseboltstoprevent theboltsfrom loosening.
(4) Re-attachthetailsealingplateof theforearmholder.

Figure5.4.1.1AdjustingthetensionoftheJ4axissynchronous belt

 Don't becaught by movingparts

 Improper adjustmentof belttensionmaydamagethebelt
 Damagetothebelt maycausethearmtofall

 J5axissynchronousbelttensionadjustment

(1) RemovethearmsidecoverL(fromtheright sideoftherobot)

(2) Loosenthefixingbolt M4*12ofthemotor flange, andusethemotor flangetoadjustthetensionof
thetimingbeltuntilthetensionreachestheestimatedvalue.
(3) Afteradjustment, tightenthethreeM4*12boltsat themotor flangewithan Allenwrench,torque
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= 4.9Nm(bolt gradedefault is12.9),
andapplythreadglueontheseboltstopreventtheboltsfromloosening.
(4) ReinstalltheforearmsidecoverL.

synchronousbelt

Fixingbolt
Forearm Motorflange
sidecover M4×12

Figure5.4.2.2AdjustingthetensionoftheJ5axissynchronous belt

 Don't becaught by movingparts

 Improper adjustmentof belttensionmaydamagethebelt
 Damagetothebelt maycausethearmtofall

 J6axissynchronousbelttensionadjustment

(1) RemovethearmsidecoverR(fromtheleft sideof therobot)

(2) LoosenthefixingboltsM4*12of themotor flangefirst. After
looseningtheboltsofthebearingseat,adjustthetimingbelt of thebearingseat firstandthentightenthe 3-
M4*12boltswithan Allenwrench,torque=4.9Nm (bolt gradedefault is12.9),
andapplythreadglueontheseboltstopreventtheboltsfromloosening. Afterlocking,adjustthetensionof
thesynchronousbeltatthemotorflangeuntilthe tension reachestheestimatedvalue.

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(3) Afteradjustingthe timingbelt at themotor flange, useanAllenwrenchtotightenthe 3-M4*12boltsat
themotorflange, torque=4.9Nm(bolt gradeis12.9bydefault),
andapplythreadglueontheseboltsToprevent theboltsfrom loosening.
(4) ReinstallthesidecoverR of theforearm.

synchronousbelt 1 Bearingseat synchronousbelt2 Motor flange

Figure5.4.2.3AdjustingthetensionoftheJ6axissynchronousbelt

 Don'tbecaught by movingparts
 Improperadjustment of belt tensionmaydamagethebelt
 Damagetothebelt maycausethearm tofall

5.4.2. Maintenance plan

1. Themaintenanceof therobotisdividedinto3 levels. Customersare advised
tochoosemaintenancebasedontheoperatingconditionsof thepurchasedrobot:

Class A:Greasereplacement, waveform detection, ironpowder concentrationdetection,

robotbodycablereplacement,bodyandcontrolcabinet batteryreplacement,etc.Throughthe
aboveoperations, thedataisobtained,
therobotphysicalexaminationreportisformed,andtherobotispre-judgedbeforethefailure,reducingthe
blindnessof sparepartsstorage.
LevelB:Greasereplacement, ironpowder concentrationdetection,
etc.Thismaintenancecanprolongthe service lifeof therobot andmonitorthewear andtearof
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thereducerof therobotbody.

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Class C:Themostbasicmaintenance,mainlyfor thepurposeof replacingthegreaseintherobotreducer,
whichcanextendthe servicelifeof therobotreducer.
2. Therobotneedstobemaintainedregularlyto ensureitsnormalfunction.
Table5.4.2.1specifiesthemaintenanceactivitiesandtime intervals:

Table5.4.2.1maintenanceitems andcycle

maintenanceInterval

maintenancePart Method maintenanceContent

Interval Interval Interval Interval Interval
Daily
1000h 6000h 12000h 24000h 36000h

Visualin Checktheexistenceo
1 ZeroPoint ● spection fzeropoint

Visualin Checkfor
2 Externalcable ● spection stainordama
ge
Cleandirtandstains,c
Overalla Visualin heckall
3 ppearance
● spection parts
foranychap.

Checkif there's
4 Pedestalbolt ● Wrench anymiss or
looseness

Checkif there's
5 Cover bolt ● Wrench anymiss or
looseness
Checkif there's
6 Mainbolt ● Wrench anymiss or
looseness

Aviation Checkif there's

7 ● Handtouch anyloosenessandpl
Plug
ugIntightly

Synchrono Check
8 ● Handtouch
us belt belttensionand
friction
9 Battery Teachingdevice
pack*1 displayalarm

Check
10 Eachjointr ● foranyabnor
educer mality
(
Visuali abnormalsoundorsha
Checkif there's
11 Cable ● nspect ke,etc.)
anyabrasionorbreak
ion age

Visualins
12 pection, Checkif there's
Endclamp ● handtouc anymiss or
h looseness

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5.5. Battery
Under normaluseconditions,aslongasthebatterymaintainsintegrityandthe
sealingisintact,theelectrodematerialandliquidelectrolyteinthebattery willnot be exposed totheoutside.
Onlyinthecaseof (mechanical, thermal, electrical) abusecantherebea
riskofexplosion,whichwillcausethesafetyvalve tobeactivatedor thebatterycontainer toburst.
Itisalsopossible that electrolyteleakageandelectrodematerialsreact withmoisture,
resultinginbatteryleakage,explosion,andfire.

5.5.1. Precautions forbattery use

After aperiodof use, thebatteryintherobot willrunout, thentherobotwillalarm theuser
toreplacethebattery. Contactusforreplacement of batteryoranydoubt.

 Donotshort-circuit, charge,puncture, incinerate,crush,

soak,forciblydischargeorplacetheproductat a temperature
exceedingthespecifiedoperatingtemperaturerangeof
theproduct,asthesemaycausefireor explosionhazards.
 Wear safetyglasseswhenhandlingbatteries.
 When handlingleakage, pleasewearglovesandchemicalprotectiveclothing.
 When dealingwithfire situations, pleaseuseself-containedbreathingapparatus.

5.5.2. Batteryreplacement

Toreplacethebattery, pleasenotifyour company‟stechniciansinadvance.It canonlybereplacedafter

obtainingwritten permission from our company. Otherwise,thecompany willnotberesponsiblefor
anylossesanddowntimecaused thereby.

5.6. Lubricatinggrease
5.6.1. J1-J3 joints grease replenishment
Inordertogivefullplaytotheperformanceoftherobot, accordingtothedifferent
brandsofreducerusedbydifferent robots,pleaseusetherobot reducergreasefor lubricatinggrease.

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Duetothespecialgrease(MollywhiteRE00)addedinthereducer,itisgenerallynotnecessarytorefueling,justche
ckthejointaxisforoilleakage.Thegreaseneedstobereplacedeverythreeyears.
Thegreaseusedfor varioustypesof robotsisshowninTable5.6.1
Table5.6.1.1List ofgreases usedby differenttypes of robots

Robotmodel Thelubricatinggreasenameofeachaxis Remark

J1～J3Lubricatinggreasecavityusesrobotreducergre J4、J5、J6Maintenance-
BR-1510A ase(MollywhiteRE00) free

J4、J5、J6Maintenance-
J1～J3Lubricatinggreasecavityusesrobotreducergre
BR-1810A free
ase(MollywhiteRE00)

J4、J5、J6Maintenance-
BR-2010A J1～J3Lubricatinggreasecavityusesrobotreducergre
free
ase(MollywhiteRE00)

Figure5.6.1.1 showsthepositionsof thegreaseholesforaddinganddraininggreaseoneachaxisof BR-

1510Aandtheoilfillingrequirements;
Figure5.6.1.2 showsthepositionsof greaseholesforaddinganddraininggreaseoneachaxisofBR-
1810AandBR-2010A .

Figure5.6.1.1.Thelocationofthegreaseinletandoutletholes for eachaxis ofBR-1510A

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60
Note: Whenfillingoilfor J1 axis,removethesheet metalpartsneartheoilfillingholes.

Table5.6.1.2Greasefillingstandardandrequirements ofBR-510

Standard Inspection
No. Project Greasemodel
method

Referencevalueoftheoreticalgr Visualgreaseinjector MollywhiteRE00Robotre

1 J1axis
reducergreaseinjec easeinjection328cc（295g） ducerrunGrease
Meterreading
tionvolume
Referencevalueoftheoreticalgre VisualgreaseinjectorM MollywhiteRE00Robotre
J2axis
2 aseinjection271CC（244g）
reducergreaseinjec eterreading ducerrunGrease
tionvolume
Referencevalueoftheoreticalgre Visualgreaseinjector MollywhiteRE00Robotre
J3axis
3 aseinjection131CC（118g） ducer runGrease
reducergreaseinjec Meterreading
tionvolume

Figure5.6.1.2Thelocationof thegreaseinletandoutletholesforeachaxisofBR-1810AandBR-2010A

Note:When fillingoilforJ1axis, removethesheet metalpartsnear theoilfillingholes.

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61
 Table5.6.1.3Greasefillingstandardandrequirementsof BR-1810A

Standard Inspection
No. Project Greasemodel
method

Visualoilinjector MollywhiteRE00R
J1axis Referencevalueoftheoreticaloi
1 obotreducerrunGrea
reduceroilinjectio linjection794CC（714g） Meterreading se
nvolume
Visualoilinjector MollywhiteRE00R
J2axis Referencevalueoftheoreticaloi
2 obotreducerrunGrea
reduceroilinjectio linjection477CC（429g） Meterreading se
nvolume
Visualoilinjector MollywhiteRE00R
J3axis Referencevalueoftheoreticaloi
3 obotreducerrunGrea
reduceroilinjectio linjection328CC（295g） Meterreading se
nvolume

Table5.6.1.4Greasefillingstandardandrequirements ofBR-2010A

Standard Inspection
No. Project Greasemodel
method

Visualgreaseinjector MollywhiteRE00
J1axis Referencevalueoftheoreticalgre
1 RobotreducerrunGr
reducergreaseinjec aseinjection794CC（714g） Meterreading ease
tionvolume
VisualgreaseinjectorM MollywhiteRE00
J2axis Referencevalueoftheoreticalgre
2 RobotreducerrunGr
reducergreaseinjec aseinjection570CC（513g） eterreading ease
tionvolume
Referencevalueoftheoreticalgre Visualgreaseinjector MollywhiteRE00
J3axis
3 aseinjection328CC（295g） RobotreducerrunGrease
reducergreaseinjec Meterreading
tionvolume

Note:When fillingoilinJ1joint,removethesheet metalpartsneartheoilinlet hole.

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 1. Eachaxisof therobothasbeenfilled withgrease whenit leavesthefactory.
Whenreplacingit, usea greaseguntofillit withgrease.
2. Accordingtotheagingof thegrease,pleasereplacetherobot greasefor
atotalof20,000hoursfrom thedateof leavingthefactory.
However,whenthesurfacetemperatureofthereducerreaches40°Cor higher duringuse,
pleaseconfirmthe
agingandcontaminationof thegrease,andshortenthegreasereplacement cycle.
3. Theamountof greaseaddedshouldreachabout 90%of thecomponent
oilcavity.Pleaseconsult ourcompany's after-
salesservicepersonnelforspecificinformation.

5.7. Zeropositioncalibration

Therobothasdonethemechanicalzeroproofreadingbeforeit leavesthefactory.
Incasetherobotloseszeropositionduetofault,therobot needstobere-
calibratedtothemechanicalzero.Detailedoperationstepsrefer tomanual“TCPcorrection”.

5.8.Warranty

1) Robot body includeelectricpartsareguaranteedfor 1 yearperiod

2) Teachpendent isguaranteedfor3 monthsbut thescreenhasnowarranty

3) Weldingmachineisguaranteedfor 1year(WithoutWearingparts)

4) Other Wearingpartsarenot coveredbythewarranty

Anydamagecausedbyimproperoperationor humancausesisnot coveredbythe warranty.

Attachment:

Duringthewarrantyperiod, if theproductisdamagedbyimproperuseof theuser,our company

willhandleit asout-of-warrantyperiod.Inout-of-warrantycondition, if theproductsaresent backtoour
companyformaintenance, onlythematerialfeeandmaintenancefee willbecharged.If thereisneedof
fieldmaintenancebyengineersof our company, thematerialfee,travelfeeandmaintenancefee
willbecharged.For specificmaintenancecosts,pleaseconsult our After-SalesServiceDepartment.

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Attention:
1. Theproductisprotectedbycopyright. The softwareandhardwaretechnicaldataof
theproductshallnot be disclosed tothirdpartieswithout authorizationof our company.
1. The softwareandhardwareofthisproductshallnot bedisassembledor
modifiedwithoutauthorizationof our company.
2. Thepurchasedmodelisbasedonthismanual,andsubsequentmanualversionupdateswillnotbenotified
separately.

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