Elite Robot User Manual

Doc. Name： EC612 User Manual

Suzhou Elite Technology Co. Ltd.

www.elibot.cn

January 18, 2020

 DOC No.：T202001006 www.elibot.cn

Original Version 4.0

Please read this manual carefully before use

Please see the chapter of version information in this manual for the product version
information corresponding to the user manual of this version, and please check the actual product
version information carefully before use, as to ensure consistency.

This user manual shall be periodically checked and revised, and the renewed contents will appear in the new
version. The contents or information herein is subject to change without prior notice.
Suzhou Elite Robot Co., Ltd. shall assume no liability for any errors which will occur in the manual probably.
Suzhou Elite Robot Co., Ltd. shall assume no liability for the accident or indirect injury as a result of using this
manual and the product mentioned herein.
Please read this manual before installing and using the product.
Please keep this manual so that you can read and use it for reference at any time.
The pictures in the specification shall be used for reference only. The goods received shall prevail.
Copyright © 2018-2019 ELITE All rights reserved.

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Contents
Contents ..................................................................................................................................... 2
Preface........................................................................................................................................ 5
Product Composition ......................................................................................................... 6
More Information ............................................................................................................... 6
Chapter 1 Safety ......................................................................................................................... 7
1.1 Profile ........................................................................................................................... 7
1.2 Safety Warning Symbols .............................................................................................. 7
1.3 Safety Cautions ............................................................................................................ 9
1.3.1 Overview ........................................................................................................... 9
1.3.2 Usage Notice ..................................................................................................... 9
1.3.3 Personnel safety .............................................................................................. 12
1.4 Liabilities and Specifications ..................................................................................... 13
1.5 Danger Identification ................................................................................................. 14
1.6 Intended Use .............................................................................................................. 15
1.7 Handling of Emergency Situations ............................................................................ 16
1.7.1 Emergency stop device ................................................................................... 16
1.7.2 Resuming from the state of emergency .......................................................... 17
1.7.3 Forced emergency movement of the joints .................................................... 17
1.7.4 Over-strong-force safety protection of the robot arm ................................... 17
Chapter 2 Carrying and Cautions ............................................................................................. 19
Chapter 3 Maintenance, Repair and Disposal .......................................................................... 20
3.1 Maintenance and Repair............................................................................................. 20
3.2 Disposal...................................................................................................................... 21
3.3 Maintenance ............................................................................................................... 21
Chapter 4 Quality Assurance ................................................................................................... 22
4.1 Product Quality Assurance ......................................................................................... 22
4.2 Disclaimer .................................................................................................................. 22
Chapter 5 Robot Hardware Composition ................................................................................. 24
Chapter 6 Robot Installation .................................................................................................... 26
6.1 Brief Installation Steps ............................................................................................... 26
6.2 Important Safety Instructions ..................................................................................... 26
6.3 Workspace of the Robot ............................................................................................. 27
6.3.1 Mechanical dimensions of the robot ............................................................... 27
6.3.2 Range of motion of the robot .......................................................................... 27
6.4 Robot Installation ....................................................................................................... 28
6.5 Installation of the End/Tool Effector.......................................................................... 30
Chapter 7 Quick Start ............................................................................................................... 32
7.1 Installation .................................................................................................................. 32
7.1.2 Cable Connection ............................................................................................ 32
7.1.2.1 Connection of the robot arm to the control box ........................................... 32
7.1.2.2 Connection of the control box to the mains supply ..................................... 33

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7.2 Robot Power-on ......................................................................................................... 34

7.2.1 Preparations before power-on ......................................................................... 34
7.2.2 System power-on............................................................................................. 35
7.3 Robot Shutdown......................................................................................................... 35
Chapter 8 Electrical Interface .................................................................................................. 36
8.1 Overview .................................................................................................................... 36
8.2 Electrical Warnings and Cautions .............................................................................. 36
8.3 Controller I/O ............................................................................................................. 38
8.3.1 Common specifications of all digital I/Os ...................................................... 40
8.3.2 Safety I/O ........................................................................................................ 42
8.3.3 General purpose digital I/O ............................................................................. 44
8.3.4 Digital input from a button ............................................................................. 45
8.3.5 General purpose analog I/O ............................................................................ 46
8.4 Ethernet ...................................................................................................................... 47
8.5 Mains Connection ...................................................................................................... 48
8.6 Robot Connection ...................................................................................................... 50
8.7 Tool I/O ...................................................................................................................... 50
8.7.1 Tool power supply ........................................................................................... 52
8.7.2 Tool digital input ............................................................................................. 52
8.7.3 Tool digital output ........................................................................................... 53
8.7.4 Tool analog input ............................................................................................ 55
8.7.5 Tool analog output........................................................................................... 55
8.7.6 Tool communication I/O ................................................................................. 56
Chapter 9 Teach Pendant .......................................................................................................... 57
9.1 Programming Pendant Display .................................................................................. 58
9.1.1 Main Menu Area ............................................................................................. 59
9.1.2 General-purpose Display Area ........................................................................ 62
9.1.3 Monitoring Area .............................................................................................. 64
9.1.4 Information Prompt Area ................................................................................ 66
9.1.5 Status Control Area ......................................................................................... 66
9.1.6 Coordinate Area .............................................................................................. 67
9.1.7 Status Display Area ......................................................................................... 69
9.1.8 Submenu Area ................................................................................................. 70
9.2 Robot Axes and Coordinates Systems ....................................................................... 70
9.2.1 Basic Operations ............................................................................................. 70
9.2.2 Coordinate Systems and Axis Operations ....................................................... 72
9.3 Teaching ..................................................................................................................... 78
9.3.1 Preparation for Teaching ................................................................................. 78
9.3.2 Teaching Procedure ......................................................................................... 80
9.3.3 List of program instructions ............................................................................ 90
9.4 Playback ..................................................................................................................... 92
9.4.1 Preparation ...................................................................................................... 92
9.4.2 Playback Operation ......................................................................................... 92
9.5 User Processes ........................................................................................................... 94
9.6 Monitoring ................................................................................................................. 94
9.6.1 Coordinates ..................................................................................................... 94

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9.6.2 Variables .......................................................................................................... 95

9.6.3 IO .................................................................................................................... 97
9.6.4 Motor............................................................................................................... 98
9.6.5 Operational Monitoring ................................................................................ 100
9.7 Convenient Functions .............................................................................................. 100
9.7.1 Key Combination Function ........................................................................... 100
9.7.2 Multi-Window Function................................................................................ 101
9.8 System Setup ............................................................................................................ 101
9.8.1 Tool Coordinates Setting ............................................................................... 101
9.8.2 User Coordinates ........................................................................................... 105
9.8.3 Interference Area ........................................................................................... 107
9.8.4 Home Position ............................................................................................... 110
9.8.5 Authority ....................................................................................................... 113
9.8.6 Speed Parameters .......................................................................................... 115
9.8.7 Limit Parameters ........................................................................................... 115
9.8.8 System Configuration ........................................................................................... 116
9.9 Backup and Upgrade ................................................................................................ 117
9.9.1 Software Information .................................................................................... 118
9.9.2 Local to USB ................................................................................................. 119
9.9.3 Local from USB ............................................................................................ 119
9.9.4 System Upgrade ............................................................................................ 120
Appendix ................................................................................................................................ 122
A Glossaries ................................................................................................................... 122
B Certification and Detection ........................................................................................ 124
C Stopping Time and Stopping Distance ....................................................................... 126
D Reference Standards ................................................................................................... 127
E Technical Specifications ............................................................................................. 128
F Alarm Information and Description of Routine Problems .......................................... 129

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Preface
Thank you for purchasing and using the light 6-degree-of-freedom (DOF) collaborative robot
EC612 developed by the company.

The EC612, as one of the ELITE modular collaborative robot series, is an intelligent light
6-DOF modular collaborative robot launched by Suzhou Elite Robot Co., Ltd., with a payload of

12kg.The ELITE collaborative robot series takes a joint modular design, and uses a

developer-oriented robot system. The user may develop his own robot control system in

accordance with an application program interface provided by a ELITE collaborative robot

platform. In addition, the ELITE collaborative robot is equipped with a dedicated programmable

interface, in this way the user may observe a running state of the robot in real time through the

interface, while implementing multiple control settings for the robot and implementing offline

simulation. Accordingly, the work efficiency of the practical application may be improved greatly.

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Product Composition

The detailed outbound list of one set of complete EC612 robot is shown in the table below.

Name Quantity
Robot body 1

Control box including teach pendant 1

Power cord 1
Base (Optional) 1
User manual (disk) 1
Thin-walled wrench 1

More Information

If you require more information, please visit the website: www.elibot.cn

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Chapter 1 Safety

1.1 Profile

This chapter introduces the safety principles and specifications that should be followed when

operating the robot or the robot system. The integrator and the user must read this manual carefully,

and need to mainly master and strictly comply with contents with warning labels. As the robot

system is complicated and dangerous, the user must fully understand the risk of operation, and

strictly comply with and implement the specifications and requirements in this manual. The user

and the integrator must have sufficient safety awareness and comply with ISO 10218 Industrial

Robots - Safety Specification

1.2 Safety Warning Symbols

The safety-related contents in this manual are illustrated with the following warning symbols.

The descriptions related to the warning symbols in this manual represent the important contents,

please comply with these symbols.

Indicating an imminently hazardous electrical situation

which, if not avoided, could result in casualties or serious

damage of the equipment.

Indicating a potentially hazardous hot surface which, if

touched, could result in the personnel injury.

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SAFETY CAUTION:

Indicating an imminently hazardous situation which, if

not avoided, could result in casualties or serious injury.

Indicating a potentially hazardous electrical situation

which, if not avoided, could result in personnel injury or

serious damage of the equipment.

Indicating a potentially hazardous situation which, if not

avoided, could result in personnel injury or serious damage

of the equipment. As for the items marked with this symbol,

the major consequence would probably occur sometimes in

accordance with the specific situation.

Indicating a situation which, if not avoided, could result

in personnel injury or damage of the equipment .

As for the item marked with this symbol, the major

consequence would probably occur sometimes in accordance

with the specific situation.

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1.3 Safety Cautions

1.3.1 Overview

This manual includes the safety measures of protecting the user and preventing the machine

from damage. The user must read all relevant descriptions in the specification and be fully

familiar with the safety cautions. In this manual, we shall try to describe various situations.

However, it seems impossible to record all the cases that cannot be done in accordance with so

many possibilities.

1.3.2 Usage Notice

The following basic information must be understood and followed when starting the robot or

the robot system for the first time, and other safety-related information shall be introduced in other

parts of the manual. However, it seems impossible to cover all aspects. In practical application, the

concrete problem needs to be analyzed in a concrete way.

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1. Please install the robot and all electrical equipments in accordance

with the requirements and specification in the manual.
2. The preliminary test and inspection mustbe implemented for the
robot and its protective system before using the robot for the first time or
putting into production.
3. Before starting the system and equipment for the first time, you must
check whether the equipment and system are complete, operate safely, and
detect any damage.During the detection, that whether it is in line with the
effective safety production rules and regulations of the country or the region
must be observed, and all safety functions must be tested.
4. Make sure that all safety parameters and user programs are correct
and all safety functions run normally. The person qualified to operate the
robot should check each safety function. The robot cannot be started until
the robot passes comprehensive and careful safety test and reaches the
safety level.
1. The professional staff are required to install and debug the robot in
accordance with the installation standards.
2. Upon completion of installation and construction of the robot, the
comprehensive risk assessment should be implemented again, with the
document records kept.
3. Only the authorized personnel could set and change the safety
parameters, and the passwords or the isolation measures must be used to
prevent the unauthorized personnel from changing or setting the safety
parameters. When the safety factors are revised, the related safety functions
must to be analyzed.
4. When the robot is trapped in accident or runs abnormally, the
emergency stop switch may be pressed to stop the action of the robot.
5. The brake is installed in the EC612 joint module, to maintain the
pose of the robot arm when the power is switched off. Do not artificially
switch the power supply system on and off frequently. It is recommended
that the time interval of switching on and off the machine should be more
than 10 seconds.
6. The EC612 has the collision detection function. When the external
force of powering on the robot arm exceeds a normal force of the user’s
safety setting, the robot arm will stop automatically, as to prevent the robot
or the operating personnel from injury due to collision. The function is
dedicatedly designed by the EC612 for the safety of human-machine
collaborative work. However, the robot system is required to run within the
normal range, and the control box of the ELITE collaborative robot series
must be used. If the user develops the controller himself/herself, the robot
will not have the abovementioned function. Moreover, the user must be
responsible for the dangerous consequence brought herefrom.

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1. The robot and the control box may generate heat during running.
When the robot is working or just stops working, please do not operate or
touch the robot.
2. The robot may not be cooled down after turning off the power
supply within an hour.
3. Do not put your finger around the heating part of the control box.

1. Make sure that the robot arm and tools are properly and securely
installed in place.
2. Make sure that the robot arm has ample space to operate freely.
3. Never use the robot which is damaged.
4. Do not connect any safety equipment to normal I/O interface. Use
safety-related interface only.
5. Make sure to implement the correct installation settings (such as the
robot installation angle, mass in TCP, TCP offset, safety configuration).
Save and load the installation file into the program.
6. The tool and obstacles shall not have sharp angles or pinch points.
Make sure that heads and faces of all people are kept outside the reach of
the robot.
7. Be aware of robot motion when using the teach pendant.
8. Any impact will release a lot of kinetic energy, which is much higher
than that at high speed and high payload.
9. Combination of different machines can increase hazards or create
new hazards. Always make an overall risk assessment for the complete
installation. When different safety and emergency stop performance levels
are needed, always choose the highest performance level. Always read and
understand the manuals of all equipments to be used during installation.
10. Never modify the robot. A modification might create hazards that
are unforeseen by the integrator. The authorized reassembling of the robot
shall be done in accordance with all relevant service manuals of the latest
versions. If the robot is changed or altered in any way, Suzhou Elite Robot
Co., Ltd. will not take any responsibility.
11. Before transporting the robot, the user needs to check the insulation
and the protective measures.
12. Comply with the transportation requirements when carrying the
robot, as to carry carefully and avoid bumping.
1. When the robot is combined, or works with the machines capable of
damaging the robot, it is highly recommended to test all functions and the
robot program separately. It is recommended to use the temporary
waypoints outside the workspaces of other machines to detect the robot
program.
2. Suzhou Elite Robot Co., Ltd.will not take any responsibility for the
damage of the robot or personal injury due to programming errors or
improper operation of the robot.
3. Do not expose the robot to permanent magnetic fields for a long
time. The strong magnetic fields may damage the robot.

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1.3.3 Personnel safety

When running the robot system, safety of the operating personnel must be ensured first. The

general cautions are listed below, please properly take corresponding measures of ensuring safety of

the operating personnel.

1. All operating personnel using the robot system should receive the training and pass the

training courses hosted by Suzhou Elite Robot Co., Ltd. The user should ensure to fully grasp the

safe and normative operational process and have the qualification of operating the robot. For detailed

training, please contact with the company by E-mail: [email protected].

2. All operating personnel using the robot system should not wear loose clothing or jewellery

when working with the robot. Long hair must be tied back when working with the robot.

3. When the equipment runs, the robot is in the state of implementing imminent action probably

because the robot is waiting for a starting signal although it seems to have stopped. Even in this state,

the robot should be regarded as being in action.

4. Lines should be drawn on the floor to mark the range of action of the robot, in this way the

operator may know the range of action of the robot including the clamping tool (the manipulator, the

tool and so on).

5. Make sure that the safety measures (for example, guardrails, ropes, or protective screens) are

established near an operating area of the robot, as to protect the operator and the surrounding people.

The locks should be arranged in accordance with the need so that the person outside the operating

personnel in charge of operation cannot touch the power supply of the robot.
6. When using the operation panel and the teach pendant, operations cannot be implemented

until the gloves are taken off as there may be operational errors if the gloves are worn.

7. In emergency and abnormal cases, such as a person is clamped or surrounded by a robot, the

joint can be forced to move by pushing or pulling the robot arm hard (at least 700 N). If there is no

electric drive available, the robot arm may be moved manually only in case of emergency, however

the joint may be damaged.

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1.4 Liabilities and Specifications

EC612, which is partly completed, may form a complete machine with other equipments.

Therefore, the information in this manual neither covers how to design, install and operate one

complete robot comprehensively, nor covers all possibilities of affecting safety of the peripheral

equipment of the complete system. The installation safety of the complete robot shall depend on how

the robot is integrated. The integrator should comply with the laws, regulations, safety specifications

and standards of the country where the integrator is located to implement the risk assessment for

design and installation of the complete system. The risk assessment is one of the most important

tasks that the integrator must complete. The integrator may implement the risk assessment process by

using the following standards for reference.

• ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction

• ISO 10218-2:2011 Robots and robotic devices - Safety requirements for industrial robots - Part 2: Industrial

robot system and integration

• RIA TR R15.306-2014 Technical report of industrial robots and robot systems - Safety requirements and

task-based risk assessment method

• ANSI B11.0-2010 Safety of machinery – General requirements and risk assessment

The ELITE robot integrator should perform, but not limited to, following responsibilities:
• Make a comprehensive risk assessment for the complete robot system.

• Confirm that the whole system is designed and installed accurately.

• Provide the user and the staff with training.

• Create the operation specification of the complete system and clarify the instructions of using the robot.

• Establish appropriate safety measures.

• Eliminate the hazards or minimize all hazards to acceptable levels with appropriate methods during the

final installation

• Pass the remaining risks to the end-user.

• Mark the logo and contact information of the integrator on the robot

• Archive the related technical documents.

For reference to applicable standards and legal guide, please visit the website: www.elibot.cn.
All safety-related information contained in this manual shall not be regarded as the warranty of

Suzhou Elite Robot Co., Ltd. Even though all safety instructions are followed, the personnel injury

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or equipment damage caused by the operating personnel may occur as well.

Suzhou Elite Robot Co., Ltd. is committed to continuously improving reliability and

performance of the products, and accordingly reserves the right to upgrade the products without prior

notice. Suzhou Elite Robot Co., Ltd. strives to ensure accuracy and reliability of the contents in this

manual, but takes no responsibility for any errors or missing information herein.

1.5 Danger Identification

Potential interaction contacts and foreseeable misoperations between the operating personnel
and the robot during normal use should be considered during risk assessment. The neck, face and
head of the operators should not be exposed, as to avoid bumping. In absence of peripheral safety
protective device, the risk assessment should be implemented first before using the robot, as to judge
whether the related dangers constitute the unacceptable risk, for example:
• The probable danger result from using of the sharp end effector or the tool connector.

• The probable danger due to handling of the toxic or other harmful substances.

• The danger in which a finger of the operating personnel is clamped by the robot base or the joint.

• The danger caused by bumping against the robot.

• The danger because the robot or the tool connected to the end is not fixed in place.

• The danger due to impact between the payload of the robot and the hard surface.

The integrator must measure this type of risks and the related risk levels through the risk

assessment, then confirm and implement the corresponding measures, as to reduce the risks to the

acceptable levels. Please note that the specific robot equipment may have other major dangers.

The risk related to collaborative operation of the EC612 may be reduced to a reasonable and

feasible level as far as possible by combining the inherent safety design measures applied to the

ELITE collaborative robot and the safety specifications or risk assessment implemented by the

integrator and the final users. Through this document, any remaining risks of the robot before

installation may be passed to the integrator and the final users. If the risk assessment of the integrator

measures that there is risk that may constitute the unacceptable risk to the user in its specific

application, the integrator must take the appropriate risk reduction measures to eliminate or minimize
the risk until the risk is reduced to the acceptable level. It is unsafe to use the robot before taking the

appropriate risk reduction measures (if needed).

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If the robot is installed non-collaboratively (for example, when using the dangerous tool), the

risk assessment may infer that the integrator needs to connect to an additional safety device (for

example, a safety starting device) when programming, as to ensure personnel and equipment safety.

1.6 Intended Use

The ELITE collaborative robot should be used on general industrial equipment only, for
example, operate or fix the tool or the equipment, process or convey the parts and the products. The
ELITE robot must be used only under the specified condition. For specific information about the
relevant operating environment and operating conditions, please refer to the appendix.

The ELITE collaborative robot has the special safety level characteristics and may implement
the collaborative operation, namely, the ELITE collaborative robot may be used in absence of the
peripheral safety protective device, however, only in the case that no danger occurs in accordance
with the risk assessment. Namely, on the premise that no safety protective device and the on-site
sensor are used, anticipated or accidental contact between the staff and the ELITE collaborative
robot or its end effector or the part would not constitute the unacceptable risk, and the anticipated or
accidental contact with other objects (the tool, the equipment, the surface and so on) in the
workspace would not constitute the unacceptable risk as well.
The robot controller and the robot should be used on the general industrial equipment only and
cannot be applied to the application breaching the intended uses. The prohibited use includes, but are
not limited to, the following situations:
• Used in flammable and explosive environment, and other dangerous environment.

• Used on the device of moving or carrying human or other animals.

• Used on the device, such as the medical device involving in the human life.

• Usedon the device which greatly influences the sociality and the publicity.

• Used in the environment subjected to vibration, such as the vehicle and the ship.

• Used as the climbing tool.

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1.7 Handling of Emergency Situations

1.7.1 Emergency stop device

All motions of the robot may be stopped upon pressing the emergency stop button. The
emergency stop cannot be taken as the measure of reducing the risk, however can be taken as the
secondary protective device. If multiple emergency stop buttons need to be connected, the
emergency stop device must be incorporated into the risk assessment of the robot application. The
emergency stop button should meet the requirements of IEC 60947-5-5.
The EC612 is equipped with the emergency stop buttons on the control box and the teach
pendant. The button should be pressed only when meeting the dangerous situations or emergencies,
as shown in following figure. The control box is equipped with the external emergency stop button
port, and the integrator or the user can use it in accordance with the actual situations.

Figure 1-1 Emergency stop button

The tool or equipment connecting to the end, if constituting the potential

threat, must be integrated into the emergency stop loop of the system. If

falling to comply with the caution, personal injury，serious property damage

and even death may be caused.

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1.7.2 Resuming from the state of emergency

All emergency stop equipments in form of button have "Locking" function. The "Lock" must be

unlocked, as to end the emergency stop state of the equipments.

The "Lock" may be unlocked by rotating the emergency stop button.

Resuming from the emergency stop state is a simple and important step which can be operated

only when the danger of the robot system is eliminated completely.

1.7.3 Forced emergency movement of the joints

In rare cases, one or more robot joints may need to be moved under the emergency situations,

namely, the power supply of the robot is trapped in failure or the operating personnel does not want

to use the power supply. In this way, the robot joints are forced to move through the following

method:

Forced reverse drive: push or pull the robot arm hard (at least 700N), as to force the joints to

move.

Forced manual movement of the robot arm should be operated only in case of emergency,

however the joints may be damaged.

1.7.4 Over-strong-force safety protection of the robot arm

The robot arm has the over-strong-force safety protection function. When the robot arm is

powered on statically, and when the operating personnel or other objects bump against the robot arm

accidentally and the impact force exceeds a safety threshold, the robot arm may move along with a
direction of the impact force. The function may ensure that the damage to the personnel, other

objects and the robot arm is reduced when the operating personnel or other objects bump against the

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robot arm.

The function may reduce the damage as a result of impact, and the risk assessment must be
implemented when used for other purposes.

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Chapter 2 Carrying and Cautions

When hoisting the robot, moving parts should be positioned with the appropriate measures, as

not to cause the unanticipated motion which may lead to harm accordingly during hoisting and

transportation. When packing and transporting, the robot should be packed in accordance with the

packing standards, and the required marks should be printed outside a packing box.

When transporting, the robot should be ensured to be stable and needs to be held and fixed at an

appropriate position.

The control box should be raised with a handle

When moving the robot to the installation position from the packing material of the robot, the

robot should be supported until all bolts of the robot base are tightened completely.

After fixing, the robot is powered on, and the pose of the robot should be adjusted to the

appropriate position with the dragged teaching function of the robot.

An original package should be kept upon completion of transportation. The packaging material

should stay dry, in case of repackaging the robot in the future.

1. Make sure that your back or other parts of the body are not overloaded when raising the

equipment.

2. All regional and national guides should be followed. Suzhou Elite Robot Co., Ltd. shall not

be responsible for damage generating during transportation .

3. Make sure that the robot is installed in strict accordance with the installation instructions in

the specification.

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Chapter 3 Maintenance, Repair and Disposal

3.1 Maintenance and Repair

The maintenance and repair work must be implemented in strictly accordance with all safety

instructions in this manual.

The maintenance, calibration and repair work must be operated in accordance with the latest

service manual which can be searched on the supported website: www.elibot.cn. All dealers of

Suzhou Elite Robot Co., Ltd. can visit the website.

After changing the control system, the robot joints or the tool, the robot and the tool zero should
be re-calibrated on the spot, and the calibration operation and the result judgment method are

introduced in the specification of check for zero. In addition, the parameter settings should be

checked. If the parameters are backed up, the backup parameters may be imported; if the parameters

are not backed up, the parameters should be set again. If the robot joints or the tool needs to be

replaced, the dynamics of the robot needs to be re-identified, with the identification method

introduced in the instructions of the control system.

Maintenance must be implemented by authorized system integrator or Suzhou Elite Robot Co.,
Ltd.When the parts are returned to Suzhou Elite Robot Co., Ltd., operation should be implemented in

accordance with the provisions in the service manual.

The safety level stipulated by the maintenance and repair work must be ensured, the effective

national or regional working safety rules must be followed, and all safety functions run normally

must be tested.

The purpose of the maintenance and repair work is to ensure normal running of the system, or to

help it return to normal status in case of the system failure. The repair work includes the failure

diagnosis and practical repair.

The following safety procedure and cautions must be followed when operating the robot arm or

the control box:

Safety procedure:

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1. Remove the mains input cable from the back of the control box to ensure that the robot is

completely powered off. Take necessary precautions to prevent other persons from re-energizing the

system during the repair period. When it is powered off, re-check the system to ensure the outage.

2. Please check the earth connection before re-starting the system.

3. Please comply with the electrostatic discharge (ESD) regulations when disassembling the

robot arm or the control box.

4. Avoid disassembling the power supply system of the control box. The high voltage can be

remained inside the power supply system for several hours when the control box is switched off.

5. Prevent water or dust from entering into the robot arm or the control box.

Cautions:

1. Replace the parts trapped in failure with new parts with the identical part number or the

corresponding parts approved by Suzhou Elite Robot Co., Ltd.

2. Reactivate all prohibited safety measures immediately upon completion of the work.

3. Record all maintenance operations in written form and save these records in the relevant

technical documents of the whole robot system.

4. The control box does not have a part that the end-user can repair by himself. If maintenance

or repair services are needed, please contact with the dealer or Suzhou Elite Robot Co., Ltd.

3.2 Disposal

The ELITE robot must be disposed in accordance with the applicable national laws and

regulations and the national standards.

3.3 Maintenance

The safety functions of the robot must be tested at least once per year, as to ensure that the
functions are correct.

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Chapter 4 Quality Assurance

4.1 Product Quality Assurance

A limited warranty period of the ELITE collaborative robot is 12 months.

Suzhou Elite Robot Co., Ltd. should provide the necessary spare parts to replace or repair
relevant parts if the new equipment and its components are trapped in defects resulting from
manufacturing and/or poor materials within 12 months after entry into service (maximum of 15
months from shipment).
Suzhou Elite Robot Co., Ltd. shall possess the ownership of the equipment or components
replaced or returned to Suzhou Elite Robot Co., Ltd.
If the product is no longer under warranty, Suzhou Elite Robot Co., Ltd. shall reserve the right
of charging the customer for replacement or repair.
In case of defects of the equipment which is out of warranty, Suzhou Elite Robot Co., Ltd. shall
not be responsible for any damage or loss caused therefrom, such as loss of production or damage
due to other production equipments.

4.2 Disclaimer

If the equipment defect is caused by improper disposal or falling to comply with the relevant
information stated in the user manual, the “Product Quality Assurance” will be invalid.
The failure caused by the following circumstances shall not be covered by the warranty:
1. Installation, wiring and connection to other control equipments are not in line with the
industrial standards or not implemented in accordance with the requirements of the user manual.
2. Outside the specification or standards shown in the user manual during use.
3. This product is applied to the non-designated purposes.
4. The storage mode and operating environment are outside the specified scope (such as
pollution, salt damage and dewing) of the user manual.
5. The product is damaged as a result of improper transportation.
6. Damage due to the accident or impact.
7. The non-original parts and accessories are installed.
8. Damage as a result of modification, debugging or repair of the original parts by the third
party outside Suzhou Elite Robot Co., Ltd. or other integrators specified by Suzhou Elite Robot Co.,
Ltd.
9. Natural disasters, such as fire, earthquake, tsunamis, lightning stroke, gale and flood.
10. Failure outside the abovementioned circumstances and not caused by Suzhou Elite Robot
Co., Ltd.
The following circumstances should not be covered by warranty:
1. The date of production or the start date of the warranty cannot be identified.
2. Alteration of the software or internal data.
3. The failure cannot be reproduced, or Suzhou Elite Robot Co., Ltd. cannot identify the
failure.

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4. This product is used on the radioactive equipment, the biological test equipment or in the
dangerous use judged by Suzhou Elite Robot Co., Ltd.
In accordance with the product quality assurance agreement, Suzhou Elite Robot Co., Ltd. shall
be responsible for making the commitment of quality guarantee for the defects or deficiencies
occurring in the products and the parts sold to the dealers.
As for any other explicit or implied warranties or liabilities including, but not limited to, any
implied warranty for marketability or specific use, Suzhou Elite Robot Co., Ltd. shall not bear the
related liability to guarantee. In addition, Suzhou Elite Robot Co., Ltd. shall not be responsible for
the related liabilities in allusion to any form of indirect damage or consequence generated by the
related product.

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Chapter 5 Robot Hardware Composition

Figure 5-1 EC612 robot system

As shown in Figure 5-1, the EC63 collaborative robot system mainly consists of the robot body,
the control box (multiple types of the control boxs are optional), the base and the teach pendant. The
robot body imitates the arm of human body, and totally has six rotating joints and each representing
one degree of freedom. As shown in Figure 5-2, the robot joint includes a substrate (joint 1), a
shoulder (joint 2), an elbow (joint 3), a wrist 1 (joint 4), a wrist 2 (joint 5) and a wrist 3 (joint 6). The
substrate is used to connect the robot body with the base, and the tool/end effector is used to connect
the robot with the tool. Arm tube connection between shoulder and elbow and between elbow and
wrist. Through the operation interface of the teach pendant or dragged teach pendant, the user may
control each joint to rotate, in this way the end/tool effector of the robot can be moved to the desired
different poses.

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Figure 5-2 Robot joints

The control box is the main part of the control system of the EC63 collaborative robot. Please
refers to the instructions of the control box in the user manual for the components inside the control
box.
The EC63 provides multiple IO interfaces, and the tool flange of the robot end is equipped with
four digital input and output interfaces and two analog input and output interfaces. The control box
can communicate with the robot arm through the high-speed dedicated bus.
The teach pendant provides the user with a visual operation interface. The user may test,
program and simulate the robot through the teach pendant, and operate the robot only through a
small programming base.

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Chapter 6 Robot Installation

6.1 Brief Installation Steps

The brief installation steps of the EC612 robot:

1. Confirm the workspace of the robot.
2. Install the robot body on the base.
3. Install the end/tool effector.

6.2 Important Safety Instructions

Environmental conditions for installation:

• Without corrosive gas or liquid
• Without dust or metal powder
• Without radioactive material
• Without oil mist
• Without mechanical shock and vibration
• Low humidity
• Less than 1000m above sea level
• Avoid direct sunshine (prevent the robot from being used outdoors)
• Without salt mist
• Without electromagnetic noise
• Without flammable materials
Ambient temperature: at 0°C ~ 45°C
Operating humidity: 5%~90% (without dewing)
Bearing capacity of the floor: the robot should be installed on a hard surface. The surface should
be able to bear at least ten times of the complete torsion of the base joints and at least five times of
the weight of the robot arm. In addition, the surface should be free from vibration. Please refer to the
appendix for the specific bearing capacity. The safety assessment must be implemented upon
completion of each installation of the robot, and the instructions in Part I (Safety) should be strictly
followed.
Description of installation of the additional device: if the additional components, such as the
cable which is outside the range that Suzhou Elite Robot Co., Ltd. should provide, are integrated into
the industrial robot, it is the user’s responsibility to ensure that these components are completely
unaffected and the safety functions would not be affected.

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6.3 Workspace of the Robot

6.3.1 Mechanical dimensions of the robot

The mechanical dimensions diagram of the EC612 robot is shown in Figure 6-1. The range of
motion of the robot must be considered during installation, as to prevent the surrounding personnel
and equipment from being bumped.

Figure 6-1 Mechanical dimensions diagram of the EC612 robot, with unit of mm

6.3.2 Range of motion of the robot

Figure 6-2 shows the range of motion of the EC612, namely, a sphere with a radius of 1304mm
except the cylindrical space directly above and directly below the base. When choosing the
installation position of the robot, the cylindrical space directly above and directly below the robot
must be considered, as to avoid the tool from being moved toward the cylindrical space as far as
possible. In addition, the rotation angle of the joints 1~6 is -175 ºto +175 ºin practical application.

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Figure 6-2 Schematic diagram of workspace of the robot

6.4 Robot Installation

The robot has the 360°pose self-adaptive function at the installation location, and is compatible
with installation, hoisting, wall mounting and other specific installation ways on the base, as shown
in Figure 6-3.

Figure 6-3 Schematic diagram of different installation poses

When installing on the base, the robot body is fixed on the base with four M8 bolts. It is
recommended to install the pins with two holes, as to improve the installation accuracy. The

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mechanical dimensions are shown in Figure 6-4.

Figure 6-4 Dimensions of installation holes on the base, with unit of mm

1. When installing on the base, the robot should closely contact with a contact surface of the
base, and the surface should be sufficient to bear at least 3500Nm torsional force in a selected
installation direction of the base joints and a weight of at least 100kg. The surface should be free
from vibration. If the robot is installed on a moving platform, an acceleration of the moving platform
should be very low, and a high acceleration would trigger the collision stop function of the robot.
2. The user is recommended to use a base contact surface with strong heat dissipation
performance, such as all-aluminium material. When the operating temperature is greater than 35°C,
the user is strongly recommended to use the material with strong heat dissipation performance.
Make sure the robot arm is correctly and securely installed in place.
If soaked in water for more than a certain period of time, the robot may be damaged. The robot
should not be installed in water or the humid place unless IP67 protection class is declared.
Danger of overturning: if not securely placed on the hard surface, the robot may overturn and
cause damage.
Installation Requirements of the Robot Arm：The robot arm having a 12kg load runs normally

without bumping against the outside, in which a center of gravity of the load is deviated from a

central axis of the tool end for 100mm. Three ways of installation (forward installation, hoisting and

vertical installation) are available, and it is recommended that the minimum anti-overturning force

should be available at each hole position of fixing the bolt of the robot arm.

Way of installation Normal running Stopping in case of emergency

Forward installation 1554N±360N 1554N±2594N

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Reverse installation 1754N±360N 1754N±2594N

Vertical installation 1554N±360N 1554N±2594N

6.5 Installation of the End/Tool Effector

The tool flange has four M6 threaded holes and one Ф6 positioning hole, in this way the clamp
may be conveniently installed and connected to the robot end. The mechanical dimensions of the tool
flange are shown in Figure 6-5.

Figure 6-5 Mechanical dimensions diagram of the tool flange of the robot, with unit of mm
1. Make sure the tool is correctly and securely installed in place.

2. Make sure the tool is safely constructed such that it cannot create a hazardous situation by a

dropping part unexpectedly.

12
Payload/ Kg

10

0
0 100 200 300 400 500 600
D(mm)

A wrist payload diagram is shown above. Herein, the horizontal ordinates D respectively
indicates the offset of the center of gravity. The offset of the center of gravity is the distance from the

center of the flange plate of the tool/end effector to the center of gravity of the tool.

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WARNING

1. The load conditions should fall within the scope shown in the chart.

2. The payload shown in the diagram indicates a maximum payload which should not exceed a

maximum weight shown in the diagram under any circumstances.

3. The components inside the robot may be damaged early if the payload exceeds an allowable

value.

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Chapter 7 Quick Start

7.1 Installation

7.1.1 Robot installation

Take the ELITE robot out of the packing box and install it on the base. Please refer to Chapter 6
Robot Installation for the specific installation instructions.
【NOTES】
1. The control box should be placed on the ground horizontally. A 50 mm clearance should be
reserved on each side of the control box to ensure smooth air circulation.
2. The teach pendant can be hung on the control box. Make sure that the cable will not cause
tripping hazard.
【DANGER】
1. Make sure the control box, the teach pendant and the cables do not come into contact with
liquids. The wet control box may cause casualties.
2. The control box and the teach pendant should not be exposed to the dust or the humid place
exceeding the level of IP54. Pay close attention to the environment of conductive dust.

7.1.2 Cable Connection

There are two sockets at the bottom of the control box, and the corresponding cable should be
inserted into the socket before use.

Figure 7-1 Plugs at the bottom of the control box

7.1.2.1 Connection of the robot arm to the control box

There is a heavy-load rectangular plug at the end of the robot arm cable. Insert the heavy-load

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rectangular plug into the control box. Pay attention to the insertion direction, and lock the connector
after tight insertion, as shown in the following figure.

Figure 7-2 Connection of the robot cable to the control box

7.1.2.2 Connection of the control box to the mains supply

There is a heavy-load rectangular plug at the end of the mains cable of the control box. Connect
the local dedicated mains cable to the heavy-load rectangular plug. Pay attention to the insertion
direction, and lock the connector after tight insertion, as shown in the following figure.

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Figure 7-3 Diagram of the power interface of the control box

【DANGER】
1. Please make sure that the robot is grounded correctly (electrical connection to ground). The
grounding conductor should have at least rated current of the highest current in the system.
2. Please make sure that all cables are correctly connected before the control box is powered
on. Always use the original power cord correctly.

【WARNING】
1. Do not disconnect the robot cable when the robot arm is turned on
2. Do not extend or modify the original cable.

7.2 Robot Power-on

7.2.1 Preparations before power-on

• Check whether the robot is well connected with the control box.
• Check whether the teach pendant is well connected with the control box.
• Check whether the power cable of the control box is well connected.
• The power master switch of the control box is OFF when the power supply is turned
off.
• The control box and the emergency stop switch of the teach pendant are in bouncing
state.
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• The mode selection button is positioned at the correct position.

• Make sure the robot would not contact with the surrounding personnel and the
equipment.

7.2.2 System power-on

7.3 Robot Shutdown

Shutdown sequence: turn off the power supply of the robot and the teach pendant first; then
turn off the power supply of an I-series control box. 1. Turn off the power supply of the robot and the
teach pendant.
Normal exit: exit the program, and press the software closing button in the upper right corner
of the operation interface of the teach pendant.
Forced shutdown: long press the starting button in the upper left corner of the teach pendant
for about 3 seconds, to turn off a blue light; and turn off the power supply of the teach pendant and
the robot. 2. Turn off the power supply of the I-series control box.
Warning: shutdown of the system by directly unplugging the power cord from the wall socket
may cause damage of the file system of the robot, and accordingly lead to function failure of the
robot.

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Chapter 8 Electrical Interface

8.1 Overview

This chapter describes all electrical interfaces of the collaborative robot. Examples are given
for most types of I/Os. The term “I/O” refers to both digital and analog control signals of an
import interface.
• Controller I/O
• Ethernet
• Power supply connection
• Robot connection
• Tool I/O

The warnings and cautions in next section are related to the four groups of interfaces, please
comply with these matters.

8.2 Electrical Warnings and Cautions

Observe the following warnings and cautions when the robot application is designed and
installed. Furthermore, observe these warnings and cautions as well when implementing
maintenance.

DANGER:
1. Never connect the safety signals to a PLC which is not a
safety-related PLC with the proper safety level. Failure to follow the
warning may result in serious injury or even death as certain safety
stop function is invalid. please separate the safety interface signal
from the general I/O interface signal.
2. All safety-related signals are constructed redundantly (two
independent channels). Keep the two channels independent so that a
single failure would not lead to loss of the safety function.
3. Some I/Os inside the control box may be configured as the normal
I/Os or the safety-related I/Os. Please read through Section 4.3.
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DANGER:
1. Make sure that all equipments which must be kept far away from
water are kept dry. If the water enters into the product, please turn off
the power supply and then contact with your provider for assistance.
2. Only use the original cables supplied with the robot. Do not use
the robot in applications where the cables are subjected to flexing. If
a longer cable or a flexible cable is needed, contact your provider.
3. A negative connector is defined as the Ground (GND) connector
which is connected to a shield of the robot and the control box. All
GND connectors mentioned in the text are only suitable for powering
and transmitting signals. For protective earth (PE), please provide
the control box with the reliable GND with the dedicated power
supply socket of the control box.
4. Please be careful when installing the interface cable to the robot
I/O. A metal plate on the back of the box is intended for the interface
cables and connectors. Please remove the metal plate before drilling
holes. Make sure that all matte sides are removed before reinstalling
the metal plate. Remember to use the correct size gland.

Caution:
1. The robot has been tested in accordance with international IEC
standards for electromagnetic compatibility (EMC). Disturbing
signals with levels higher than those defined in the IEC standards
may cause unexpected behaviors of the robot. Very high signal level
or excessive exposure may damage the robot permanently. The EMC
problems happen usually during welding and are usually prompted
by the error messages in the log. ELITE shall not be held responsible
for any damages caused by EMC problem.

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2. The I/O cable for connecting the control box to other machinery
and factory equipments may not be longer than 30m, unless the
prolonged test are performed.

NOTE:
All voltages and currents are in direct current (DC), unless
otherwise specified.

8.3 Controller I/O

This chapter describes how to connect the equipment to the I/O inside the control box. The
I/O is extremely flexible and may be applied to various different equipments, including the
pneumatic relay, the PLC and the emergency stop button.
The layout of the electrical interfaces inside the control box is shown in the following figure.

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J106 Dedicated safety signals

J102,J103,J104,J105 Configurable digital input DI
J109,J110,J111,J112,J113 General purpose digital DO
J108,J107 General purpose analog I/O

The following chapters shall describe how to use the digital I/O. This section describes
the common specifications that must be followed.

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8.3.1 Common specifications of all digital I/Os

This section defines the electrical specifications of the following 24V digital I/Os of
the control box.
• Safety I/O.
• Configurable I/O.
• General purpose I/O.
It is important to install the Elite robot in accordance with the electrical specifications which
must be done for both two types of inputs. The internal 24V power supply shall be provided to
the digital I/O, and access of the power interface shall be implemented through the J14 terminal
on the IO plate via the internal 24V power supply.
The configurable I/O is defined that the digital input may be configured to two input modes
including NPN and PNP, which may implement selection with J22 on the IO plate. The NPN
input is default, namely, J22 short-circuit 24V and the intermediate terminal. Furthermore, the

short-circuit may be implemented for the GNDP and J22 intermediate terminal with a short
circuit cap, as to configure the input as the PNP mode.

The electrical specifications of the internal power supply is shown below.

Terminal Parameter Min Type Max Unit

Internal 24V power supply
[24V - GNDP] Voltage 22.8 24 26.4 V
[24V - GNDP] Current 0 -- 4 A

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The digital I/O should be constructed in compliance with IEC 61131-2. The electrical
specifications are shown below.

Terminal Parameter Min Type Max Unit

Digital output
[DOUTx/ILOx] Current 0 - 0.7 A
[DOUTx/ILOx] Voltage drop 0 - 1 V
[DOUTx/ILOx] Leakage current 0 - 0.1 mA
[DOUTx/ILOx] Function - PNP - Type
[DOUTx/ILOx] IEC 61131-2 - 1A - Type
Digital input
[DINx] Voltage -3 - 30 V
[DINx] OFF region -2 - 2 V
[DINx] ON region 8 - 30 V
[DINx] Current (8-30V) 2 - 8.5 mA
[DINx] Function - PNP - Type
[DINx] IEC 61131-2 - 3 - Type
Digital input/safety input
[DINx /x_STOPx] Voltage -10 - 26 V
[DINx /x_STOPx] OFF region 22 - 26 V
[DINx /x_STOPx] ON region -10 - 19 V
[DINx /x_STOPx] Current (-10V-19V) 1 - 10 mA
[DINx /x_STOPx] Function - NPN - Type
[DINx /x_STOPx] IEC 61131-2 - 3 - Type

NOTE:
The word “Configurable” is intended for the input which may be
configured as the NPN input or PNP input.

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8.3.2 Safety I/O

This section introduces the dedicated safety input. Please observe the common specifications
in Section 4.3.1.
The safety device and equipment must be installed in accordance with the safety instructions
and the risk assessment in Chapter 1.
All safety I/Os are paired (redundant) and two separate branches must be retained. A single
failure should not cause loss of the safety function. There are two permanent inputs: emergency
stop and safeguard stop.
The emergency stop input should be applied to the emergency stop equipment only.
The safeguard stop input should be applied to all types of safety-related protective
equipments. The functional differences are shown below.

Emergency stop Safeguard stop

Motion stop of the robot Yes Yes
Program execution Stop Pause
Power supply of the robot Off On
Reset Manual Automatic or manual
Frequency of use Infrequent Once within each cycle
Requires re-initialization Brake released only No
Stop category (IEC 60204) 1 2
Performance level (ISO 13849-1) PLd PLd
The emergency stop output and other safety I/O functions may be set with the
configurable I/O.
Some examples about how to use the safety I/O are given in the section below.

DANGER:
1. Never connect the safety signals to a PLC which is not a
safety-related PLC with the improper safety level. Failure to
follow the warning may result in serious injury or even death as
certain safety stop function is invalid. Please separate the safety

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interface signal from the general I/O interface signal.

2. All safety-related I/Os are constructed redundantly (two
independent channels). Keep the two channels independent so
that a single failure may not lead to loss of the safety function.
3. Safety functions must be verified before putting the robot
into operation. Safety functions must be tested regularly.
4. The robot installation must conform to these specifications.
Failure to do so may result in serious injury or even death as
the safety stop device may be invalid.

8.3.2.1 Default safety configuration

The default configuration is implemented for the delivered robot, which can be operated in
absence of any additional safety equipment (the teach pendant is equipped with the emergency
stop button; the equivalent circuit is shown below; and the short circuit is required to implement
for E_STOP1 and GNDP when the E_STOP1 enabling is not configured in the software).

8.3.2.2 Connecting with the emergency stop button

Most applications require one or more additional emergency stop buttons. The operational
principle (the E_STOP1 function enabling needs to be configured in the software) of the one or
more emergency stop buttons is shown in the following figure.

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8.3.2.3 Safeguard stop with automatic resume

The door switch is an example of the basic safeguard stop equipment. When the door is
opened, the robot is stopped. Please refer to the figure below (the software is required to
configure the safeguard stop function cooperatively).

This configuration is only intended for application where the operator cannot go through the
door and close it behind him. The configurable I/O may be used to set a reset button outside the
door, as to reactivate motion of the robot.

DANGER:
The robot shall resume motion automatically when the safeguard
signal is re-established. Do not use this configuration if the signal
can be re-established from the inside of the safety perimeter.

8.3.3 General purpose digital I/O

This section introduces the general purpose 24V I/O. The common specifications in section
4.3.1 must be followed. The general purpose I/O may be used to directly drive the equipment,
such as the pneumatic relay, or to communicate with other PLC systems. All digital outputs may

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be disabled automatically when program execution is stopped. Refer to Part II for details. In this
mode, the output will always be the high level when the program does not run. Several examples
are shown in the section below. The regular digital outputs are taken in these examples, however
this type of outputs may also be used if the configurable output is not configured to perform the
safety function.
Load controlled by the digital output
This example shows a connection way of the load controlled by the digital output. See the
figure below.

8.3.4 Digital input from a button

This example shows a connection way of a simple button and the digital input.

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8.3.5 General purpose analog I/O

The analog I/O interface can be used to set or measure the voltage (-10V~10V) in and out of
other equipments.
In order to acquire a high accuracy, it is recommended to comply with the following
instructions:
• Use the GNDPA terminal closest to the I/O. The I/O pair shares a common mode filter.
• Use the same GND (0V) for the equipment and the control box. The analog I/O is not
galvanically isolated from the control box.
• Use a shielded cable or twisted pair. Connect the shielded cable to the “GNDP” terminal
on the “Power” terminal.
The electrical specifications are shown below.

Terminal Parameter Min Type Max Unit

Analog input
[AINx - GNDPA] Voltage -10 - 10 V
[AINx - GNDPA] Resistance - 100 - Kohm
[AINx - GNDPA] Resolution - 12 - bit
Analog output
[AOUTx - GNDPA] Voltage -10 - 10 V
[AOUTx - GNDPA] Resistance - 10 - ohm
[AOUTx - GNDPA] Resolution - 12 - bit

The following example shows a way of using the analog I/O.

8.3.5.1 General purpose analog output

The following example illustrates how to control a welding current of a welder with an
analog input.

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8.3.5.2 Using an analog input

This example illustrates how to connect with an analog sensor.

8.4 Ethernet

The Ethernet is provided on the top of the control box. Please refer to the figure below.

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The Ethernet interface can be applied to the following applications:

• Remote access and control

The electrical specifications are shown below.

Parameter Min Type Max Unit
Communication speed 10 - 100 Mb/s

8.5 Mains Connection

The mains cable of the control box has a standard rectangular heavy-load plug at the end.
Connect the local dedicated mains socket or cable to the rectangular heavy-load plug.
In order to power on the robot, the control box must be connected to the power supply. This
process must be completed by connecting with the rectangular heavy-load plug at the bottom of
the control box with the corresponding wire. Please refer to the figure below.

The power supply should be equipped with at least following accessories:

• Connection to ground
• Mains fuse
• Residual current device
It is recommended to install a mains switch to the power supply of all equipments in the
robot application, in order to facilitate lockout and tagout during repair.
The electrical specifications are shown in the table below.

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Parameter Min Type MaxUnit

Input voltage 90 - 240 VAC

External mains fuse (when the voltage is 90-130V) 32 - 64 A

External mains fuse (when the voltage is 200-240V) 16 - 32 A

Input frequency 47 - 63 Hz

Rated operating power 300 500 2400 W

NOTE:
The switch inside the NED-100D switching power needs to be
switched to the gear 115V when the external mains supply is
90~130VAC.

DANGER:
1. Please make sure that the robot is grounded correctly
(electrical connection to ground). Please establish the common
grounding for all equipments inside the system with bolts which are
unused and connected to the grounding symbols inside the control
box. The grounding conductor should have at least the rated current
of the highest current in the system.
2. Make sure that the input current of the control box is protected
with the residual current device (RCD) and the appropriate fuse.
3. The lockout and tagout should be implemented for all power
supplies when the robot needed to complete all services is installed
and set. The robot I/O should not be powered by other equipments
when the system is locked.
4. Please make sure that all cables are connected correctly before the
control box is powered on. Always use the original power cord.
5. The operation of switching the switch inside the NED-100D
switching power should be implemented before the box is not

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connected with the power supply.

8.6 Robot Connection

The robot cable must be inserted into the connector on the top of the control box, as shown

in the figure below. Appropriately lock the connector when the robot arm is started. The power

supply of the robot must be turned off when disconnecting the robot cable.

Caution:
1. Do not disconnect the robot cable when the robot arm is
started.
2. Do not extend or modify the original cable.

8.7 Tool I/O

A 12-pinned connector is arranged near the tool flange of the collaborative robot end,
for providing the different grippers and sensors connected to the robot with the power
supply and the control signals.

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NOTE:
The tool connector must be manually tightened up, with a maximum
moment of force of 0.4Nm.

The following figure should be used for reference for a function list of 12 connecting pins of
an aviation plug:

Note: the mode of the aviation plug is HR10A-10R-12P of HRS company

Pin No. Function description

1 Digital ground (GND)
2 Digital output interface 1 (DO1)
3 Digital output interface 2 (DO2)
4 Digital input interface 1 (DI1)
5 Digital input interface 2 (DI2)
6 Analog input interface (AI1)

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7 Analog output interface (AO1)

8 RS485+
9 RS485-
10 +24V power output
11 Blank, no connection therein
12 Blank, no connection therein

Herein, the electrical specifications of the 24V internal power supply are shown in the
table below:

Parameter Min Type Max Unit

24V supply voltage 23.5 24 24.8 V
24V supply current - 800 1000* mA

*1000 mA for max 1 second. Maximum duty cycle: 10%. Average current should not exceed
600 mA

8.7.1 Tool power supply

The tool I/O of the Elite collaborative robot can provide the external tool with a 24V power
supply.

8.7.2 Tool digital input

The implementation mode of the digital input interface is shown in the figure below:

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The electrical specifications are shown in the table below:

Parameter Min Type Max Unit

Input voltage -0.5 - 26 V
Logical low voltage - - 10 V
Logical high voltage 22 - - V

Using the tool digital input:

This example illustrates how to connect with a simple button.

8.7.3 Tool digital output

The digital output is compatible with a sinking drive mode (NPN), namely, it is in the low
level state when the output port is activated; and the level state is in a high-impedance breaking
state when the output port is not activated.

The electrical specifications of the digital output port are shown below:

Parameter Min Type Max Unit

Voltage when open -0.5 - 26 V
Voltage when sinking 1A at 25 °C - 0.19 0.24 V
Sinking current 0 600 1000 mA

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Using the tool digital output

This example illustrates how to open and use a load of the internal 24V power supply:

It is recommended to use a protective diode for the inductive load, as shown in the figure
below.

Caution:
Even when the load is off, voltage is still present between the power
connector and the shield / ground

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8.7.4 Tool analog input

The tool analog input is a non-differential input, with voltage (0-10V). The electrical
specifications are shown below.

Parameter Min Type Max Unit

Input voltage -0.5 - 24 V
Input resistance - - >100 MΩ
Resolution - 10 - Bit

Two examples of how to use the analog input are illustrated in the following section.
Using the tool analog input, non-differential
This example illustratesan analog sensor connection with a non-differential output.

Using the tool analog input, differential

This example illustrates an analog sensor connection with a differential output. Work in the
same way as the non-differential sensor after connecting a negative output end to the GND (0V).

8.7.5 Tool analog output

The tool analog output is a non-differential output, with voltage (0-10V). The electrical

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specifications are shown below.

Parameter Min Type Max Unit

Output current - 17 - mA
Output short circuit current - 60 - mA
Resolution - 10 - Bit

The examples of how to use the analog output are illustrated in the following section.
Using the tool analog output
This example illustrates a method of connecting to an analog signal with a non-differential
output.

8.7.6 Tool communication I/O

 Signal requests: RS485 signals use internal fail-safe biasing. If the connected device is not
compatible with this fail-safe, the signal biasing must either be done in the connected tool, or
added externally by adding a pull-up resistor to RS485+ and a pull-down resistor to RS485-.
 The latency is 2ms to 4ms from writing in data to be sent on a robot controller to the start of
sending the data on the RS485. The latency is 2ms to 4ms from the start of receiving the data
on the RS485 to receiving of the data by the robot controller and the start of handling.

Baud rate 2.4k, 4.8k, 9.6k, 19.2k, 38.4k, 57.6k, 115.2k

Stop bit 1, 2
Parity bit Null, Odd, Even

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Chapter 9 Teach Pendant

The teach pendant is an important component of the ELITE robot. Through the teach

pendant, the user may read log information of the robot while enabling the robot to move with a

teaching way and simply programming the robot.

Figure 9-1 Components of the teach pendant

The teach pendant mainly includes a 8.4-inch LCD touch screen, a mains switch, an

emergency stop button, a force switch and a socket for a teach pendant connecting line. The

touch screen may not only show the detailed motion of the robot to the user clearly, including the

position and pose parameters and so on, but facilitate operations of the user. All operations may

be completed by directly clicking the screen.

The housing of the teach pendant is designed in combination with aesthetics and ergonomics,

and the back thereof is equipped with a nylon rope and two hanging rings. The nylon rope is used

to hold the teach pendant, and the teach pendant can be suspended on an electric control cabinet

by making use of the hanging rings.

The force switch belongs to the three-position enabling switch which can implement

three-position motions of avoiding the danger: OFF (release)⇒ ON ⇒ OFF (press). When the

switch is ON, the teaching operation can be implemented by dragging the robot.

You can see the detailed instructions of the control system of the teach pendant in
“ERC-G200 System Operation Manual”.

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Note: the pictures of the following Settings are for reference only

9.1 Programming Pendant Display

Instruction

Programming pendant supports keyboard and touch operations. The status

control area, coordinate area and submenu area support operations by pendant keys,
while all buttons, input boxes, options, etc. can be clicked and controlled.

Keyboard and click operations differ in status control area, coordinate area, and
sub-menu area; Could click to switch status, pop-up dialog box, etc.; While it only
changes status (no pop up dialog boxes) when using keyboard.

After clicking in the input box, the number or character will be recognized
automatically and corresponding full keyboard or numeric keyboard pop up.

Manipulator can be operated only by pendant keys, clicking in the display

interface is invalid.

1. The display part of the programming pendant is an 8-inch colored touch screen, used for

displaying the manipulator operation interface that could be used for performing corresponding

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operations.

2. The display interface is mainly composed of three areas (general-purpose display area,

monitoring area, information prompt area) around with the main menu area, status control area,

coordinate area, status display area.

3. Three display areas can be switched by pressing button or directly clicking on

the screen to switch the activation status. When a certain display area is switched focused, the

background color of this area changes or a cursor bar appears. The status control area, the

coordinate area and the sub-menu area changes accordingly when the display area is switched.

4. Activation status of general-purpose display area: Display blue cursor bar when the

program list is displayed. The background is beige when the program is open. The background is

blue when the monitoring area is activated. The blue cursor bar is displayed when the information

prompt area is activated.

5. The monitoring area and information prompt area in the three display areas can be

hidden. When the monitoring area or information prompt area is displayed, the general-purpose

display area will be automatically reduced to half display；When the monitoring area or

information prompt area is hidden, the general-purpose display area is automatically enlarged to

the entire display.

6. The main menu area can only be operated by clicking on the screen.

7. The status control area, coordinate area, and sub-menu area can be switched or directly

pressing by the corresponding keys outside of the screen; The button with corner mark will pop

up when pressing, while it will directly switch the status when the key has no corner mark.

8. Icon or area with triangular corner mark can be clicked, and a dialog box will

pop up.

9.1.1 Main Menu Area

The main menu options are mainly used for various parameter settings, such as system

setting, program editing, parameter setting, monitoring, instructions editing, operation

preparation, and user process.

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System
First Level Operation
Second Level Menu
Menu Authority
Parameter backup
IO annotation backup
Local to
PLC backup Expert user
USB
User data backup
Script backup/delete
Parameter upgrade
IO annotation upgrade
USB to PLC upgrade
Expert user
Local User data recovery
Script upgrade
Identification file import
System
Expert user
Upgrade
Robot configuration Root
System
Network configuration Root
Configuration
Language configuration Root
Institutional
General user
Information
Software
General user
information

Program Edit
First Level Menu Second Level Menu Operation Authority
Line copy
Copy
Block copy
Line cut
Cut
Block cut
Paste
Line delete
Delete Expert user
Block delete
Search
Replace
Logic instruction
customization
Reset

Parameter Setting
First Level Menu Second Level Menu Operation Authority
Speed parameter Root
System parameters Administrator
Limit parameter Root

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Servo parameter Administrator
Institutional
Administrator
parameter
Other parameters Administrator
Switch user General user
Permission
Change password Expert user

Monitoring
First Level Menu Second Level Menu Operation Authority
Joint coordinates
Coordinate Cartesian
coordinates
Variable B
Variable I
Variable
Variable D
Variable P
Input
General user
Output
IO
Virtual input
Virtual output
Impulse
Motor Motor speed
Absolute position
Operational
monitoring

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Edit Instruction
Second Level
First Level Menu Operation Authority
Menu
Input/output
instructions
Control instruction Expert user
Calculation instruction
Process instruction

Readiness for Operation

First Level Menu Second Level Menu Operation Authority
Tool coordinates Expert user
User coordinates Expert user
Interference area Expert user
Expert user
(returnable operation)
Mechanical home
Administrator (can
position
modify the home
Home position position)
Program home
Expert user
position
Home position
Expert user
calibration

User processes
Corresponding process setting menu will display under the user processes
option according to the actual configuration of the system.

9.1.2 General-purpose Display Area

The general-purpose display area is mainly used to display program list, program editing

interface and various system setting interfaces. Most of the operations and settings of the system

are displayed and set in this general-purpose display area. The following figure shows the

interfaces active status in the general-purpose display area.

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Program list

Program editing

Speed parameter setting

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Tool coordinate setting

9.1.3 Monitoring Area

The monitoring area is mainly used to display the robot coordinates, variable values, IO port

status, motor running status, etc. All the options under the “Monitor” menu are displayed in the

monitoring area, as shown in the following figure (the half-width display and full-frame display

of the monitoring area).

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Half display of the monitoring area

Full display of the monitoring area

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9.1.4 Information Prompt Area

The information prompt area is mainly used to display work information, alarms, prompts,

records of the manipulator.

9.1.5 Status Control Area

The status control area mainly contains state control related to the robot, such as area

folding/unfolding, coordinate system selection (joint, cartesian, tool, user, cylinder), operation

cycle selection (single step, single cycle, continuous cycle), synchronized / unsynchronized state

switching, reset, etc.

The area can be operated by directly clicking the icon or clicking the corresponding button.

The coordinate and operation cycle need to be selected finally in the pop-up window and can

only be operated by clicking the icon.

：Information prompt area expands and collapses；

：monitoring area expands and collapses；

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：Coordinate system selection, can only be operated in TEACH mode；

：Operation cycle selection, can only be selected in PLAY mode；

：Sync / Unsync button；

：Alarm reset button；

9.1.6 Coordinate Area

The coordinate area will display the corresponding icon according to the selected coordinate
system. The icon of the coordinate area can only be displayed when the servo is enabled，For

"joint coordinates", display from top to bottom are -J1+、-J2+、-J3+、-J4+、-J5+、-J6+；For "

Cartesian/Tools/User Coordinates", display from top to bottom are -X+、-Y+、-Z+、-RX+、-RY+、

-RZ+；For "Cylinder Coordinates", display from top to bottom are -θ+、-R+、-Z+、-RX+、-RY+、

-RZ+.

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Joint coordinates

Cartesian / User / Tool coordinates

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Cylindrical coordinates

9.1.7 Status Display Area

The status display area is mainly used to display the current status of the robot, including
permissions, running status/mode/speed, current tool coordinate number, current user coordinate
number, system time, external axis, etc., as shown below.

Permissions: Display the current permissions, can open the permission settings window
by touching screen；

Running status: Display the current running status of the robot, including stop, pause,
run, alarm, etc.；

Running mode: Display the current running mode of the robot, including TEACH, PLAY,
REMOTE mode；

Speed: Display the current speed. The same speed in PLAY and REMOTE mode while a
separate speed in TEACH mode, you can click to pop up the speed control window；

Current tool coordinate: Display the current tool coordinate number, which can be open by

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clicking the tool coordinate setting page；

Current user coordinate: Display the current user coordinate number, which can be open by
clicking the user coordinate setting page；

System time: Display the current time of the system, click to pop up the modify system
time page；

External axis: If the system is configured with an external axis option, click to open the
external axis setting page；

9.1.8 Submenu Area

The submenu area is mainly used as an auxiliary button for the focus area, which changes
depending on the focus area. The submenu area can be operated by clicking the icon or by the
corresponding key. The submenu area shows as below when program list is focused.

9.2 Robot Axes and Coordinates Systems

9.2.1 Basic Operations

9.2.1.1 Security Confirmation

Before operating, please read the chapter “Note for Safe Operation” of this manual again to
eliminate the potential dangers of the manipulator system and peripheral equipment to the
surrounding environment.

9.2.1.2 Alarm Confirmation

After the system powered on, the alarm should be confirmed first. After eliminating the
alarm, press the [RESET] button in the status control area of the pendant to clear the alarm.

Confirm the status of the “Synchronized/Unsynchronized” button in the status control area and

status can be switched by pressing that button. The axis operation of the manipulator must be in

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the “Synchronized” status .

9.2.1.3 TEACH Mode Selection

The axis operation can only be performed in TEACH mode (turn the key in the upper right
corner of the pendant to the middle position).

9.2.1.4 Coordinate System Selection

Press the coordinate option icon of the status control area, will pop up the menu which
displays the options of [JOINT], [CARTESIAN], [TOOL], [USER], [CYLINDER], and then
select the coordinate system.

9.2.1.5 Speed Selection

The speed contains manual (teach) speed, play speed and remote speed. The play speed and
remote speed are the same. There are three ways to adjust the speed:

(1) Loosen the enable switch, press the coordinate area , select the speed icon or drag
the slider to adjust speed directly in the pop-up dialog box.

(2) Press the area in the status display area and select or drag the slider to adjust
the speed in the pop-up dialog box. When the speed of the area is within 0.05-30%, the icon is

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displayed in green (safe speed) . When the speed is within 31%-70%, the icon is gray

(normal speed) ; when the speed is within 71%-100%, the icon is displayed in Red

(alert speed) .

(3) Press the speed adjustment button on the right side of the pendant directly to
adjust the running speed.
9.2.1.6 Servo on

First confirm that there is no alarm and the status control area is displayed as
“Synchronized”. In TEACH mode, hold the enable switch (middle position) on the back of the
programming pendant. At this time, the SERVO indicator in the upper left corner of the

programming pendant is on. In PLAY mode, press the servo enable button in the bottom

right corner of the programming pendant. At this time, the SERVO indicator in the upper left
corner of the programming pendant is on. In REMOTE mode, the servo is turned on
automatically.

9.2.1.7 Axis Operations

In the TEACH mode with the servo on, pressing an axis key in the teach mode makes it
possible to move the respective axis of the manipulator and station to a desired position. The
motion of each axis depends on the specified coordinate system.

9.2.2 Coordinate Systems and Axis Operations

9.2.2.1 Joint Coordinates

The manipulator moves independently along each axis, and the coordinates used is the joint
coordinates. The joint coordinates are set and cannot be changed when the manipulator
debugging completes. The positive direction of each axis is marked at the joint of the
manipulator.

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9.2.2.2 Cartesian Coordinates

Robot’s Cartesian coordinates is also called the geodetic coordinates. The direction of the
Cartesian coordinates of each manipulator type is different, and the position of the corresponding
Cartesian coordinate origin is also different.

After setting the manipulator’s parameters, the origin and direction of the Cartesian
coordinates are determined, and the direction of the Cartesian coordinates cannot be modified.

In a non-singular position, the manipulator can move parallel to the X-, Y-, or Z-axes. When
using a manipulator of 6 axes, rotation Rx, Ry, Rz can also be performed, Rx rotates around the
X axis, Ry rotates around the Y axis, and Rz rotates around the Z axis respectively, following the
right-hand rule. Taking a manipulator of 6 axes as an example, the directions of motion are as
shown below.

9.2.2.3 Tool Coordinates

The tool coordinates are defined at the tip of the tool, assuming that the effective direction
of the tool mounted on the manipulator wrist flange is the Z-axis. Therefore, the tool coordinates
axis direction moves with the wrist.

In tool coordinates motion, the manipulator can be moved using the effective tool direction

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as a reference regardless of the manipulator position or orientation. These motions are best
suited when the manipulator is required to move parallel while maintaining the tool orientation
with the workpieces.

User can set the tool coordinates number 0-7 according to the actual tool conditions.

9.2.2.4 User Coordinates

The user coordinates are defined by teaching the manipulator three points, and the
manipulator moves parallel to each axis of the coordinates which are set by the user.

The user can set the user coordinates number 0-7 as needed.

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9.2.2.5 Cylindrical Coordinates

In the cylindrical coordinates, the manipulator rotates around the Z axis of the body or
moves parallel to the Z axis at right angles. The θ-axes, R-axes and Z-axes directions of the
cylindrical coordinates are shown as below.

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9.2.2.6 Control Points Remain Unchanged

The operation in which the control point remains unchanged means that the position of the
tool tip point (control point) is not changed, and only the axis operation of the tool posture is
changed. Turning of each wrist axis differs in each coordinate system.

In Cartesian or cylindrical coordinates, wrist axis rotations are based on the X-, Y-, or
Z-axis.

In the Cartesian/cylindrical coordinates, the X-, Y-, and Z-axis of the body are used as the
reference for the rotate motion.

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In tool coordinates, wrist axis rotations are based on X-, Y-, or Z-axis of the tool
coordinates.

In user coordinates, wrist axis rotations are based on X-, Y-, or Z-axis of the user
coordinates.

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9.3 Teaching

9.3.1 Preparation for Teaching

Before teaching, please verify the emergency stop buttons are normal. If the manipulator is
used for the first time, you need to verify the mechanical zero.

9.3.1.1 Emergency Stop Buttons Verification

Before using the manipulator, please verify all the emergency stop buttons on the control
cabinet and the teach pendant are function correctly. Verify the emergency stop button is pressed,
ensure the servo power supply is disconnected and whether the manipulator alarms. When an
external emergency stop button is connected, you should also ensure that the emergency stop
button is valid.

9.3.1.2 Mechanical Zero Verification

Each point data of the manipulator is the angle value related to each axis based on the
mechanical zero point. If there is deviation for the mechanical zero point, all the points will be
wrong, so the mechanical zero point must be verified before operating the manipulator.

Each robot has a fixed mechanical zero point (the zero-point mark on each axis of the robot).

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After performing the zero-return operation, please observe whether the mark of each axis
overlaps. For the specific mechanical zero return operation, please refer to Section9.8.4.1.

9.3.1.3 Program File Operations

When the program list is focused in the programming pendant, the options for program file
operation appear in the submenu area, as shown below.

All points and instructions of the teaching process are stored in the program file, so you
should first familiarize with the various operations of the program file before teaching.

New: Press [NEW], the dialog box will pop up, user can select [FOLDER], [FILE] or
[CANCEL]. Press [FILE], the dialog box for inputting the file name will pop up, enter the file
name, press [OK]. The required file will be created successfully.

Rename: Select the program that need to be renamed in the program list and press
[RENAME]. Enter the required new file name in the pop-up dialog box and press [OK].

Delete: Select the program that needs to be deleted in the program list and press
[DELETE]. In the pop-up confirmation prompt box, press [OK] to delete, press [CANCEL] to
cancel deletion; the previously opened program is in activated status and cannot be deleted, you
can delete it by opening another program first.

Copy: Select the program you want to copy in the program list and press [COPY].
Enter the required new file name in the pop-up dialog box and press [OK].

Move: The move operation is to move the program file into or out of one folder. Select
the program file to be moved and press [MOVE]. Select the destination folder and press [OK].

Open: Select the program and press [OPEN] to open the program in the program
editing page.

Backup: When the controller has a USB device connection, select the program to be
backed up and press [BACKUP]. The program will be saved to the USB device.

Open USB Device: When the controller has a USB device connection, press [OPEN USB]
to display the existing program in the USB. Select the desired program file and press [USB TO
LOCAL] in the sub-menu bar. The file will be imported successfully.

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9.3.2 Teaching Procedure

9.3.2.1 Teaching Window

Open the program file and enter the program editing page. After entering the teaching
window, the [PROGRAM EDITING] and [EDITING INSTRUCTIONS] in the main menu bar
are enabled. The current file name, the total number of lines, and the current line number will be
displayed at the bottom of the general-purpose display area. The sub-menu displays the
corresponding program editing options. Each program file starts with “NOP” and ends with
“END”. The line where the cursor locates will be displayed in blue.

9.3.2.2 Interpolation Type and Play Speed

When performing the manipulator playback operation, the method of determining the
trajectory between two points is called the interpolation method.

The speed of motion between two points is called the play speed.

The destination position, the interpolation method, the play speed, etc. are registered in the
move instruction.

 Joint Interpolation

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The joint interpolation is used when the manipulator does not need to move in a specific
path toward the next step position. When the joint interpolation is used for teaching a robot axis,
the move instruction is MOVJ. For safety purposes, use the joint interpolation to teach the first
step.

 Linear Interpolation

The manipulator moves in a linear path from one taught step to the next. When the linear
interpolation is used to teach a robot axis, the move instruction is MOVL. Linear interpolation is
used for work such as welding. The manipulator moves automatically changing the wrist position
as shown in the figure below.

 Circular Interpolation

The manipulator moves in an arc that passes through three points. When circular
interpolation is used for teaching a robot axis, the move instruction is MOVC.

When a single circular movement is required, teach the circular interpolation for three points,
P1 to P3, as shown in the following figure. If joint or linear interpolation is taught at P0, the point
before starting the circular operation, the manipulator moves from P0 to P1 in a straight line.

Point Interpolation Instruction

Type
Joint or Linear MOVJ
P0
MOVL
P1-P3 Circular MOVC

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Joint or Linear MOVJ

P4
MOVL
9.3.2.3 Teaching Steps

There are two types of program instruction

mode in this system: normal mode and advanced
mode. The normal mode is used by default after
booting.

In the normal mode, only the basic items for each instruction are available for editing. After
enabling the advanced mode, all the extensions will be displayed when inserting program
instructions. Select the appropriate mode according to your requirements.

The instruction mode can be switched as follows: When pressing and holding [WINDOW
SWITCHING KEY] in the program editing page, two new options will appear in the submenu
area: [NORMAL MODE] and [ADVANCED MODE]. Then press the desired option to switch
the instruction mode.

The electronic handwheel is disabled by default in the program editing page after booting.
Push the electronic handwheel inward to switch between the enable mode and the disable mode.

 Inserting Move Instructions

Whenever one step is taught, one move instruction is inserted. When inserting a move
instruction without using P variables, the current position of the manipulator is recorded into the
move instruction. The detailed procedures are as follows:

1) Move the manipulator to the desired position using the axis key.

2) Move the cursor on the line immediately before the position where a move
instruction to be inserted.

3) When holding the Enable switch and the SERVO ON lamp is lit, press [MOVE
INSTRUCTION] in the submenu area and select the desired interpolation type in the pop-up
window.

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4) After selecting the move instruction, edit the contents of its additional items and
press [OK] to insert it. The Enable switch must be hold when inserting the move instructions.
Otherwise, the move instruction cannot be inserted.

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 Inserting Other Instructions

The methods of inserting other instructions except the move instruction are identical. In the
program editing page, move the cursor on the line immediately before the position where the
instruction to be inserted. Then press [EDIT INSTRUCTIONS] under the main menu or [QUICK
INSTRUCTIONS] in the submenu area to select the instruction to be inserted. After editing the
additional items, press [OK] to insert the instruction.

[QUICK INSTRUCTIONS] in the submenu area contains only part of the instructions, and
all instructions can be found by pressing [EDIT INSTRUCTIONS] under the main menu. Select
the appropriate one according to your requirements.

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 Modifying Instructions

Select the instruction to be modified in the program editing page. Then press [MODIFY] in
the submenu area, and the instruction editing window will pop up.

For the non-motion instructions, only [UPDATE PARAMETERS] can be used. After
modifying the instruction, press [UPDATE PARAMETERS] to use the modified instruction.
Press [CANCEL] to exit the modification operation.

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For the move instructions, two options can be used in the submenu area: [UPDATE POINT]
and [UPDATE PARAMETERS]. [UPDATE PARAMETERS] can only update the additional
items of the move instruction, and cannot modify the point data. [UPDATE POINT] can record
the current position of the manipulator into the instruction while modifying the addition items.
[UPDATE POINT] can be used only when holding the Enable switch.

9.3.2.4 Checking Steps

After completing the program editing, the manipulator can be moved ahead in step number
sequence manually, in order to check in advance whether the motion paths of the manipulator are
correct.

 Forward Operation

The forward operation can be used to move the manipulator to the position of the taught
steps in order to check whether the position is appropriate.

1) Switch to TEACH mode using the mode switch.

2) Set manual speed at an appropriate level for safety.

3) Scroll the handwheel to select the instruction to be executed in the program.

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4) Hold the Enable switch to turn on the servo. continuously press the [PROGRAM START]

button on the bottom right corner of the programming pendant, the manipulator will

move to the step point and stop. Release the [PROGRAM START] button, the manipulator will
slow down and stop.

5) When the manipulator reaches the target step point, the information prompt area will
display the following message: “The manipulator reaches the target point”.

 Precautions When Using Forward Operation

1) [PROGRAM START] button should be released when you are willing to stop the
manipulator. You can also directly release the Enable switch or press [EMERGENCY STOP]
button in an emergency, the manipulator will stop immediately with a large vibration instead.

2) The forward operation in TEACH mode can only execute the move instruction. The
non-motion instructions can only be executed in PLAY mode.

9.3.2.5 Editing Programs

When editing the program, the [Program Edit] option under the main menu provides many
convenient and quick operations: copying, cutting, pasting, deleting, searching, replacing,
customizing quick instructions, resetting, etc.

 Copying

There are two types of copy operations: [LINE COPY] and [BLOCK COPY]. [LINE COPY]
only copies the instruction line selected by the cursor (Note that the NOP and END lines cannot
be copied). Press [BLOCK COPY], and the dialog box will pop up for specifying the range of the
instruction lines to be copied. Press [OK] to complete the copy operation.

 Cutting

There are two types of cut operations: [LINE CUT] and [BLOCK CUT]. [LINE CUT] only
cuts the instruction line selected by the cursor (Note that the NOP and END lines cannot be cut).
Press [BLOCK CUT], and the dialog box will pop up for specifying the range of the instruction
lines to be cut. Press [OK] to complete the cut operation.

 Pasting

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After performing a copy operation or a cut operation, move the cursor to the line
immediately before the desired position in the program editing page. Press [PASTE] to complete
the paste operation. Note that the instruction lines are inserted in the next line of the cursor line.

 Deleting

There are two types of delete operations: [LINE DELETE] and [BLOCK DELETE]. [LINE
DELETE] only deletes the instruction line selected by the cursor (Note that the NOP and END
lines cannot be deleted). Press [BLOCK DELETE], and the dialog box will pop up for specifying
the range of the instruction lines to be deleted. Press [OK] to complete the delete operation.

 Searching

Press [SEARCH] and the search window will pop up. The items can be searched are the
additional items of each instruction. Note that the items displayed for each instruction in the
normal instruction mode and advanced instruction mode are different. Select the item to search,
and input the corresponding value. Then press [SEARCH] in the submenu area to find the
instruction line that meets the requirements in the current program. The cursor will move to the
line automatically.

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 Replacing

The replace operation is used to replace the additional item value that meets the search
requirements with the given value. Press [REPLACE], then the submenu area displays three new
options: [REPLACE], [SKIP] and [REPLACE ALL]. [REPLACE] can be used to sequentially
replace the value of the matching item with the specified value one by one. [SKIP] can be used to
skip the current matching item. [REPLACE ALL] can be used to replace the values of all
matching items in the program with the specified value at once.

 Customizing Quick Instructions

In the program editing page, [QUICK INSTRUCTIONS] in the submenu area can be
pressed to customizing the quick instructions for editing the program. The frequently used
instructions can be added to the quick instructions for easy use.

Press [CUSTOMIZING QUICK INSTRUCTIONS] to enter the customizing page. Select

the desired instruction in the left instruction selecting window, and press the right arrow to add
the selected instruction to quick instructions. Select the desired instruction in the right quick
instruction window, and press left arrow to remove the selected instruction.

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 Resetting

If a failure occurs during the welding process or in the reservation mode, the program needs
to be reset before re-execution. [RESET] under the [PROGRAM EDIT] menu can be pressed to
reset the system status.

9.3.3 List of program instructions

Instruction Group Instruction Description

DOUT Digital output.
MOUT Virtual digital output.
I/O Instructions DIN Digital input.
PULSE Pulse output.
AOUT Analog output.
AIN Analog input.
CCOOD Specify the coordinate.
JUMP Jump to the specified label.
CALL Call a subprogram.
AXISDISA Axis prohibition of movement.
BLE
LABEL Instruction tag.
Control Instructions TIMER A timer.

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// A comment.
RET Subprogram return.
PAUSE Program pause.
WAIT Wait.
CLEAR Clear the variable.
INC Variable plus one.
DEC Variable minus one.
SET Variable assignment.
SETJOINT Position assignment.
ADD Add operation.
SUB Subtraction operation
MUL Multiplication operation.
Calculation DIV Division operation.
Instructions MOD Mod operation.
AND Logic AND operation.
OR Logic OR operation.
NOT Logic NOT operation.
XOR Logic XOR operation.
GETPOS Get the current position of
manipulator.
MFRAME Establish a coordinate.
DIST Calculate the distance between
the two points.
MOVJ Joint interpolation.
MOVC Circular interpolation.
Move Instructions MOVCA Circular interpolation.
MOVL Linear interpolation.
MOVML Micro-interpolation.
ARCON Arc begins.
ARCOFF Arc stops.
ARCSET Welding condition setting.
ARCCTE End gradient welding condition
Arc welding setting.
instruction ARCCTS Start gradient welding
condition setting.
WVON Swing welding begins.
WVOF Swing welding stops.
STITCHO Open tungsten inert gas
N welding.
STITCHOF Close tungsten inert gas
F welding.

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9.4 Playback

9.4.1 Preparation

Before performing playback operations, confirm that the program to be executed is correct
and that there are no person or obstacles present in the work envelope of the manipulator.

9.4.1.1 Selecting Programs

Playback is the act of executing a taught program.

Before playback operation, first select the program to be executed in the program list, and
press [OPEN] in the submenu area to open the program. Then move the cursor to the starting line
where the program is executed. Generally, the program is executed from the NOP line.

9.4.1.2 Selecting Operation Cycles

Switch to PLAY mode, press the icon in the status control area to select one of three types
of manipulator operation cycles:

SINGLE STEP: Executes one step (instruction) at a time.

SINGLE CYCLE: Executes a program once. The program will be executed again if
[PROGRAM START] button is pressed.

CONTINUOUS CYCLE: Repeats a program continuously.

Please select the appropriate one according to your requirements.

9.4.1.3 Modifying Play Speed

The TEACH mode and PLAY mode use different speed values. After switching to PLAY
mode, the speed can be modified to an appropriate level by following the instructions shown in
Section 9.2.1.

9.4.2 Playback Operation

9.4.2.1 Startup

After completing all above preparations, first press [SERVO ENABLE] button on

the bottom right corner of the programming pendant. The SERVO ON lamp lights up when the

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servo is enabled. Then press [PROGRAM START] button , and the program starts running

automatically.

9.4.2.2 Modifying Speed in Play Mode

When the program is executed in PLAY mode, [SPEED CONTROL] buttons are invalid and
the speed value cannot be modified. If speed adjustment is required in this mode, first press

[PROGRAM PAUSE] button to pause the program. Then change the speed value and

press [PROGRAM START] button to resume the program execution.

9.4.2.3 Stop and Restart

 Program Pause Operation

In PLAY mode, if the program pause operation is executed, the program will pause at the
current line, and the moving manipulator will slow down and stop.

There are two ways to pause the program:

1) Press [PROGRAM PAUSE] button on the programming pendant.

2) Use the external input signal. The program pause operation will be executed when the

input “EXT-HD” of the dedicated IO board is valid.

 Emergency Stop Operation

If the emergency stop operation is executed, the servo power will be turned OFF and the
manipulator will stop immediately.

There are three methods for executing emergency stop operation:

1) Press [EMERGENCY STOP] button on the programming pendant.

2) Press [EMERGENCY STOP] button on the cabinet.

3) Use the external input signal. The emergency stop operation will be executed when the

input “EXT-SP” of the dedicated IO board is invalid.

After an emergency stop, first correct the cause of the alarm and then reset [EMERGENCY
STOP] button. After that, the alarm reset and program start operations for programming pendant

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can be conducted.

Note: After the emergency stop, the program call relations between the main program
and the subprogram will be cleared.

 Stop Caused by Alarm

Except for program pause and emergency stop, when other system alarms occur during
program runtime, the program execution will be stopped, and the manipulator will stop
immediately. The programming pendant will display an alarm message simultaneously.

 Other Stops

In addition to the above stop methods, there are two ways to stop the program:

1) The mode switch is switched from PLAY mode to TEACH mode.

2) The PAUSE instruction is executed in the program.

9.5 User Processes

The ERC-G200 control system includes user processes such as arc welding, reservation,
external axes, laser tracking, scripting, vision, tracking, palletizing, stamping, etc., which can be

enabled in “System - System Configuration - Manipulator Configuration”.

The configuration and operation instructions for above user processes are not described in
detail in this manual. Please refer to the corresponding application manual for more information.

9.6 Monitoring

The monitoring options in the main menu area are mainly used to view the current working
status of the manipulator and the variables of various data types. The system can monitor the
following contents: coordinates, variables, IO (input and output), motor, reservation, operational
monitoring, etc.

9.6.1 Coordinates

The coordinate monitors are used to monitor coordinate data, including joint coordinates and

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Cartesian coordinates.

9.6.2 Variables

The variable monitor page displays 4 types of variables: B, I, D, and P. The data formats and
number ranges for the variables are described as follows:

B: Byte Type, B000 - B255 (256);

I: Integer Type,I000 - I255 (256);

D: Double Type,D000 - D255 (256);

P: Position Type,P000 - P255 (256).

In the variable monitor page, the user can switch between different variable types by
pressing the buttons in the submenu area. Select the target variable by the cursor, and press
[MODIFY] button in the submenu area to input the required value in the pop-up box. Note that
the values in the variable monitor page can only be modified in TEACH mode.

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The P variable is the position type variable. Select the desired P variable using the cursor in
the variable monitor page. Press [VIEW] to view its value in the information prompt area. Press
[CLEAR] to reset it to the default value. Press [MODIFY] to record the current joint coordinates
into the variable.

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9.6.3 IO

The IO monitor page includes four options: input, output, virtual input, and virtual output.
Select the desired option to open the corresponding monitor page. The user can switch between
the four options in the submenu area quickly.

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The inputs and virtual inputs can only be used to monitor the state changes. The states of the
outputs and the virtual outputs can be modified. Note that the outputs and the virtual outputs with
red labels are used by the system, and their states cannot be modified. For example, in the output
monitor page, select Y000 using the cursor and press [MODIFY] in the submenu area to reverse
its state. Its value will become 1 from 0, or become 0 from 1.

9.6.4 Motor

The motor monitor page includes three options: pulse, motor speed and absolute position.
The pulse monitor page displays three items: the sending pulse counting, the feedback pulse
counting and the difference. For pulse motors, if there is a movement position deviation, you can
monitor the changes of various values on this interface to find out the cause. This monitor option
is hardly used by the general users.

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In the motor speed monitor page, the real-time rotational speed of each axis can be viewed
according to the actual requirements.

In the absolute position monitor page, the pulse counting at the current position for the
motor of each axis can be viewed according to the requirements.

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9.6.5 Operational Monitoring

In the operational monitor page, the coordinate values at the current position and the
coordinate values of the target point recorded in the move instruction can be viewed. The joint
coordinates are displayed by default, which can be switched to the Cartesian coordinates by
pressing [JOINT/CARTESIAN] button in the submenu area. In the program editing window, use
the cursor to select the desired move instruction, and the coordinate values of the target point
corresponding to the instruction will be displayed in the operational monitor page.

9.7 Convenient Functions

9.7.1 Key Combination Function

In this system, press and hold [WINDOW SWITCH] button , several

additional options will appear in the submenu area, which are corresponding to different
convenient functions. The conventional key combination functions include screen validation,

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screenshot, normal mode, advanced mode, etc. There are different key combination functions for
different user processes, which can be used according to the actual requirements.

9.7.2 Multi-Window Function

Some windows in the system can be displayed in both full size mode and half-size mode.
The selected window can be expanded towards the desired direction by pressing [Expand Up /
Down] and [Expand Left / Right] buttons. Therefore, the multiple windows can be displayed
during the program execution, which is convenient for debugging the program.

9.8 System Setup

9.8.1 Tool Coordinates Setting

To ensure that the manipulator can perform motion type operations such as linear and
circular motion type correctly, accurate dimensional information on tools such as torches, tools,
and guns must be registered and the position of the TCP must be defined. The tool coordinates

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are established by registering the coordinates of the TCP and the tool angle in the flange
coordinates of the manipulator. After that, the TCP is automatically calculated and registered in
the tool file.

There are 8 tool coordinates numbered from 0 to 7 can be set in the system. Go to the page
of "Readiness for operation - Tool coordinates", and select the tool coordinate number. The TCP
can be calculated by inputting the tool coordinate values (the position of TCP and the tool angle)
in the flange coordinates or performing the seven-point tool calibration.

9.8.1.1 Registering Tool Coordinate Data

When the number input operation is used for registering the tool coordinate, input the TCP
of the tool in the flange coordinates.

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Three cases corresponding to the tool A, B and C are given as examples for registering the
coordinate data, as shown in the figures below.

tool A tool B tool C

 Cases of Tool A, B:

X, Y, Rx, Ry, Rz are 0, and Z is 260.

 Cases of Tool C:

X, Rx, Ry, Rz are 0, Y is 145, and Z is 260.

Enter the value into the coordinate input box, and press [SET] button in the submenu area.

Then the information prompt area will display the following message: “The tool coordinate is

successfully set!"

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9.8.1.2 Seven-point Tool Calibration

In order to perform the seven-point tool calibration, seven points with different postures
must be taught with the TCP as the reference point. The tool dimensions are automatically
calculated on the basis of these seven points.

In the page of tool coordinates, press [CALIBRATE] in the submenu area to enter the
seven-point tool calibration window. Then record seven points numbered from P1 to P7
according to the schematic diagram. For the five points from P1 to P5, the TCP should always be
the same point (e.g., the tip of the calibration cone), and each angle must be arbitrary. Accuracy
may decrease when pose setting is rotated in a constant direction. The points P6 and P7 are used
to define the X-axis direction and the Z-axis direction of the tool coordinate.

First select the target point in the window, then press [RECORD] to record the current
position of the manipulator. After that, the color corresponding to the point will change from red
to green. Record the seven points respectively. After selecting the taught point, [RUN POINT]
button can be pressed to move the manipulator to the point, and [CLEAR POINT] button can be
used to clear the point data. After teaching all points, press [CALCULATE] to generate the
desired tool coordinate.

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9.8.2 User Coordinates

The user coordinate settings allow easy teaching and programming in various situations.
When multiple positioners are used, manual operation can be simplified by setting the user
coordinates for each fixture, as shown in the following figure.

User coordinates are defined by three points that have been taught to the manipulator
through axis operations. These three defining points are RORG, RXX, and RXY, as shown in the
diagram below. These three points of positional data are registered in a user coordinate file.

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User coordinate definition: RORG is the home position, and RXX is a point on the X-axis.
RXY is a point on the Y-axis side of the user coordinates that has been taught, and the directions
of Y- and Z-axes are determined by point RXY. Note that it is important that the two points
RORG and RXX be taught accurately.

Go to "Readiness for Operation - User coordinates" to open the user coordinate setting page.
First select the user coordinate number to be set. Then select one of the three defining points and
press [RECORD] button in the submenu area after moving the manipulator to the desired position.
The color corresponding to the taught point will change from red to green. After recording all
three points, press [CALCULATE] button to generate the desired user coordinate. When holding
the Enable switch, [RUN RORG], [RUN RXX] and [RUN RXY] in the submenu area can be
used to move the manipulator to the corresponding point.

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9.8.3 Interference Area

The interference area is a function that prevents interference between multiple manipulators
or the manipulator and peripheral device. The area can be set up to 16 areas. There are two types
of interference areas:

 Cubic Interference Area

 Axis Interference Area

9.8.3.1 Cubic Interference Area

This area is a rectangular parallelepiped which is parallel to the base coordinate (Cartesian
coordinate). The system judges whether TCP of the current position of the manipulator is inside
or outside this area, and outputs this status as a signal. (ON: inside, OFF: outside)

There are two ways to set cubic interference areas, as described in the following:

(1) Teaching Corner

Move the manipulator at the maximum and minimum value positions of the cube corner
using the axis keys, and record them respectively. Then press [SAVE] button in the submenu area,

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and the target cubic interference area will be set successfully.

(2) Number Input of the Side of Cube and Teaching Center

Move the manipulator to the center point of the cube using the axis keys and record it. Then
enter the length, width, and height of the cube, and press [SAVE] button in the submenu area.

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9.8.3.2 Axis Interference Area

The axis interference area is a function that judges the current position of each axis and
outputs a signal. Once the maximum and minimum values have been set at the plus and minus
sides of the axis to define the working range, a signal indicating whether the current position of
the axis is inside or outside this range is output. (ON: inside, OFF: outside)

In the interference area setup page, select “Axis” for the usage mode. Then select the axis

number, and move the axis to the minimum and maximum points using the axis keys. Record the
points and press [SET] in the submenu area.

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9.8.3.3 Signal Corresponding to Interference Area

The output signals of the interference area 1 to 16 are corresponding to the virtual outputs
M440 to M455 respectively. If the signal needs to be output to the external device, the
corresponding virtual output should be mapped to the actual output Y by modifying the PLC
program.

9.8.4 Home Position

The "Readiness for Operation - Home position" menu includes three options: mechanical
home position, program home position, and home position calibration.

9.8.4.1 Mechanical Home Position

Although the mechanical home position is calibrated prior to shipment at the factory, the
following cases require the calibration to be performed again.

 Change in the combination of the manipulator and cabinet.

 Replacement of the motor or absolute encoder.

 Mechanical home position deviation caused by hitting the manipulator against a

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workpiece, etc.

To calibrate the mechanical home position, use the axis keys to calibrate the home position
mark on each axis so that the manipulator can take its posture for the home position by pressing
[RECORD] button for each axis in the mechanical home position page. The calibration can also
be directly completed by modifying the pulse counting at the mechanical home position.

For the detailed instructions of setting mechanical home position, please refer to the chapter
of setting mechanical home position in << Initial Configuration Manual >>.

9.8.4.2 Program Home Position

The program home position is the reference point for manipulator operations. It prevents
interference with peripheral device by ensuring that the manipulator is always within a set range
as a precondition for operations such as starting the line.

In the page of setting program home position, press [SET] button to set the current position
of the manipulator as the program home position. When the manipulator is located at the program
home position, the value of the virtual output M401 is 1, and the special output signal "Home" is
valid. The program home position can be set and used according to the requirements of the
production line.

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9.8.4.3 Home Position Calibration

The mechanical home position of the manipulator body and the accuracy of TCP can be
calibrated by using the home position calibration function. The operation procedures can be
described as follows:

(1) Create a program with 20 positions which must be taught with the TCP as the reference point,
and the TCP can be defined by the tip of the calibration cone.

(2) Go to "Readiness for Operation - Home Position – Home Position Calibration".

(3) Select the above program and the tool number that needs to be calibrated.
(4) Press [Set] button, and if the calibration data is valid, the information prompt area will
display the following message: "The mechanical home position is calibrated successfully!
(5) Press [CALIBRATE] button.
(6) Go back to "Readiness for Operation - Home Position - Mechanical Home Position".
(7) Hold the Enable switch, and press [RETURN HOME] to move the manipulator back to the
mechanical home position. Then press [RECORD] to record the home position for each axis
respectively.

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For the detailed setting instructions, please refer to << ERC-G200 Mechanical Home
Position Calibration Manual >>.

9.8.5 Authority

There are two options under the "Settings - Authority" menu: switching users and changing
password.

9.8.5.1 Switching users

The system provides four types of user authorities: general user, expert user, root and
administrator. The user authorities required by the options in the operating system are provided in
section 1.4.1. In the page of switching users, enter the password of the current user authority,
then press [OK] to switch user authorities.

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9.8.5.2 Changing Password

The password of the current user authority can be modified in the page of changing password.
Enter the previous password and the new password at the given locations, and press [OK] to
change the password.

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9.8.6 Speed Parameters

In the page of "Settings - Speed Parameters", the following parameters can be set: the
maximum and minimum rotational speeds of each axis, the maximum and minimum speeds for
moving in straight line, the maximum and minimum posture angle speeds, the speed of returning
to the home position, the joint acceleration time, etc. Generally, the factory default values can be
used for the parameters in this page, which most users do not need to set.

9.8.7 Limit Parameters

In the page of "Settings - Limit Parameters", the maximum and minimum angular position of
each axis can be set as the joint soft limits. If one of the joint positions is out of the soft limits
during the operation, the manipulator will stop immediately and give an alarm. The limit
parameters are set to the default values when shipping from the factory. Note that the soft limits
cannot be expanded in order not to damage the manipulator body. However, the limit range can
be reduced according to the actual requirements.

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9.8.8 System Configuration

The "System - System Configuration" menu includes three options: robot configuration,
network configuration and language configuration.

9.8.8.1 Robot Configuration

The robot process settings, additional function selections and drive mode settings can be
configured in the robot configuration page, as shown in the figure below.

After finishing the robot configurations, press [SET] button, and the users will be prompted
to decide whether to restart the system. Then press [OK] button, all the settings will take effect
after the restart. Generally, all above settings are configured successfully when shipping from the
factory, and the users do not need to set them.

9.8.8.2 Network Configuration

The network configuration is mainly used to change the IP address, subnet mask and
gateway of the system controller. All above parameters can be modified in the network
configuration page, as shown in the figure below. After the modifications, press [SET] button,
and the changes will take effect immediately.

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9.8.8.3 Language Configuration

The current system supports two display languages: Simplified Chinese and English. Select
the language configuration, and choose Simplified Chinese or English in the popup window.
Press [OK] button, and the selected language will take effect after the restart.

9.9 Backup and Upgrade

The backup and upgrade operations of the system software are simple, fast, and convenient,
which only need an ordinary USB flash disk. After preparing the USB flash disk according to the
upgrade or backup requirements, insert it into the USB port of the controller (for the collaborative
robot, the USB port is on the surface of the cabinet), and simply a few operations on the
programming pendant can complete the backup or upgrade of the system software.

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9.9.1 Software Information

Under the "System - Software Info" menu, the basic information, detailed information and
registration information of the system software can be viewed.

9.9.1.1 Basic Information

The basic information includes the IP address of the controller, the software version number
and the system version number. The software information page displays the basic information by
default.

9.9.1.2 Detailed Information

Press [DETAILED INFORMATION] in the submenu area to display the detailed

information page, where the version number and the compilation time of the system components
can be viewed.

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9.9.2 Local to USB

The "System - Save to USB" option includes parameter backup, IO annotation backup, PLC
backup, user data backup and script backup / delete.

Parameter Backup: Backup all parameter settings, including speed parameters, system
parameters, limit parameters, servo parameters, mechanism parameters, and other parameters.

IO Annotation Backup: Backup comment files for input, output, virtual input and virtual
output.

PLC Backup: Backup system PLC program files.

User Data Backup: Include parameter backup, IO annotation backup, and PLC backup. In
addition, backup all program files, user coordinates files, tool coordinates files, user processes
files and screenshots, etc.

Script Backup/Delete: Backup or delete script files.

When performing "Save to USB" operation, if there is no folder called "rbctrl" in the root
directory of the USB flash disk, the system will automatically generate the folder and save the
backup file in it. If the folder exists in the root directory, the backup file will be saved in it
directly.

9.9.3 Local from USB

The "System - Load from USB" option includes parameter upgrade, IO annotation upgrade,
PLC upgrade, user data recovery, script upgrade, and identification file import.

When performing "Load from USB" operation, a folder named "rbctrl" must be created in
the root directory of the USB flash disk. After placing the upgrade file in the folder, the upgrade
operation can be performed. If the folder does not exist, the alarm with the message "Failed to
load the upgrade file" will be given by the system when performing the upgrade operation.

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9.9.4 System Upgrade

9.9.4.1 System Upgrade

System upgrade can be performed when the software needs to be updated or system failures
occur. The existing user data should be backed up before the system upgrade. Note that the
mechanical home position is not included for user data backup. Thus, take a photo or screenshot
of the mechanical home position page before the system upgrade.

The detailed upgrade procedures are as follows:

(1) Prepare a USB flash disk and copy the system upgrade file "firmware.bin" to its root
directory;

(2) Insert the USB flash disk into the USB port of the controller or the collaborative robot
cabinet;

(3) Go to "System - Save to USB" and select "User Data Backup" to back up the user data;

(4) Go to "System - System Upgrade", then press [OK] button and wait several minutes. The
system will check the firmware and be upgraded automatically. It will restart the system after
successful upgrade.

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9.9.4.2 Firmware Upgrade

The firmware upgrade is peculiar to the collaborative robot and the detailed upgrade
procedures are as follows:

(1) In the root directory of the USB flash disk, create a new folder named "rbctrl" and copy
the firmware upgrade file into it;

(2) Insert the USB flash disk into the USB port of the collaborative robot cabinet, and a USB
device icon will be displayed in the coordinate area of the programming pendant screen;

(3) Go to "System - System Upgrade", and a dialog box with the message "Confirm System
Upgrade" will pop up. After pressing [OK] button, the system will give the message "Please
select the content that needs to be upgraded". Then select "Upgrade Firmware";

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Appendix

A Glossaries

Stop Category 0: The robot motion is stopped immediately when the power supply of the

robot is turned off. It is an uncontrolled stop, where the robot may deviate from the programmed

path as each joint may brake as fast as possible. This protective stop may be used when a

safety-related assessment limit is exceeded, or when a fault occurs in the safety-related

assessment part of the control system. For more information, please refer to EN ISO13850:2008

or IEC60204-1:2006.

Stop Category 1: The robot motion is stopped with power available for the robot to achieve

the stop, and the power supply is turned off when the stop is achieved. It is a controlled stop,

where the robot will comply with the programmed path. The power is turned off after one second

or once the robot stands still. For more information, please refer to EN ISO13850:2008 or

IEC60204-1:2006.

Stop Category 2: It is defined as a controlled stop with power available to the robot. The

robot stops all motions within one second. Through the operation of the safety-related assessment

control system, the robot may stay at the stop position. For more information, please refer to

IEC60204-1:2006.

Diagnostic coverage (DC): It is used to measure effectiveness of the diagnosis which is

implemented to achieve the assessed performance level. For more information, please refer to EN

ISO13849-1:2008.

Integrator: The integrator is an organization designing the final installation of the robot.

The integrator is responsible for implementing the final risk assessment, and must make sure that

the final installation comply with the local laws and regulations.

Mean time to dangerous failure (MTTFd): The MTTFd is defined as a value acquired by

calculation and detection which are implemented to achieve the assessed performance level. For

more information, please refer to ENISO13849-1:2008.

Risk assessment: The risk assessment is the whole process of identifying all risks and

reducing these risks to an appropriate level. The risk assessment should be recorded and archived.

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please refer to ISO 12100 for details.

Performance level (PL): The PL is a discrete level which is used to specify the ability of

each safety-related part in the control system to implement the safety function under foreseeable

conditions. PLd is a second highest reliability classification, meaning that the safety function is

extremely reliable. For more information, please refer to EN ISO13849-1:2008.

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B Certification and Detection

Through verification and evaluation of the quality management system and the sample type

test of the enterprise by the third party certification organization, the product EC612 of the

company is confirmed to be in line with the specific requirements and have the ability of

producing the qualified products continuously and steadily, with the written confirmation. The

description is as follows:

The EC612 has passed detection and certification of multiple well-known international third

party organizations, and has acquired the EU CE certification and Korean KC certification. The

product safety has achieved the international leading level.

The EC612 has passed the robot performance test of National Robot Testing and Assessment

Center (Headquarters) of China; and the performance indexes have exceeded most of the

domestic brands and achieved the standard of the traditional industrial robot, and have been

gradually narrowing a gap with the top international brands.

The EC612 robot has passed the EU CE certification, and the product is in line with all

relevant requirements of the EU CE directive:

Low-voltage Directive (LVD) 2006/95/EC

Machinery Directive (MD) 2006/42/EC

Electro Magnetic Compatibility Directive (EMC) 2004/108/EC

EN ISO 10218-1:2011

EN ISO 12100: 2010

EN ISO 13849-1: 2008

EN 60204-1: 2006+A1: 2009

The EC612 robot has been certified and tested by the official authority of Korea, has passed

Korean KC certification, and is in line with all relevant requirements of the certification

standards of Korea.

The EC612 robot has been certified and tested by National Robot Testing and Assessment

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Center (Headquarters) of China, has passed the CR certification and is in line with all relevant

requirements of the CR certification standards regarding the collaborative robot. The test

standards are as follows:

GB 5226.1-2008, GB 11291.1-2011

GB/T 15706-2012

GB/T 17799.2-2003, GB 17799.4-2012

The EC612 robot is subjected to the robot performance test implemented by National Robot

Testing and Assessment Center (Headquarters) of China, and the test basis and standards are as

follows:

GB/T 12642-2013 Industrial robots -- Performance criteria and related test methods

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C Stopping Time and Stopping Distance

Stopping distance and stopping time of stop category 0

The table below shows the stopping distance and the stopping time measured when the stop

category 0 is triggered. These measuring results correspond to the following configurations of the

robot:

• Extension: 100% (the robot arm is completely extended horizontally)

• Speed: 100% (the general speed of the robot is set as 100%, and the robot moves at a

joint speed of 180︒/s)

• Payload: a maximum payload (12kg) that can be handled by the robot connected to TCP.

The Joint 0 test was carried out by performing a horizontal movement, where the rotational

axis was perpendicular to the ground. During the Joint 1 and Joint 2 tests, the robot followed a

vertical trajectory, where the rotational axes were parallel to the ground, and the stop was

performed while the robot was moving downward.

Stopping distance (rad) Stopping time (ms)
Joint 0 (base) 0.21 350
Joint 1 (shoulder) 0.21 350
Joint 2 (elbow) 0.21 350

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D Reference Standards

The robot is designed by using the following standards for reference:

Standard Definition

2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the

Council of 17 May 2006 on machinery, and amending Directive

95/16/EC (recast)

2004/108/EC:2004 EMC Directive:

Directive 2004/108/EC of the European Parliament and of the

Council of 15 December 2004 on the approximation of the laws of the

Member States relating to electromagnetic compatibility and repealing

Directive 89/336/EEC

EN ISO 13850:2008 Safety of machinery:

Emergency stop - Principles for design

EN ISO 13849-1:2008 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles

of design

EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 10218-1:2011 Industrial robots:

Safety

Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1

ISO/TS 15066: 2016 Safety requirements for collaborative industrial robot

Robots and robotic devices —Collaborative robots

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E Technical Specifications

Robot type EC612

Weight 31kg

Maximum payload 12kg

Reach 1304mm

Joint speed 120°/s to 224°/s

TCP speed 1m/s

Repeated positioning
0.03mm
accuracy

Control box IO 16 digital in, 16 digital out, 2 analog in and 4 analog out

Tool IO 2 digital in, 2 digital out, 1 analog in and 1 analog out

IO power supply The control box is 24V 2A, and the tool end is 24V 0.8A

TCP/IP 100Mbit, IEEE 802.3u, 100BASE-TX, compatible with

Communication with
Modbus TCP.
control box
RS485, compatible with Modbus RTU.

Tool Communication RS485

Protection class IP54

Typical power consumption 500W

Temperature 0-50°C

85-265VAC，50-60Hz
Power supply
18-72VDC

Anticipated service life 25000 hours

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F Alarm Information and Description of Routine Problems

See the detailed instructions of the control system for the alarm information.

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 WEB：www.elibot.cn

Sales business email：[email protected]

Technical support email：[email protected]

TEL：4001899358/ 0512-83951898/ 18616750806

Headquarters：Building C, 28 Heshun Road, Suzhou Industrial Park；

Beijing R & D Center：Room D102A-3, 1st Floor, Building B-2, Dongsheng Science and Technology Park,

West Xiaokou, Haidian District, Beijing；

Shanghai office：B306, Building L1, Hongqiao World Center, Lane 1588, Zhuguang Road, Shanghai;

Shenzhen Technical Service Center：Room 601, Building 2B, Taihua Wutong Island Science and

Technology Innovation Park, Hangkong Road, Hangcheng Street, Baoan District, Shenzhen