ESTUN Arc Welding Robot - EWAS Series Robot Body Operation Instructions M1201EN-04

ESTUN Arc Welding Robot- EWAS series
Robot Body Operation Instructions
M-1201EN-04
Thank you for purchasing ESTUN robots.
Before using the robot, be sure to read the SAFETY PRECAUTION and understand the content.
ESTUN endeavor to improve the products. All specifications and designs are subject to change
without notice.
In this manual, all specifications and information are checked on a regular basis. Nevertheless,
discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity.
ESTUN assumes no responsibility for any direct or indirect losses arising from use of this manual and
products described herein.
Keep this manual handy for easy access at all times.
No part of this manual may be reproduced in any form.

ESTUN Robotics. All Rights Reserved Copyright.
Service Line: 400-025-3336

ADD: No.1888, Ji Yin Avenue, Jiangning Area, Nanjing, ChinaPost Code: 211102
TEL: +86-025-58328532
WEB: www.estun.com
E-mail: [email protected]
SAFETY
SAFETY
This chapter describes the precautions which must be followed to ensure the safe use of the robot. Before
using the robot, be sure to read this chapter thoroughly.
ESTUN robots must be transported, mounted and operated in accordance with national laws, regulations
and standards. Appropriate safeguards must be correctly performed to protect the users. Before using (mounting,
operating, maintaining, repairing) the robot, be sure to read and understand this manual and its relevant
manuals. Be sure to have familiarization with the knowledge of robot system and the safety precaution. Even if
all instructions are followed, this is not a guarantee that the robot will not cause injuries or damage.
DEFINITION OF USER
The personnel can be defined as follows.
 Operator
Turns the robot power ON/OFF.
Starts the robot program from the panel.
 Programmer
Operates the robot.
Teaches the robot inside the safety area.
 Maintenance engineer
Operates the robot.
Teaches the robot inside the safety area.
Maintenance (repair, adjustment, replacement).
Operator must not work in the safety area.
Programmer and maintenance engineer can work in the safety area.
During operation, programming, and maintenance of the robot, the operator, programmer, and maintenance
engineer should take precautions to ensure the safety by wearing the following safety items.
 Clothes for operation
 Safety shoes
 A helmet
SPECIAL TRAINING
Tasks in the safety area include transportation, setting, teaching, adjustment, maintenance, etc.
Training course must be performed before operating the robot.
For more information about training course, contact ESTUN.
DEFINITION OF SAFETY NOTATIONS

Precautions and information are defined as follows.
Definitions
Symbol
Danger notation
！ Death or serious injury will be expected to occur if the user fails to follow the approved
WARNING procedure.
Caution notation
！ Minor or moderate injury of the user or equipment damage will be expected to occur if
CAUTION the user fails to follow the approved procedure.
Information
IN FO A supplementary explanation helps users operating the robot more efficiently.
S-1
SAFETY
SAFETY OF THE USER
(1) The robot should be transported and installed as procedures recommended by ESTUN. Wrong
procedures may cause severe injuries or damage due to the robot fall.
(2) Draw an area clearly indicates the safety area. Install a fence or hang a warning board to ensure the
safety operation of the robot, and keep unauthorized personnel outside the safety area.
(3) Never hang any tools above the robot. Falling of these tools may cause damage to equipment.
(4) Never lean on the cabinet. Never touch any buttons without permission. Unexpected movement of the
robot may cause personnel injuries and equipment damage.
(5) Take precautions for falling parts to avoid injuries when disassemble the robot.
(6) Turn off the power when adjusting peripheral equipment.
(7) Peripheral equipment must be grounded.
(8) The robot should be operated in a low speed in the first operation. The speed should be added
gradually to check if there is any abnormal situation.
(9) Do not wear gloves when using the teach pendant. Operate with gloves may cause an operation error.
(10) Programs, system variables, and other information can be saved on the memory card or USB
memories. Be sure to save the data periodically in case that the data is lost.
(11) Never forcibly move any axis of the robot. Move the axes forcibly may cause injuries or damage.
(12) Take precautions when wiring and piping between the robot, the cabinet, and peripheral equipment.
Put the pipes, wires or cables through a pit or covered with a protective lid, to avoid stepped by
personnel or run over by a forklift.
(13) Unexpected movement may occur on any operating robot, which will cause severe injuries or damages
in the working area. Test (safe door, brake, safe indicators, etc.) must be performed on each safety
measures before using the robot. Before turn on the system, make sure that no one is in the working
space.
(14) Never set motion range or load condition exceeds the rated range. Incorrect setting may cause
personnel injury and equipment damage.
(15) Observe the following precautions when teaching inside the working space of the robot：
 Do not enable the system unless the mode is switched to manual, and make sure that all auto-
control is cut off.
 Speed must be limited under 250mm/s at manual mode. Only authorized person with fully
understand of the risks can adjust the robot to rated speed manually.
 Be careful about rotating joints to prevent hair and clothes involved. Take precautions of injury or
damage caused by the manipulator or other auxiliary devices.
 Check the motor brake to avoid personnel injuries caused by unexpected situation.
 Always have an escape plan in mind in case the robot comes towards you unexpectedly.
 Ensure that there is a place to retreat to in case of emergency.
！ Never stand beneath the robot in case of unexpected movement or the system be turned
on inadvertently.
WARNING
！ Make sure there is a CO2 fire extinguisher at hand.

CAUTION
SAFETY OF OPERATORS：
(1) Before operating the robot, check that the SERVO ON indicator goes out when the EMERGENCY
STOP button on the right of the front door of the controller and the pendant are pressed. And confirm
that the power is turned off.
(2) Never allow unauthorized personnel to touch the controller during operation. This may result in
unexpected movement of the robot, severe injuries and material damage.
(3) When attaching tools to the robot, be sure to turn off the power of the controller and the peripheral
equipment, and display a warning sign. Turning the power on during equipment installation may cause
electric shock or injury due to unexpected movement of the robot.
(4) Emergency stop
Emergency stop is an external button of the controller that can stop the robot operation.
When emergency button is pressed, the power of the robot (except the power of the servo) is cut off.
S-2
SAFETY
The system will not run unless the pressed emergency button being released and the system being turned
on.
There are several emergency stop buttons in a robot system to stop the robot in case of
emergencies. The red button, as shown in the left figure, can be mounted on the teach
pendant and the controller. Certainly, the emergency buttons can be mounted by special
requirement.
Emergency stop button should be mounted where is easy to reach, so that the buttons
can be pressed down immediately in case of emergencies.
！ Operators must take precautions to avoid high voltage from cables of servo motors,
grippers and other devices.
WARNING
！ Emergency button is used in case of emergency only. Do not use it to stop the robot for
normal operation.
CAUTION
SAFETY OF PROGRAMMERS：
While teaching the robot, the programmer must enter the robot operation area. The programmer must
ensure the safety especially.
！ Turn on or off the system by press or release Mot button on the teach pendant.
CAUTION
To use the teach pendant safely, the following precautions should be taken.
 Be sure that the enable switch is effective at any time.
 Turn off the enable switch when pausing, programming or testing the system.
 Teach pendant must be taken with the programmer when teaching in the work space, to avoid
inadvertent operation by unauthorized person.
 Teach pendant must not be left within the work space of the robot, as injury or damage can occur
if the robot comes in contact with the teach pendant.
SAFETY OF MAINTENANCE ENGINEERS：
(1) Heated parts
Some parts of the robot are heated when the robot is operating, especially the servo motor and
reducer. If a maintenance engineer needs to touch such a part, the user should wear heat-resistant gloves
or use other protective tools.
Try to feel the temperature of heated parts before touching them, to avoid burn injuries.
！ After turning off the power supply, wait until the heated parts cool down before
CAUTION performing any maintenance.
(2) Disassembly parts
Open the cover or shell only after interior parts such as gears are not moving any more. Never open
the cover or shell when the gear or bearing is moving. Use auxiliary device to keep interior part to its
position.
Observe the following precaution when performing the first test after installation, inspection or
maintenance:
a) Clear tools to proper locations outside of the working space of the robot.
b) Make sure that all precaution measures are available.
c) Make sure that there is no one in the working space of the robot.
d) Pay special attention to working condition of the maintenance parts when performing test.
Never use the manipulator as a ladder when performing maintenance. Never climb on the manipulator
to avoid falling down.
(3) Pneumatic / hydraulic pressure
There may be air/liquid residue in the system when the air pump or hydraulic pump is turned off.
Before checking the pneumatic or hydraulic parts, release remaining pressure from the system to avoid
S-3
SAFETY
personnel injury or equipment damage.
！ Install a safety valve in case of accident.

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

Peripheral device may still be running even after the system has been turned off. Personnel injury may
occur due to damaged power lines.
SAFETY OF THE ROBOT MECHANICAL UNIT

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

There are three types of robot stop.
Power-off stop
Servo power is turned off and the robots stops immediately. Servo power is turned off when the robot
is moving, the path of the deceleration in uncontrolled.
The following processing is performed at Power-off stop:
 An alarm is generated and servo power is turned off immediately.
 Execution of the program is paused.
Frequent Power-off stop of the robot during operation can cause failures of the robot. Avoid system
designs that require routine or frequent Power-off stop conditions.
Alarm stop
S-4
SAFETY
The robot system sends alarm (not include power-off alarm), and the robot is decelerated until it stops
by control instructions.
The following processing is performed at Alarm stop:
 An alarm (not include power-off alarm) is generated due to overload, system faulty, etc.
 Control instruction is send from servo system. The robot operation is decelerated until it stops.
Execution of the program is paused.
 Servo power is off.
Hold
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold:
 The robot operation is decelerated until it stops. Execution of the program is paused.
LABELS
(1) Electric Shock Warning
Fig 0.1 Electric Shock Warning

This label indicates hazardous voltage or electric shock.
(2) High-temperature Warning
Fig 0.2 High-temperature Warning

Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protection provision such as heat-resistant gloves.
(3) No Step-on Warning
S-5
SAFETY
Fig 0.3 Step-on prohibitive Warning

Never step on or climb the robot or controller as it may adversely affect the robot or controller and may
get hurt if you lose your footing as well.
(4) Personal Injury Warning
Fig 0.4 Personal Injury Warning

Never enter the operation area while the Manipulator is moving. This is extremely hazardous and may
result in serious safety problems.
(5) No Disassembly Warning
Fig 0.5 No Disassembly Warning

Never perform disassembly arbitrarily where the warning is affixed. Contact ESTUN for disassembly.
(6) Handling Identification
S-6
SAFETY
Fig 0.6 ER8-1450-HW Transport Identification
Fig 0.7 ER8-1500-CW Transport Identification
S-7
SAFETY
Fig 0.8 ER8-2000-CW Transport Identification
Fig 0.9 ER8-2000-HW、ER8-2000-HW-T Transport Identification
S-8
PREFACE
PREFACE
This manual describes the following manipulators.
Model Load capacity
ER8-1450-HW 8kg
ER8-1500-CW 8kg
ER8-2000-CW 8kg
ER8-2000-HW 8kg
ER8-2000-HW-T 8kg
Related manual
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ESTUN RCS2 System Operator’s Manual
ESTUN Robot S1F Control Cabinet Operation Instructions
ESTUN Robot S1E Control Cabinet Operation Instructions
P-1
CONTENTS
CONTENTS
SAFETY .............................................................................. 1
PREFACE ............................................................................. 1
1. TRANSPORTATION AND INSTALLATION .................................................. 1
1.1 TRANSPORTATION...................................................... 1
1.1.1. Transport by a forklift ................................................. 3
1.2 INSTALLATION .......................................................... 5
1.3 INSTALLATION CONDITIONS ............................................. 9
2. CONNECTION WITH THE CONTROLLER .................................................. 7
3. SPECIFICATIONS .................................................................. 8
3.1 ROBOT CONFIGURATION................................................ 8
3.2 EXTERNAL DIMENSIONS AND OPERATING SPACE ....................... 12
3.3 ZERO POINT POSITION AND MOTION LIMIT .............................. 16
3.4 WRIST LOAD CONDITION ............................................... 22
3.5 ADDITIONAL LOAD CONDITION ......................................... 23
4. EQUIPMENT INSTALLATION TO THE ROBOT ............................................ 26
4.1 FLANGE DIMENSION ....................................................... 26
4.2 EUIPMENT MOUNTING FACE ............................................... 27
4.3 PIPES AND TUBES ......................................................... 32
5. CHECK AND MAINTENANCE ........................................................... 34
5.1 DAILY CHECKS ........................................................ 34
5.2 PERIODIC CHECKS AND MAINTENANCE ................................. 35
5.5.1. POSITION OF OIL INLET/OUTLET ON EACH AXIS ..................... 40
5.5.2. PROCEDURE OF GREASING ........................................ 45
5.5.3. PROCEDURE FOR RELEASING REMAINING PRESSURE WITHIN THE
GREASE BATH ..................................................... 46
6. CALIBRATION ..................................................................... 47
6.1 INTRODUCTION ........................................................ 47
6.2 QUICK ZERO POSITION CALIBRATION ...................................... 47
6.3 MECHANICAL ZERO POSITION CALIBRATION ............................ 48
6.3.1. ZERO POSITION CALIBRATION METHOD ............................. 48
6.3.2. CALIBRATION IN EACH AXIS ........................................ 48
7. TROUBLESHOOTING ................................................................. 54
7.1 TOOLS .................................................................... 54
7.2 TROUBLESHOOTING ...................................................... 54
7.3 REPLACING THE SERVO MOTOR ........................................... 55
APPENDIX ........................................................................... 31
APPENDIX A BOLT TORQUE LIST ................................................... 31
APPENDIX B SPECIFICATION OF BOLT............................................... 31
APPENDIX C ER8-1450-HW Suggested spare parts list（for single unit） ...................... 33
APPENDIX D ER8-1500-CW Suggested spare parts list（for single unit） ...................... 33
APPENDIX E ER8-2000-CW Suggested spare parts list（for single unit） ...................... 33
APPENDIX F ER8-2000-HW Suggested spare parts list（for single unit） ...................... 33
APPENDIX G ER8-2000-HW Suggested spare parts list（for single unit） ...................... 33
c-1
CONTENTS
REVISION RECORD .................................................................... 34
c-2
TRANSPORTATION AND INSTALLATION
1. TRANSPORTATION AND INSTALLATION

1.1 TRANSPORTATION
！ When transport the robot, be sure the robot is in safe condition, or it may result in
serious personnel injury and/or equipment damage.
WARNING
Turn each axis to transportation gesture before move the robot and be sure to keep the gesture during
transportation until it be properly installed and mounted. Transportation gesture of each axis is shown
below. Perform the transportation properly, or it may result in personnel injury or equipment damage.
Position J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis

ER8-1450-HW 0° -75° +75° 0° +45° 0°
ER8-1500-CW 0° -75° +75° 0° 0° 0°
ER8-2000-CW 0° -50° +70° 0° 0° 0°
ER8-2000-HW
0° -80° +80° 0° +90° 0°
ER8-2000-HW-T
Refer to theoretical weight of main parts shown below to install, disassemble and transport the robot.
Weight（kg）
Parts ER8-2000-HW
ER8-1450-HW ER8-1500-CW ER8-2000-CW
ER8-2000-HW-T
Robot 170 165 281 286
Big arm casting 19.4 19 38.4 39.7
Base assembly 99 177.8 178.3
100.8
(Including rotation base)
Small arm assembly
(Including motor casing
28.6 25 32.4 45
and motors of J3,J4 J5
axes)
Wrist (including motors 11 11 11.8
11.6
of J6-axis)
IN FO Some parts with less weight are not listed. Contact ESTUN
For ER8-1450-H robot ,fixed bracket should be mounted before transport the robot and be removed
before install the robot. Refer to the following figures when remove the bolts on fixed bracket.
M8 screw mounting hole*2 M8 screw mounting hole*2
1
Fig 1.1 Robot fixed bracket(ER8-1450-HW)
M6 screw mounting hole*2
Fig 1.2 Robot fixed bracket(ER8-1500-CW)

Fig 1.1 Robot fixed bracket（ER8-2000-CW）
2
Fig 1.2 Robot fixed bracket（ER8-2000-HW、ER8-2000-HW-T）
1.1.1.Transport by a forklift
The robot described in this manual can be transported by a forklift. Use eight bolts to fix the 4 fixed
plates on the forklift to the robot base, use a forklift to heave the robot. Make sure that the fixed bolts of the
robot are removed before transportation.
Robot
center of
gravity
Notes：Transportation conditions：① need crane with minimum capacity 1t;② the rod shall has capacity of
500kg;③ according to Standard GB/T825-1988. ④M12 bolt
Fig 1.5 The robot lifting and transportation instructions(ER8-1450-HW)
3
Robot
center of
gravity
Notes：Transportation conditions：① need crane with minimum capacity 1t;② the rod shall has capacity of
500kg;③ according to Standard GB/T825-1988. ④M16 bolt
Fig 1.6 The robot lifting and transportation instructions(ER8-1500-CW)
Robot
center of
gravity
Notes：Transportation conditions：① need crane with minimum capacity 1t;② the rod shall has capacity of 500kg;③
according to Standard GB/T825-1988. ④M16 bolt
Fig 1.7 The robot lifting and transportation instructions(ER8-2000-CW)
4
Robot
center of
gravity
Notes：Transportation conditions：① need crane with minimum capacity 1t;② the rod shall has
capacity of 500kg;③ according to Standard GB/T825-1988. ④M16 bolt
Fig 1.8 The robot lifting and transportation instructions(ER8-2000-HW、ER8-2000-HW-T)
！ The sling shall be suppled by the customer. Please remove the sling bolts before running
the body.
CAUTION
1.2 INSTALLATION
！ Make sure the system is properly grounded before installation.
CAUTION
The following precautions must be fully understood and observed before installing the robot.
 Ensure that the information in the Safe Use Notice has been read and understood;
 Ensure that robots are installed by qualified installers and that installation procedures comply with
local legal rules;
 Check whether the outer packaging of the robot is bumped or damaged; Unpack the robot and
check whether the robot product is damaged from the appearance;
 Ensure that when installing the robot, the lifting equipment can bear the weight of the lifting robot
parts, see 1.1 Handling;
 The environmental conditions of robot storage and installation must meet the 1.3 installation
conditions.
When mounting the robot base, consider its structure and the force upon it. Concrete on the base may not
have any crack and conform to the specified codes. The bearing capacity and compaction of the concrete
foundation should be in accordance with the design guideline. Concrete strength level C20/C25 should be in
accordance with the following codes:
 GB50010-2010 Code for design of concrete structures
 GB/T50081-2002 Standard for test method of mechanical properties on ordinary concrete
5
Rotate horizontally Rotate vertically

Horizontal force Fh Torque Mr Vertical force Fv Torque Mk
Emergency stop 4800 N 3750 N·m 5750N 4165N·m
Accelerating 1600N 1250N·m 2300N 1666N·m
Fig 1.9 Robot base specification(ER8-1450-HW)

Fig 1.10 Robot base specification(ER8-1500-CW)
3

Fig 1.11 Robot base specification(ER8-2000-CW)

Fig 1.12 Robot base specification(ER8-2000-HW、ER8-2000-HW-T)

4
Through
Through
Fig 1.13 Robot base mounting dimension(ER8-1450-HW、ER8-1500-CW)
Through
Through
Fig 1.14 Robot base mounting dimension(ER8-2000-CW、ER8-2000-HW、ER8-2000-HW-T)
！ Use 8-M12 threaded hole on the base to fix the robot if necessary.
CAUTION
5
Tab 1.1 Robot fixing components
Item and model Number
Fixed screw: M16X40 (GB/T 70.1 12.9 level) 4
Spring washer: Spring washer 16 (GB/T 93) 4
Positioning pin: Cylindrical pin 12X45 (GB/T120.2) 2
Flat washer16(GB/T 97.1) 4

Flat washer16(GB/T 97.1) 4
Positioning pin can reduce the influence on current program caused by re-installation or
IN FO replacement of the robot. If the recovery of programmed path is needed, perform
adjustment. If not, positioning pin can be eliminated.
6
Through Through J1-axis rotation center
Base mounting screws
Level: 12.9
Tightening torque: 339N.m
Note: use four M16x190 chemical bolts to fix the mounting plate on the concrete floor. The thickness of the concrete should be
no less than 160mm, effective area no less than 1000mmx1000mm. Fix the robot base with parts shown in the table above.
The dimension with a * is recommended. A strict calculation based on the force upon the base and the structure of the base
must be performed before any change of these dimensions.
Fig 1.15 ER8-1450-H Robot mounting plate dimension and mounting method
7
Through Through J1-axis rotation center
Level: 12.9
Note: use four M16x190 chemical bolts to fix the mounting plate on the concrete floor. The thickness of the concrete should be
no less than 160mm, effective area no less than 1000mmx1000mm. Fix the robot base with parts shown in the table above.
The dimension with a * is recommended. A strict calculation based on the force upon the base and the structure of the base
must be performed before any change of these dimensions.
Fig 1.16 ER8-1450-H Robot mounting plate dimension and mounting method
8
1.3 INSTALLATION CONDITIONS

！ Damage of the cable jacket can cause water intrusion. Take care when installing the
cable and exchange if it is damaged.
CAUTION
See the table below about installation conditions. Robot storage conditions are also listed in case that
the robot needs to be stored for a period of time.
Foundation
Max. surface roughness 0.5mm
Max. inclination angle 5°
Storage condition
Min. ambient temperature -25℃
Max. ambient temperature +55℃
Max. humidity 95%RH
Protection level
ER8-1450-HW
ER8-1500-CW
ER8-2000-CW IP54
ER8-2000-HW
ER8-2000-HW-T
Performance of resistant chemicals and resistant solvents.
(1) The robot (including severe dust/liquid protection model) cannot be used with the following liquids.
Potentially these liquids will cause irreversible damage to the rubber parts (such as gaskets, oil seals, O-
rings etc.). (As exception to this only liquids tested and approved by ESTUN can be used with the robot).
(a)Organic solvents
(b)Cutting fluid including chlorine/gasoline
(c)Amine type detergent
(d)Acid, alkali and liquid causing rust
(e)Other liquids or solutions, that will harm NBR or CR rubber
(2) When the robots work in the environment, using water or liquid, complete draining of J1 base must be
done. Incomplete draining of J1base will make the robot break down.
(3) Do not use unconfirmed liquid.
(4) Do not use the robot immersed in water, neither temporary nor permanent. Robot must not be wet
permanently. Example: in case motor surface is exposed to water for a long time, liquid may invade
inside the motor and cause failure.
9
CONNECTION WITH THE CONTROLLER
2.CONNECTION WITH THE CONTROLLER

The figure below shows the cables connect the robot with the controller. Connect these cables on
the back of the base.
Robot
Control cabinet
Detail A
Flat washers 8 Screw M8*16
(nickel-plated) (nickel-plated)
Robot connection cable
(Power cable, signal cable,
I/O cable, earth wire) Grounding Spring washer 8
terminal (nickel-plated)
Fig 2.1 Cable connection

1. It is essential to ensure that the serial number of the robot body matches the serial
number of the control cabinet. Mismatched serial numbers can result in deviation in
robot accuracy.
2. Before turning on the power supply to the control device, please connect the robot
！ and the control device with a grounding wire. There is a risk of electric shock if the
CAUTION grounding wire is not connected.
3. Install the grounding terminal between the flat washer and the spring washer. The
grounding position of the robot may have a small amount of anti-rust oil, so please clean
it properly before grounding.
7
SPECIFICATIONS
3.SPECIFICATIONS
3.1 ROBOT CONFIGURATION
Fig 3.1 The composition of robots（ER8-1450-HW）

Wrist joint
(J6-axis motor included) Small arm Motor base
J5-axis
J4-axis motor J4-axis

J6-axis
J3-axis
Wrist joint
(J5-axis motor included)
J3-axis motor
Big arm
J2-axis motor J2-axis

J1-axis motor
Swivel base
J1-axis
Base
Fig 3.2 The composition of robots（ER8-1500-CW）
8
SPECIFICATIONS
Wrist joint J5-axis
J6-axis
J4-axis
Motor base
J3-axis
J4-axis motor
Big arm
J3-axis motor
J2-axis
J1-axis motor
J2-axis motor
Swivel base
Battery box
J1-axis
Base
Fig 3.3 The composition of robots（ER8-2000-HW、ER8-2000-HW-T）

Wrist joint J5-axis
J6-axis
J4-axis
Motor base
J3-axis
J4-axis motor
Big arm
J3-axis motor
J2-axis
J2-axis motor J1-axis motor
Swivel base
Base J1-axis
Battery box
Fig 3.4 The composition of robots（ER8-2000-CW）
9
SPECIFICATIONS
Tab 3.1 Robot Specification Table
Model ER8-1450-HW ER8-1500-CW ER8-2000-CW
Type Articulated robot
Controlled axis 6-axis（J1，J2，J3，J4，J5，J6）
Installation floor/top Floor
Allowable weight 8kg 8kg 8kg
J1-axis ±170° ±170° ±170°
J2-axis -85°~ +160° -90°~ +155° -100°~ +155°
J3-axis -150°~ +85° -145°~ +85° -160°~ +86°
Motion range
J4-axis ±150° ±170° ±170°
J5-axis ±135° ±135° ±135°
J6-axis ±210° ±360° ±360°
J1-axis 240°/s 242°/s 180°/s
J2-axis 240°/s 242°/s 180°/s
Max. speed J3-axis 260°/s 283°/s 242°/s
(Note 1) J4-axis 440°/s 476°/s 480°/s
J5-axis 400°/s 412°/s 412°/s
J6-axis 700°/s 685°/s 705°/s
J4-axis 0.38 kg·m 2
0.38 kg·m 2
0.46 kg·m2
Allowable load
0.38 kg·m 2
0.46 kg·m2
inertia at wrist
0.08 kg·m 2
0.08 kg·m2
J4-axis 15.6（N.m） 15.6（N.m） 17.4（N.m）
Allowable torque
J5-axis 15.6（N.m） 15.6（N.m） 17.4（N.m）
at wrist
J6-axis 6.3（N.m） 6.3（N.m） 6.04（N.m）
Drive method Electric servo drive by AC servo motor
Repeatability ±0.08mm ±0.05mm ±0.05mm
Max. reach 1445mm 1527mm 2010mm
Weight 170kg 165kg 281kg
Ambient temperature: 0～45℃ (Note 2)
Ambient humidity: 20~80%RH
Installation environment Height: Up to 1000 meters above the sea level required
Vibration acceleration: 4.9m/s2 (0.5G) or less
Free of corrosive gases (Note 3)
Tab 3.1 Robot Specification Table
Model ER8-2000-HW ER8-2000-HW-T
Type Articulated robot
Controlled axis 6-axis（J1，J2，J3，J4，J5，J6）
Installation floor/top floor/top
Allowable weight 8kg 8kg
J1-axis ±170° ±170°
J2-axis -100°~ +155° -100°~ +155°
J3-axis -160°~ +86° -160°~ +86°
动作范围
J4-axis ±150° ±150°
J5-axis ±135° ±135°
J6-axis ±210° ±210°
J1-axis 180°/s 206°/s
J2-axis 180°/s 206°/s
Max. speed J3-axis 241°/s 238°/s
(Note 1)） J4-axis 430°/s 442°/s
J5-axis 400°/s 417°/s
J6-axis 640°/s 700°/s
0.38 kg·m2
Allowable load
0.38 kg·m2
inertia at wrist
0.08 kg·m2
Allowable torque J4-axis 15.5（N.m） 15.5（N.m）
at wrist J5-axis 15.5（N.m） 15.5（N.m）
10
SPECIFICATIONS
J6-axis 6.3（N.m） 6.3（N.m）
Drive method Electric servo drive by AC servo motor
Repeatability ±0.08mm ±0.08mm
Max. reach 2015mm 2015mm
Weight 286kg 286kg
Ambient temperature: 0～45℃ (Note 2)
Ambient humidity: 20~80%RH
Installation environment Height: Up to 1000 meters above the sea level required
Vibration acceleration: 4.9m/s2 (0.5G) or less
Free of corrosive gases (Note 3)
(Note 1) During short distance motions, the axis speed may not reach the maximum value stated.
(Note 2) When the robot is used in low temperature environment that is near 0℃ or not operated for a long
time in the environment that is less than 0℃ in a holiday or the night, collision detection alarm may occur
since the resistance of the drive mechanism could be high immediately after starting the operation. In this
case, we recommend performing the warm up operation for several minutes.
(Note 3) Contact the service representative, if the robot is to be used in an environment or a place
subjected to hot/cold temperatures, severe vibrations, heavy dust, cutting oil splash and or other foreign
substances.
11
SPECIFICATIONS
3.2 EXTERNAL DIMENSIONS AND OPERATING SPACE

The following figures illustrate the range of motion of the robot and serves as a reference for selecting
and setting up the robot's installation position. When installing peripheral devices, it is important to ensure
they do not interfere with the main body of the robot and its range of motion.
Fig 3.5 Motion range(ER8-1450-HW)
12
SPECIFICATIONS
point P
Range of motion at point P
Fig 3.6 Motion range(ER8-1500-CW)
13
SPECIFICATIONS
point P
Fig 3.7 Motion range(ER8-2000-CW)
14
SPECIFICATIONS
point P
Fig 3.8 Motion range(ER8-2000-HW、ER8-2000-HW-T)
15
SPECIFICATIONS
3.3 ZERO POINT POSITION AND MOTION LIMIT
Zero point and motion range are provided for each controlled axis. Exceeding the software motion limit
of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for each
axis. The robot cannot exceed the motion range unless there is a loss of zero point position due to
abnormalities in servo system or system error. In addition, the motion range limit by a fixed mechanical
stopper is also prepared to improve safety.
！ Do not reconstruct the fixed mechanical stopper. There is a possibility that the robot
doesn’t stop normally.
CAUTION
Fig 3.9 Zero point position （ER8-1450-HW）
Fig 3.10 Zero point position （ER8-1500-CW）
16
SPECIFICATIONS
Fig 3.11 Zero point position （ER8-2000-CW）
Fig 3.12 Zero point position （ER8-2000-HW、ER8-2000-HW-T）
17
SPECIFICATIONS
Fig 3.13 Mechanical stoppers(ER8-1450-HW)
18
SPECIFICATIONS
J4-axis mechanical stopper

(movable side)

(fixed side)

(movable side)

(fixed side)

(movable side)

(fixed side)

(movable side)

(fixed side)
Fig 3.14 Mechanical stoppers(ER8-1500-CW)
19
SPECIFICATIONS

(movable side)

(fixed side)

(movable side)
J1-axis mechanical stopper J1-axis mechanical stopper

(movable side) (fixed side)

(fixed side)

(movable side)

(fixed side)
Fig 3.15 Mechanical stoppers(ER8-2000-CW)
20
SPECIFICATIONS

(movable side)

(fixed side)

(movable side)

J1-axis mechanical stopper (fixed side)
(movable side)

(fixed side)

(movable side)

(fixed side)
Fig 3.16 Mechanical stoppers(ER8-2000-HW、ER8-2000-HW-T)

Refer to system operation manual for more information about setting motion range.
21
SPECIFICATIONS
3.4 WRIST LOAD CONDITION

Robot load capacity (including weight of gripper or welding gun) coincides with robot model. Observe
restrict of load torque and load inertia strictly.
Overload the robot may result in a worse movement performance on the robot or a
reduction of service time on the reducer.
！ Payloads include total weight of tools such as grippers, welding guns, tool convertors,
CAUTION dampers, etc. If payload exceeds allowable value, it is necessary to consult ESTUN
representatives.
Refer to ESTUN robot bearing capacity calculation table when calculate load torque and load inertia.
Contact ESTUN sales representatives for more detail.
Note: Allowable load inertia at J5 axis 0.38 kg.m^2

Allowable load inertia at J6 axis 0.08 kg.m^2
Fig 3.17 Load capacity at wrist（ER8-1450-HW）

Fig 3.18 Load capacity at wrist（ER8-1500-CW）
22
SPECIFICATIONS
Fig 3.19 Load capacity at wrist（ER8-2000-CW）

Fig 3.20 Load capacity at wrist（ER8-2000-HW、ER8-2000-HW-T）
3.5 ADDITIONAL LOAD CONDITION

ER8-1450-H robot may have additional loads. Additional load condition is shown as below.
23
SPECIFICATIONS
Notes：
1. The coordinate origin is on the midpoint of center line of additional load mounting holes. Unit: mm.
2. Centroid of additional load should be within the shadow as shown in the figure above, and be less than 10kg.
Fig 3.21 Additional load condition（ER8-1450-HW）
W: Loadable weight of the end flange mounting
surface
W: Loadable weight on motor mount surface
Notes：
Fig 3.22 Additional load condition（ER8-1500-CW）
24
SPECIFICATIONS
W: Loadable weight of the end flange mounting surface
W: Loadable weight on motor mount surface
Notes：
Fig 3.23 Additional load condition（ER8-2000-CW）
Notes：
Fig 3.24 Additional load condition（ER8-2000-HW、ER8-2000-HW-T）
25
EQUIPMENT INSTALLATION TO THE ROBOT
4.EQUIPMENT INSTALLATION TO THE

ROBOT
4.1 FLANGE DIMENSION
This section describes the mounting face dimension of the end effector. Consider the depth of the
screw holes and pin holes sufficiently before choose the length of the bolts and pins. Antirust measures of
screws, grippers, etc., should be considered as well.
Item and model QTY

Fixed screw：M5（GB/T 70.1 12.9 grade） 5
Spring washer：Φ5（GB/T 93） 5
Positioning pin：cylindrical pin Φ4（GB/T120.2） 1
Fig 4.1 End flange mounting dimension（ER8-1450-HW）
Item and model QTY

Fig 4.2 End flange mounting dimension（ER8-1500-CW）
26
Item and model QTY

Fig 4.3 End flange mounting dimension（ER8-2000-CW）
Item and model QTY

Fig 4.4 End flange mounting dimension（ER8-2000-HW、ER8-2000-HW-T）
4.2 EUIPMENT MOUNTING FACE

As shown in the figures below, tapped holes are provided to install equipment to the robot.
27
Fig 4.5 Equipment mounting face(ER8-1450-HW)
28
Fig 4.6 Equipment mounting face(ER8-1500-CW)
29
4-M5 Through
4-M6 Through
Fig 4.7 Equipment mounting face(ER8-2000-CW)
4-M5 Through
4-M6 Through
Fig 4.8 Equipment mounting face(ER8-2000-HW、ER8-2000-HW-T)
30
！ Take precautions to avoid interference between peripheral device and the robot.
CAUTION
Payload on J3-axis should not exceed 10kg.
31
4.3 PIPES AND TUBES

The robot has inlets and outlets openings to supply air or hydraulic pressure to the end effector.
Fig 4.9 Pipes and tubes（ER8-1450-HW）

Pipe joint 2 -Φ8
Fig 4.10 Pipes and tubes（ER8-1500-CW）
32
Pipe joint 2 -Φ8
Fig 4.11 Pipes and tubes（ER8-2000-CW）
Pipe joint 2 -Φ8
Fig 4.12 Pipes and tubes（ER8-2000-HW、ER8-2000-HW-T）
33
CHECK AND MAINTENANCE
5. CHECK AND MAINTENANCE

Before performing any maintenance, be sure to read SAFETY PRECAUTIONS and understand the
content.
！ Never implement any maintenance unless the power of the robot is cut off.
CAUTION
5.1 DAILY CHECKS

Check the items below before daily operation as occasion demands.
Item Check item Check points
1 Oil seepage Check if there is oil on the sealed part. If there is an oil seepage, clean it.
Check whether vibration or abnormal noises occur in each transmission
Vibration, abnormal
2 mechanism. If there is vibration or abnormal noises, perform measures referring
noises
to section 7.2.
Check whether the taught positions of the robot have not deviated from the
3 Positioning accuracy previous taught positions. Check whether the stop position have not deviated
from the previous stop positions.
Check whether poor ventilation or abnormal noise occur in the cooling fan on
4 Cooling fan in the cabinet
the backside.
5 Peripheral cable set part Check if there is missing parts, fray or rust.
Peripheral electrical Check whether the connection of peripheral electrical equipment or the button is
6
equipment normal. Check if there is any fray on the surface.
Check whether unexpected warnings occur in the alarm screen on the teach
7 Warnings pendant. If unexpected warnings occur, perform measures as described in the
ALARM DISPLAY in Cabinet Operator’.
34
5.2 PERIODIC CHECKS AND MAINTENANCE

Check the items at the intervals recommended below based on the total time or the accumulated operating
time, whichever comes first. Periodic checks keep the performance of the robot. The items below can be
performed by yourself, or you can contact ESTUN for maintenance service.
Check and maintenance intervals

(Operating time,
Accumulated operating time)
Check and
Check points, management and maintenance method
maintenance item
1 month 3 months 1 year 1.5 years 3years 4years
320h 960h 3840h 5760h 11520h 15360h
  Cleaning the Confirm the controller ventilation system is not dusty. If dust has
Only
1st controller ventilation accumulated, remove it.
check
system
 Check the external Check whether the robot has external damage or peeling paint
damage or peeling due to the interference with the peripheral equipment. If an
paint interference occurs, eliminate the cause. Also, if the external
damage is serious, and causes a problem in which the robot
will not operate, replace the damaged parts.
 Check damages of Check whether the cable protection sheaths of the mechanical
the cable protection unit cable have holes or tears. If damage is found, replace the
sheaths cable protection sheath. If the cable protection sheath is
damaged due to the interference with peripheral equipment,
eliminate the cause.
 Check for water Check whether the robot is subjected to water or cutting oils. If
water is found, remove the cause and wipe off the liquid.
  Check for damages Check whether the cable connected to the teach pendant,
Only
1st to the teach pendant operation box and robot are unevenly twisted or damaged. If
check
cable, the operation damage is found, replace the damaged cables.
box connection cable
or the robot
connection cable
  Check for damage to Observe the movable part of the mechanical unit cable, and
Only
1st the mechanical unit check for damage. Also, check whether the cables are
check
cable (movable part) excessively bent or unevenly twisted.
  Check for damage to Check whether the end effector connection cables are
Only
1st the end effector unevenly twisted or damaged. If damage is found, replace the
check
(hand) connection damaged cables.
cable
  Check the Check the connection of each axis motor and other exposed
Only
1st connection of each connectors.
check
axis motor and other
exposed connectors
  Retightening the end Retightening the end effector mounting bolts.

Only
1st effector mounting
check
bolts
  Retightening the Retighten the robot installation bolts, bolts to be removed for
Only
1st external main bolts inspection, and bolts exposed to the outside. Refer to the
check
recommended bolt tightening torque guidelines at the end of
the manual. An adhesive to prevent bolts from loosening is
applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the adhesive might be
removed. Therefore, follow the recommended bolt tightening
torque guidelines when retightening the bolts.
35
  Check the Check that there is no evidence of a collision on the mechanical
Only
1st mechanical stopper stopper, and check the looseness of the stopper mounting
check
bolts.
  Clean spatters, Check that spatters, sawdust, or dust does not exist on the
Only
1st sawdust and dust robot main body. If dust has accumulated, remove it.
check
Especially, clean the robot movable parts well (each joint, the
balancer rod, the support part of in front and behind of the
balancer, and the cable protection sheaths).
  Check the operation (When cooling fans are installed on the each axis motor)
Only
1st of the cooling fan Check whether the cooling fans are operating correctly. If the
check
cooling fans do not operate, replace them.
 Replacing the Replace the controller battery.

mechanical unit
battery
 Replacing the grease Replace the grease of each axis reducer.

of each axis reducer
 Replacing the Replace the mechanical unit cable. Contact ESTUN

mechanical unit representative for information regarding replacing the cable.
cable
36
5.3 ADJUST THE BELT

J4-axis, J5-axis and J6-axis of the robot are drove by timing belt. The belt tense tends to reduce after a
period of operation. This section describes how to strain the belt
A loose timing belt may cause a reduction of robot repeatability and a shortness of belt
！ lifetime. Use a proper force when straining the timing belt. Excessive tense may shorten
WARNING the belt lifetime.
Procedures of straining J4-axis timing belt are shown below.

1. Disassemble the hexagon flat round head screw M4X12 under the cover of the small arm. Remove the
cover and keep it in a proper place.
2. Unscrew the hexagon screw M5X30 on the mounting plate of J4-axis.
3. Adjust the device at left side of the mounting plate (mainly adjust the M5 nut), make the screw firmly
against to J4-axis motor mounting plate.
4. Test the tense on the side of the timing belt. Proper tense value is list in the table below.
5. Tighten the hexagon screw M5X16 on the mounting plate to remount the plate.
6. Use hexagon flat round head screw to fix the cover of the small arm. Tighten the screw.
Fig 5.1 Strain the J4-axis timing belt

Procedures of straining J5-axis and J6-axis timing belt are shown below.
1. Disassemble the hexagon flat round head screw M4X10 in the side cover of the small arm. Remove the
cover and keep it in a proper place.
2. Unscrew the hexagon screw M4X12 on the mounting plate of J5-axis and J6-axis.
3. Adjust the position of mounting plate to strain the timing belt.
4. Test the tense on the side of the timing belt. Proper tense value is list in the table below.
5. Tighten the hexagon screw M4X12 on the mounting plate to remount the plate.
6. Use hexagon flat round head screw to fix the side cover of the small arm. Tighten the screw.
37
Fig 5.2 Strain the J5-axis and J6-axis timing belt（ER8-1450-HW）

Hexagon socket head cap screw M4*12
J6-axis motor
fixing plate
Hexagon socket head cap screw Aim headpin of the straining device to the belt in line at 5-7mm
M4*12 distance. Use an internal hexagon wrench to wave the belt
when measuring tense.
J5-axis motor fixing plate
Fig 5.3 Strain the J5-axis and J6-axis timing belt（ER8-2000-HW、ER8-2000-HW-T）
ER8-2000-CW robot J5 axis tensioning timing belt steps:

1. Disassemble the hexagonal flat round head screw M4X12 inside the right cover plate of the forearm, remove
the right cover plate of the forearm and place it in the storage area;
2. Loosen the Allen screw M5X16 on the fixed plate of the J5 shaft motor;
3. Adjust the adjustment device under the fixed plate, mainly adjust the M4 nut, so that the screw is pressed
against the J5 axis motor fixed plate;
4. Test the timing belt tension on the side of the timing belt to make the timing belt tension appropriate (see the
table below for the specific range);
5. Tighten the Allen screw M5X16 that fixes the motor fixing plate to fix the motor fixing plate;
6. Install the right cover plate of the forearm to the wrist body through the hexagon flat round head screw, and
tighten the screw symmetrically.
38
Hexagon socket head cap screw M6*16

内六角圆柱头螺钉M5*16
Aim headpin of the straining device to the belt in line at 5-7mm

J5-axis motorJ5轴电机固定板
fixing plate distance.
张紧仪针头沿直线方向对准同步带，保持5-7mm间距，
Use an internal hexagon wrench to wave the belt
使用内六角扳手波动同步带进行测试。
when measuring tense.
Fig 5.4 Strain the J5-axis and J6-axis timing belt（ER8-2000-HW、ER8-2000-HW-T）
Tab 5.1 Timing belt tense/frequency value reference(ER8-1450-HW、ER8-

2000-HW、ER8-2000-HW-T)
Model Range of belt tense Range of frequency
new belt 37.8-41.6N 134-140Hz
J4 Timing belt
used belt 26.5-30.2N 112-119Hz
new belt 9.6-10.6N 80-90Hz
J5 Timing belt
used belt 6.72-7.68N 73-83Hz
new belt 24.1-26.5N 60-70Hz
J6 Timing belt
used belt 16.8-19.2N 53-63Hz
Tab 5.1 Timing belt tense/frequency value reference(ER8-2000-CW)
Model Range of belt tense Range of frequency
new belt 44.2～48.6N 129～136Hz
Timing belt
used belt 31.0～35.4N 108～116Hz
Measure the belt tense according to frequency, as internal parameter set is not required.
5.4 REPLACING THE BATTERIES

The position data of each axis is preserved by the backup batteries. The batteries need to be replaced
every 1 year. Also use the following procedure to replace when the backup battery voltage drop alarm
occurs.
Procedure of replacing the battery is shown below.
1. Press the emergency stop button to stop the robot motion.
2. Remove the plug cover on the robot base.
3. Take out the old batteries from the battery case fixed on the base.
4. Insert new batteries into the battery case while observing the correct direction.
5. Re-mount the plug cover after replacing the battery.
Fig 5.5 Battery replacement
！ Be sure to keep the power on. Replacing the batteries with the power turned off causes
all current position data to be lost. Therefore, calibrating will be required again.
CAUTION
39
5.5 ROBOT GREASING

Greasing is required every 3 years, or for a cumulative operation time of 11520 hours, whichever occurs first,
according to the following steps. Refer to the table below for the brand and quantities of the grease applied to
each joint.
！ Reduce greasing period when the robot is subject to extreme conditions.

CAUTION
Tab 5.2 Replacing the grease every three years

Model Position QTY
J1-axis reducer 330g
ER8-1450-HW J2-axis reducer 305g
ER8-1500-CW
J4-axis齿轮箱 245g
ER8-2000-CW
J4-axis齿轮箱 280g
ER8-2000-HW J2-axis reducer 1410g
ER8-2000-HW-T J2-axis reducer 1460g
Recommend greasing gesture is list below.
Tab 5.3 the axis angle of robot lubrication（ER8-1450-HW、ER8-2000-HW、

ER8-2000-HW-T）
Position Gesture
J1 J2 J3 J4 J5 J6
J1-axis reducer
Any
J2-axis reducer Any 0° Any Any Any
J3-axis reducer 0°
Tab 5.4 the axis angle of robot lubrication（ER8-1500-CW、ER8-2000-CW）
Position Gesture
J1 J2 J1 J4 J1 J6
J1-axis reducer
Any
J2-axis reducer Any
Any 0° Any Any
J3-axis reducer
0°
J4-axis reducer 0°
5.5.1. POSITION OF OIL INLET/OUTLET ON EACH AXIS
！ Be sure to read SAFETY PRECAUTIONS and understand its contents before greasing.
CAUTION
40
J1-axis oil inlet

J1-axis oil outlet
Fig 5.6 J1 axis oil inlet and outlet
J2-axis oil inlet
J2-axis oil outlet
Fig 5.7 J2 axis oil inlet and outlet(ER8-1450-HW)
41
J2-axis oil inlet
J2-axis oil outlet
Fig 5.8 J2 axis oil inlet and outlet(ER8-1500-CW)
J2-axis oil inlet
J2-axis oil outlet
Fig 5.9 J2 axis oil inlet and outlet(ER8-2000-HW、ER8-2000-HW-T)
42
J2-axis oil inlet
J2-axis oil outlet

J3-axis oil inlet J3-axis oil outlet
Fig 5.11 J3 axis oil inlet and outlet(ER8-1450-HW)
J3-axis oil inlet
J3-axis oil outlet
43
J3-axis oil inlet
J3-axis oil outlet
Fig 5.13 J3 axis oil inlet and outlet(ER8-2000-HW、ER8-2000-HW-T)
J3-axis oil inlet
J3-axis oil outlet
J4-axis oil inlet
J4-axis oil outlet

44
J4-axis oil inlet
J4-axis oil
inlet

5.5.2. PROCEDURE OF GREASING
The following steps only applied to operation of reducers of J1, J2, and J3 axis.
a) Teach each joint to run at a speed of 100% for 10-20min, to make the grease into oil with low
viscosity.
b) Move the robot to the gesture of greasing, then turn off the power supply.
c) Put an oil recycle container beneath the grease outlet.
d) Remove the screw on the inlet and outlet of each joint.
e) Inject new grease via the oil inlet until new grease goes out of the outlet. The amount of oil injected
should be equal to the amount that is discharged (including those discharged after warming up the
machine).
f) Release the residual pressure in the grease groove according to section 5.4.3.
g) Install the screw to oil inlet and outlet with a torque of 13.7N·m.
If greasing is not performed properly, the internal pressure inside the grease bath may increase suddenly,
which will damage the seal part, resulting in oil leakage and abnormal operation. Therefore, when performing
greasing, observe the following precautions.
 Open the grease bath vent (remove the screw on the oil outlet) before greasing.
 Inject the grease/oil slowly without excessive force.
 Avoid compressed gas pump (powered by factory gas source) whenever possible.
 Use specified model of grease/oil. Unauthorized model of grease may cause damage to the reducer or
other problems.
 When greasing is completed, make sure that there is no oil/grease leakage outside the outlet. and the
grease bath is not pressurized. Then close the outlet.
 Clean the excess oil/grease on the floor to avoid accidents such as slipping or fire.
45
TROUBLESHOOTING
5.5.3. PROCEDURE FOR RELEASING REMAINING PRESSURE WITHIN THE
GREASE BATH
Release remaining pressure with the following procedures. Attach bags under the oil outlet to prevent
spilled oil/grease from splattering.
1. Power the robot, and operate at a 100% speed with full load for 4 hours continuously.
2. Stop the running program of the robot at zero position, turn off the servo power with the teach pendant.
3. Disassemble the screw at oil inlet of each axis after safety confirmation. Do not face the screw when
removing it, in case that oil with high pressure and high temperature ejects, resulting personnel injury.
4. Retighten the screw 3% seconds later after removing it, and clean up the oil around the screw with a
clean cloth.
5. Be sure to complete pressure releasing of a robot (step c and step d) in 15 minutes. Otherwise, it
should be repeated from step 1.
46
TROUBLESHOOTING
6. CALIBRATION
6.1 INTRODUCTION
Calibration associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulse coder connected to the corresponding axis motor. To be specific, calibration is an operation for obtaining
the pulse count value, corresponding to the zero position.
“Calibration” is factory-performed. It is unnecessary to perform calibration in daily operation. However,
calibration becomes necessary after:
 Motor replacement
 Pulsecoder replacement
 Reducer replacement
 Cable replacement
 Batteries for pulse count backup in the mechanical unit have gone dead
Robot data (including calibration data) and pulse coder data are backed up by their
！ respective backup batteries. Data will be lost if the batteries die. Replace the batteries in
the controller and mechanical units periodically. An alarm will occur when battery
CAUTION
voltage is low.
6.2 QUICK ZERO POSITION CALIBRATION

Quick zero position calibration is performed at factory with all loads uninstalled using special apparatus.
Based on the robot parameter, this method provides the most precise zero position calibration.
Quick zero position calibration can reload zero position data that stored in the controller, when zero
position data lost due to electrical or software faults. If the zero position data lost due to disassembly or
maintenance, this method cannot be used.
ESTUN robot use encoder data as an auxiliary of calibration. Procedures are shown below.
a) Jog the robot manually to the place where the calibration marks are align.
b) Display the encoder information screen. Jog the axis at a low speed to make the real single loop
value close to the reference value.
c) Calibrate the zero position of the axis. Create a new program, then create a new instruction
“RefRobotAxis”, and run it.
47
TROUBLESHOOTING
Fig 6.1 Single loop value of quick zero position calibration（ ERC controller）
6.3 MECHANICAL ZERO POSITION CALIBRATION

6.3.1. ZERO POSITION CALIBRATION METHOD
Mechanical disassembly or maintenance may cause zero position data lost. mechanical zero position
calibration is performed with all axes jogged to zero-position using their respective witness marks.
Use the J1 axis as an example to illustrate the calibration procedure. There is a marking on the robot base
and the rotation base, please follow the steps below to calibrate.
a) With using teaching pendant to move J1 axis so that the middle tick marks of the two scale plates are
aligned.
b) Set this position as zero position of J1-axis with the teach pendant.
Perform zero position calibration for each axis with procedures recommended above. If calibration for all
axes has been performed and recorded, zero position for each axis can be set with teach pendant. Figures in
this section are reference for calibration of other axes.
6.3.2. CALIBRATION IN EACH AXIS
48
TROUBLESHOOTING
J1 zero calibration
Fig 6.2 J1 axis calibration
J2 zero calibration
Fig 6.3 J2 axis calibration（ER8-1450-HW）
49
TROUBLESHOOTING
J2 zero calibration
Fig 6.4 J2 axis calibration（ER8-1500-CW、ER8-2000-CW、ER8-2000-HW、

ER8-2000-HW-T）
J3 zero calibration
J4 zero calibration

50
TROUBLESHOOTING
J3 zero calibration
J4 zero calibration
Fig 6.7 J3、J4 axis calibration（ER8-1500-CW）
J4 zero calibration
J3 zero calibration
Fig 6.8 J3、J4 axis calibration（ER8-2000-HW、ER8-2000-HW-T）
51
TROUBLESHOOTING
J4 zero calibration
J3 zero calibration
J6 zero calibration
J5 zero calibration
Fig 6.10 J5、J6 axis calibration（ER8-1450-HW）
J6 zero calibration
J5 zero calibration
52
TROUBLESHOOTING
J6 zero calibration
J5 zero calibration
Fig 6.12 J5、J6 axis calibration（ER8-2000-HW、ER8-2000-HW-T）
J5 zero calibration
J6 zero calibration
53
TROUBLESHOOTING
7. TROUBLESHOOTING
Be sure to read SAFETY PRECAUTIONS and understand its contents before any maintenance.
！ Never perform any maintenance unless the power of the robot system is turned off.
CAUTION
7.1 TOOLS
Troubleshooting tools includes travelling crane, forklift, internal hexagonal wrench, monkey wrench and
special tools for removing the bearings.
7.2 TROUBLESHOOTING
Symptom Description Cause Measure
Frequent vibration due to robot Reinforce the connection
Unfirm connection between
operation causes unfirm between robot base and
base and floor.
connection. floor.
It is likely caused by a loose
bolt, or lack of bolt fastening
Re-mount and re-fasten the
Joint connection is loose. measures (such as screw
bolts.
fastening agent, spring
washer) on the joint.
Vibration becomes serious The robot control program is
when the robot is at a certain too demanding for the robot Modify the control program.
Vibration speed. hardware.
and Noise Vibration becomes serious
It is likely the robot is
when the robot adopts a Reduce the robot load.
overloaded.
specific posture.
Prolonged usage of the
Damaged reducer. Replace the reducer.
reducer.
Vibration occurs after the robot The reducer or the joint Replace the reducer or
collided with an object or was structure was damaged due to structure where the
overloaded for a long period. collision or overload. vibration occurs.
Some relationship may occur Change the distance
The robot resonates with the
between the robot and the between the robot and the
machine near it.
machine near it. other machines.
Check tightness of motor
retaining bolt, reducer
The robot wobbles due to Bolts in the robot joint loosen retaining bolt, reducer
Click
push by hand when turn off it. due to overload or collision. retaining bolt and mounting
bolt of each joint. If any bolt
is loose, re-tight it.
The motor overheated due to Reduce the ambient
Ambient temperature roses or
the ambient temperature rose temperature, make
the motor is overheated, and
Motor or a cover was attached to the ventilation well and remove
could not release the heat.
overheat motor. the cover of the motor.
Changing the robot control Program or load is too Modify the program and
program or the load. demanding for the robot. reduce the load.
54
TROUBLESHOOTING
Symptom Description Cause Measure
Parameters imported to the
Parameters imported are not
controller are changed, the Import correct parameters.
correct with the robot.
motor overheated.
Prolonged usage of the robot
Replace the oil seal and O-
leads to a damage of the oil
ring.
Gear case seal.
grease Grease leakage from the joint. There is a gap on the surface Re-mount and tighten the
leakage of the seal. oil seal.
There is a problem with the oil Replace the oil inlet or the
inlet or outlet. bolt.
The robot axis cannot stop at
Dropping There is a problem with the
a certain position, or drops in Replace the servo motor.
joint servo motor brake.
standstill due to gravity.
7.3 REPLACING THE SERVO MOTOR

Contact ESTUN representative if servo motor replacement is needed.
When removing some parts of the robot, other parts may lose support, thus leads to
！ unexpected movement, and cause personnel injury and equipment damage.
WARNING Disassembling of the robot must been performed by authorized person.
！ When replacing servo motors, the disassembled parts should be kept properly and
cleaned thoroughly before remounting. Replace it when damage occurs.
CAUTION
55
APPENDIX
APPENDIX
APPENDIX A BOLT TORQUE LIST
Bolt Models
M3 M4 M5 M6 M8 M10 M12 M14 M16 M18
(GB/T 70.1)
Tightening Torque 9.01 15.6 37.2 73.5 129 205 319 441
2 4
/N.m (Level 12.9) ±0.49 ±0.78 ±1.86 ±3.43 ±6.37 ±10.2 ±15.9 ±22
APPENDIX B SPECIFICATION OF BOLT

Designed Designed
Nominal Screw Drill Anchor Max. anchor Anti-pull
pulling shearing
diameter dimension diameter depth(mm) thickness(mm) force(kN)
force(kN) force(kN)
M8 φ8×110 φ10 80 13 10.3 12.3 ≥20KN
M10 φ10×130 φ12 90 20 12.3 14.2 ≥30KN
M12 φ12×160 φ14 110 25 16.8 17.5 ≥40KN
M16 φ16×190 φ18 125 35 28.9 35 ≥60KN
M20 φ20×260 φ25 170 65 50.1 51.5 ≥90KN
M24 φ24×300 φ28 210 65 75.5 80 ≥140KN
M30 φ30×380 φ35 280 70 121.3 163.7 ≥200KN
M33 φ33×420 φ38 300 90 135 182 ≥260KN
31
REVISION RECORD
APPENDIX C ER8-1450-HW Suggested spare parts list（for single unit）

S/N Material code Name Qty. Remark
1 12700000375 Robot servo motor（J1、J2-axis） 2
2 12700000376 Robot servo motor（J3-axis） 1
5 31500000010 Lithium battery LS14500[No leads, no plugs] 6
6 G5400000323 Timing belt（J4-axis） 1
APPENDIX D ER8-1500-CW Suggested spare parts list（for single unit）

6 51200000103 Sunmoon_3.6V/AA/ER14505_Wuhan Zhongyuan 6
APPENDIX E ER8-2000-CW Suggested spare parts list（for single unit）

APPENDIX F ER8-2000-HW Suggested spare parts list（for single unit）

APPENDIX G ER8-2000-HW Suggested spare parts list（for single unit）

33
REVISION RECORD
REVISION RECORD
Revision Date Contents
01 2021.07 New edition.
02 2022.01 Modify 5.5 Robot lubrication notes.
03 2022.07 Add ER8-1500-CW、ER8-2000-CW、ER8-2000-HW
04 2022.09 Add ER8-2000-HW-T，Update the connection to the control unit.
34
33

ESTUN Arc Welding Robot - EWAS Series Robot Body Operation Instructions M1201EN-04

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ESTUN Arc Welding Robot- EWAS series

Robot Body Operation Instructions

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

Service Line: 400-025-3336

DEFINITION OF SAFETY NOTATIONS

！ Make sure there is a CO2 fire extinguisher at hand.

！ Install a safety valve in case of accident.

SAFETY OF THE TOOLS AND PERIPHERAL EQUIPMENT

SAFETY OF THE ROBOT MECHANICAL UNIT

STOP TYPE OF ROBOT

Fig 0.1 Electric Shock Warning

Fig 0.2 High-temperature Warning

Fig 0.3 Step-on prohibitive Warning

Fig 0.4 Personal Injury Warning

Fig 0.5 No Disassembly Warning

Fig 0.6 ER8-1450-HW Transport Identification

Fig 0.7 ER8-1500-CW Transport Identification

Fig 0.8 ER8-2000-CW Transport Identification

Fig 0.9 ER8-2000-HW、ER8-2000-HW-T Transport Identification

ESTUN Robot Ewas Series - Mechanical Unit Operator’s Manual

1. TRANSPORTATION AND INSTALLATION

Position J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis

M8 screw mounting hole*2 M8 screw mounting hole*2

M8 screw mounting hole*2

Fig 1.2 Robot fixed bracket(ER8-1500-CW)

M8 screw mounting hole*2

M8 screw mounting hole*2

M8 screw mounting hole*2

Fig 1.1 Robot fixed bracket（ER8-2000-CW）

M8 screw mounting hole*2

M8 screw mounting hole*2

M6 screw mounting hole*2

M8 screw mounting hole*2

Fig 1.2 Robot fixed bracket（ER8-2000-HW、ER8-2000-HW-T）

Rotate horizontally Rotate vertically

Rotate horizontally Rotate vertically

Horizontal force Fh Torque Mr Vertical force Fv Torque Mk

Emergency stop 4800 N 3750 N·m 5500N 4165N·m

Rotate horizontally Rotate vertically

Horizontal force Fh Torque Mr Vertical force Fv Torque Mk

Emergency stop 10800 N 9900 N·m 11500N 8575N·m

Rotate horizontally Rotate vertically

Horizontal force Fh Torque Mr Vertical force Fv Torque Mk

Emergency stop 11700 N 9900 N·m 11750N 8575N·m

Fig 1.12 Robot base specification(ER8-2000-HW、ER8-2000-HW-T)

Fig 1.13 Robot base mounting dimension(ER8-1450-HW、ER8-1500-CW)

Fig 1.14 Robot base mounting dimension(ER8-2000-CW、ER8-2000-HW、ER8-2000-HW-T)

Tab 1.3 Robot fixing components

Through Through J1-axis rotation center

Base mounting screws

Base mounting screws

Tightening torque: 150N.m

Through Through J1-axis rotation center

Base mounting screws

Base mounting screws

Tightening torque: 150N.m

1.3 INSTALLATION CONDITIONS

2.CONNECTION WITH THE CONTROLLER

Fig 2.1 Cable connection

M8 screw mounting hole2 M8 screw mounting hole2