Shenzhen Elephant Robotics Technology Co., Ltd.

Elephant Robotics User Manual
Elephant Series Robot

Version 2.0
Language: English
Compiled in 2019/01© Copyright 2017-2019 Shenzhen Elephant Robotics Technology Co., Ltd.
All rights reserved.

Shenzhen Elephant Robotics Technology Co., Ltd.

Copyright Declaration
No unit or individual may extract, compile, translate or reproduce any
contents of this manual (eg: technical documentation, software, etc.), nordisseminate in any form (including materials and publications) without thewritten permission of Shenzhen Elephant Robotics Technology Co., Ltd.
(hereinafter referred to as “Elephant Robotics”).
In addition, the product information and related resources mentioned inthis manual are for reference only and the contents are subject to change
without notice.
Except as expressly stated in this manual, nothing in this manual should beconstrued as any warranty or guarantee by the Elephant Robotics of personalloss, damage to property, or fitness for a particular purpose.
All rights reserved!

Shenzhen Elephant Robotics Technology Co., Ltd.

Catalog
Overview of the manual...........................................................................................................................1
About the manual............................................................................................................................1
Reading objects of the manual.........................................................................................................1
How to use....................................................................................................................................... 1
Main contents of the manual............................................................................................................1
Before the official reading of the manual........................................................................................ 2
1 Security................................................................................................................................................. 3
1.1 Introduction................................................................................................................................3
1.2 Safety alert symbol description..................................................................................................3
1.3 Hazard identification..................................................................................................................4
1.4 Safety Precautions......................................................................................................................6
1.5 Label, nameplate introduction................................................................................................... 7
1.5.1 Nameplate....................................................................................................................... 7
1.5.2 Label............................................................................................................................... 8
1.6 Avoid misuse............................................................................................................................. 9
1.7 Emergency stop....................................................................................................................... 10
1.7.1 Emergency button.........................................................................................................10
1.7.2 Collision checking........................................................................................................ 10
1.8 Urgent handling....................................................................................................................... 11
2 About product..................................................................................................................................... 12
2.1 Overview of the robot system..................................................................................................12
2.2 Robot....................................................................................................................................... 122.2.1 Characteristics of the robot...........................................................................................122.2.2 Model............................................................................................................................132.2.3 Introduction to the robot parts...................................................................................... 13
2.3 Scope of work..........................................................................................................................14
2.4 Active load...............................................................................................................................15
2.5 Technical Parameter Table...................................................................................................... 17
3 Environment and installation..............................................................................................................19
3.1 Transportation and storage...................................................................................................... 19
3.2 Open box examination.............................................................................................................19
3.3 Working environment and conditions..................................................................................... 20
3.4 Installation............................................................................................................................... 20
3.4.1 Installation requirements.............................................................................................. 20
3.4.2 Installation.................................................................................................................... 20
3.5 Electrical connections..............................................................................................................24
3.5.1 Cable connection.......................................................................................................... 24
3.6 System startup debugging........................................................................................................25
3.7 IO Board.................................................................................................................................. 26
3.7.1 IO board introduction................................................................................................... 26
3.7.2 IO port principle and application..................................................................................31
4 Calibration.......................................................................................................................................... 34
5 Maintenance........................................................................................................................................35
5.1 On the safety of maintenance.................................................................................................. 35
5.2 Maintenance plan.....................................................................................................................36
5.3 Who to contact.........................................................................................................................36
6 Repair..................................................................................................................................................37
Appendix 1 CE Qualification................................................................................................................ 38

Shenzhen Elephant Robotics Technology Co., Ltd.

Overview of the manual
About the manual

Welcome to use Elephant series robot and thanks for your purchase.
This manual describes the precautions for proper installation and use of the
Elephant series robot.
Please read this manual and other related manuals carefully before
installing this robot system. After reading, please keep it in a safe place so thatyou can access it at any time.

Reading objects of the manualThis manual is targeted to:
installer.

Debugger.

Maintenance staff.

Those who install/debug/maintain the Elephant series robot must be trained in
Elephant Robotics and have the mechanical and electronic knowledge required forthe above work.

How to use
This manual should be used when doing the following works:
Installation work: Move the robot to the working position and fix it tothe base according to the installation instructions.

Debugging: Debugging the robot to work status.
Maintenance work: regular maintenance robot system to ensure its
normal functioning. When the robot malfunctions due to environmental
influences or improper operation of the user, or a certain component of
the robot system exceeds the normal service life, the robot needs to be
repaired.

Main contents of the manualPrecautions for safe use of the robot.
Mechanical, electrical installation and commissioning of the robot.
Maintenance and repair of the robot.
1Shenzhen Elephant Robotics Technology Co., Ltd.

Before the official reading of the manual
Before you officially read the manual, you need to know:
1. About the robot system
Elephant series robot is the first robotic product series launched by
Elephant Robotics. The robot system includes a collaborative robot body, acontroller (Core control system), and a teach pendant (RoboFlow operating
system). It can work safely with workers and independently complete theprocesses of loading, unloading, testing, testing and packaging in industrial
manufacturing.
2. About product warranty
During the warranty period of the delivered product, the company will only
repair the failures that occur when the robot is normally used. However, in thefollowing cases, the customer will be charged for repairs (even during thewarranty period):
1) Damage or malfunction caused by incorrect use and improper use of themanual.
2) Failure caused by unauthorized removal by the customer.
3) Damage caused by improper adjustment or unauthorized repair.
4) Damage caused by natural disasters such as earthquakes and floods.
Therefore, please operate the robot in strict accordance with the
instructions in this manual and related manuals.
3. About help
For any questions or suggestions on the contents of the manual, you canquery on the official website of the Elephant Robotics to submit the relevant
information: https://www.elephantrobotics.cn.

2Shenzhen Elephant Robotics Technology Co., Ltd.

1 Security
1.1 Introduction
1，Introduction to this chapter
This chapter details general safety information for people who perform
installation, maintenance, and repair work on Elephant series robot. Please readand understand the contents and precautions of this chapter before handling,
installation and use.
As described in GB 11291.1-2011, whether it is a robot manufacturer,
system integrator, or individual user, it is necessary to carry out hazard
identification and risk assessment before using the robot. It is required to
conduct a hazard analysis to identify any hazards that may arise; and for hazards
identified in hazard identification, a risk assessment should be performed tomaximize personal safety and property safety.
This chapter provides a basic guide to safe use by introducing different
safety alert symbols and precautions.
2，Interpretation of related terms
1) Collaborative operation
A specially designed robot that works directly with people in a defined
workspace.
2) Collaborative workspace
In the safety protection space of the robot work unit, the robot and theperson can complete the task at the same time in the production activity.

1.2 Safety alert symbol description
As shown in Table 1-1, this section describes the safety alert symbols usedin this manual. You can find the corresponding symbols described in thischapter in other chapters, please note the meaning of these symbols and their
meanings.
Table1- 1 Safety Warning Symbol Table
Danger: A dangerous situation that is likely to result in death or serious
injury if not avoided.

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WARNING: Conditions that may cause a hazard that, if not avoided,
could result in personal injury or serious damage to the equipment.

Be careful of electric shock: It may cause dangerous use of electricity. If it
is not avoided, it may cause personal injury or serious damage toequipment.

Prohibited: Things that are not allowed to do.

Caution: Important things to be noted.

1.3 Hazard identification
The safety of the collaborative robot is based on the premise of proper
configuration and use of the robot, and even if all safety instructions areobserved, the injury or damage caused by the operator may still occur.
Therefore, it is very important to understand the safety hazards of robot use,which is beneficial to prevent problems before they occur.
For example, as shown in the “Watch Your Hand” picture shown in Figure
1-1, placing your hand at the link of the link (such as the gap at the 1-2 axis
connection) may cause the fingers to be pinched.

Figure 1- 1 Watch Your Hand

Tables 1-2~4 below are common safety hazards that may exist in thecontext of using robots:4

Shenzhen Elephant Robotics Technology Co., Ltd.

Table1- 2 Dangerous safety hazards

1 Personal injury or robot damage caused by incorrect operation during robot handling.
Personal injury or robot damage caused because the robot is not fixed as required, for
2 example, the screw is not screwed or tightened, and the base is not enough to stably
support the robot for high-speed movement, causing the robot to tip down.
Failure to perform proper safety function configuration of the robot, or installation of3
safety protection tools, etc., may cause the safety function of the robot to fail.
Table1- 3 Warning level security risks

1
2
3
4
5

6
7

Play around the robot, you may be hit by a running robot, or be tripped by an obstacle
such as a cable to cause personal injury.
Unauthorized personnel change the security configuration parameters, causing thesafety function to fail or danger.
Scratches and punctures caused by sharp surfaces such as other devices in the work
environment or robot end effector.
The robot is a precision machine and pedaling may cause damage to the robot.
If the clamp is not in place or before the power supply of the robot is turned off or thegas source is turned off (it is not determined whether the end effector firmly holds theobject without falling off due to loss of power). If the clamped object is not removed,
it may cause danger, such as people being injured by crashing.
There is a risk of accidental movement of the robot. Under no circumstances should
you stand under any axis of the robot!
The robot is a precision machine. If it is not placed smoothly during handling, it may
cause vibration and may cause damage to the internal components of the robot.
Table1- 4 Potential safety hazards that may result in electric shock

1
2
3
4

Using a non-original cable may pose an unknown hazard.
Contact with liquids by electrical equipment may result in a risk of electric leakage.
There may be an electric shock hazard when the electrical connection is incorrect.
Be sure to handle replacement work after turning off the power to the controller and5Shenzhen Elephant Robotics Technology Co., Ltd.

related equipment and unplugging the power cord. If the work is performed while thepower is on, it may cause electric shock or malfunction.

1.4 Safety Precautions
In general, compared with ordinary machinery, robots have thecharacteristics of larger working range and faster speed, so they areaccompanied by the dangers that ordinary machinery does not have. Wheninstalling, using, and maintaining the robot, please pay attention to thefollowing items shown in Table 1-5 and Table 1-6 (the followings are some of
the common precautions listed):
Table1- 5 Safety precautions on acts that need to be banned

12
3

It is forbidden to modify the robot or use non-original accessories.
Untrained non-professionals are prohibited from entering the robot work area at will,pressing any button or doing other operations at will.
The relevant personnel shall not maintain, repair or use the robot after being affectedby drinking, taking drugs or stimulating drugs.
Table1- 6 General safety precautions

1
2
3

4

Anyone responsible for installing and maintaining the robot must read and follow
these safety instructions.
Ensure that safety measures and robot safety configuration parameters are defined as
required in the risk assessment to protect programmers, operators, and bystanders.
Production operators should not loosen long hair (long hair must be picked up) andwear a work cap, not wearing jewelry.
Operators operating in conjunction with the robot must be familiar with andunderstand the content and exact location of the various warning signs and warning
symbols on the equipment and ensure that all warning signs and warning symbols arecomplete and clear, and that all safety devices are secured before opening and starting
the equipment. And make sure the relevant accessories are normal and no one is in adangerous location where the equipment is activated. When the robot runs
abnormally, it should be stopped immediately and the situation must be reported it in6Shenzhen Elephant Robotics Technology Co., Ltd.

5

6
7
8
9
10
11
12
13
14
15
16
17
18

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time.
The operator must clarify the scope of operation, commissioning, maintenance andrepair. The operator is not allowed to change the operating procedures and trials atwill, and other personnel are not allowed to enter the collaborative operation spaceand danger zone.
When repairing work, operators must hang the warning sign to enter the collaborative
operation space.
When the operator enters the safety zone of the equipment protected by the safety
guard door, it shall be absolutely guaranteed that the safety guard door will always
open when working in the area, and the door must be in an unlocked position.
When the operator is in production, it should be ensured that each starting device isnormal and cannot be started at will.
When the maintenance and operation personnel perform maintenance on theequipment, the main power switch must be turned off to perform maintenance work.
No items should be stacked in the robot working area, and no debris should be placedin the control box.
After the operation is completed, the safety protection door should be closed
immediately, and the various switches of gas and electricity should be closed
according to the procedure, and the work site should be cleaned up.
Do not shake the robot and hang heavy objects on the robot.
No dangerous behaviors or games around the robot.
After installing the robot, make sure the robot is fixed on a stable surface forsubsequent operations.
Make sure that the robot does not collide with itself or other objects during running.
If the robot is damaged, do not continue to use it.
Please use the robot within the robot's parameter range and service life, otherwise it
will cause serious safety problems.
After the emergency stop state is canceled, and before the servo power is turned on, it
is necessary to remove the obstacles and faults that cause the emergency stop, andthen turn on the servo power.
Please pay attention to the rotating shaft of the robot to prevent the cable and the airtube from being entangled. Keep a distance from the shaft to prevent hair or clothingfrom getting entangled.

1.5 Label, nameplate introduction
1.5.1 Nameplate
There are two types of nameplates used in the robot system, as shown in
Figures 1-2~3, which are the nameplates of the robot body and controller. The
nameplate records some basic information about the product. It should be notedthat the production number on the nameplate is unique. That is to say, eachproduct has a unique ID, which is an important basis for distinguishing each7Shenzhen Elephant Robotics Technology Co., Ltd.

product, and is also important information to be provided when applying for
maintenance. The nameplate shows that the Elephant 5 robot has passed CE
certification and the certificate is attached to Appendix 1 of this manual.

Figure 1- 2 Nameplate of the robot

Figure 1- 3 Controller nameplate

1.5.2 Label
1，Label on the robot body
In order to facilitate the operator to distinguish the direction of motion ofeach axis, a label as shown in FIG. 1-4 is attached to the robot body to indicate
the direction of motion of each axis.

8Shenzhen Elephant Robotics Technology Co., Ltd.

Figure 1- 4 Labels defining the direction of motion of each axis on the body

2，Label on the robot controller
Robots are high-precision equipment, and they are more dangerous thanordinary machines when they are unfamiliar or not in accordance with themanual. As shown in Figure 1-5, the labels are attached to the controller toremind the operator to read the relevant operating manual before use.

Figure 1- 5 Reading manual before the operation

The controller provides the power supply of the entire robot system, so it
must be operated correctly to prevent electric shock. Figure 1-6 is the anti-shockwarning label attached to the controller, in order to remind the operator to notice
the danger of electric shock when touching it. It needs to be used correctly toprevent electric shock.

Figure 1- 6 Label to caution preventing electric shock

1.6 Avoid misuse
Please do not use the Elephant series robot for the following purposes.
 Medical and life-critical applications.
 In environment that may cause an explosion.
 Used directly without risk assessment.
 Insufficient use of safety function levels.
 Inconsistent use of robot performance parameters.
9Shenzhen Elephant Robotics Technology Co., Ltd.

1.7 Emergency stop
This section describes two types of emergency stop for robots:
 If you feel abnormal during the robot's motion, immediately press the
emergency stop switch.
 When the force generated by the collision of the robot with the person
or object is greater than the threshold, the robot detects the force
generated by the collision, thereby stopping or moving to a certain
position (collision return).
1.7.1 Emergency button
When the emergency stop button on the teach pendant is pressed, the drive
will be stopped, the brake will start, the motor power will be turned off, and theelectromagnetic brake will stop the robot's inertial motion, the robot will stop all
motion, the program running in RoboFlow. It will also be stopped.
However, during normal operation, do not press the emergency stop switch
at will. If the emergency stop switch is pressed during the operation, the robot
movement trajectory before stopping will be different from the trajectory during
normal operation and may hit a peripheral device or the like.
When the vehicle is in an emergency stop state (normal), if the robot
system is to be placed in an emergency stop state, press the emergency stop
switch when the robot does not operate.
Before using the emergency stop switch, you need to know the followings:
 The emergency stop (E-STOP) switch can only be used to stop therobot in an emergency.
 To stop the robot running the program in a non-emergency situation,
use the Pause or STOP command. The Pause and STOP commands
will not turn off the motor. Therefore, the brake will not work.
 Do not use the E-STOP circuit for safety system.
1.7.2 Collision checking
During the operation of the robot, it is possible to touch people or objects.
It can be protected by setting a protection threshold. The specific operation
mode is as follows: When the force generated by the collision of the robot withthe person or the object is greater than the threshold, the robot detects the force
generated by the collision, thereby stopping or moving to a certain position(collision return).
Please note that when the protection threshold is set too high, a large force
is required to stop the robot, which will reduce the sensitivity of the collision
detection to a certain extent. When the protection threshold is set too low, the10Shenzhen Elephant Robotics Technology Co., Ltd.

robot may stop when it is holding the load due to the excessive torque generated
by its own motion. Please set the threshold of protection under guidance.
In addition, you can set the protection threshold for each movement andeach movement of the robot, and set the two protection threshold directions
including the X-Y plane (horizontal direction) and the Z plane (verticaldirection).

1.8 Urgent handlingIf the software pops up with a fatal error message, please activate the emergency
stop quickly, write down the condition that caused the error, and contact yoursupplier.
In the event of a fire, use a carbon dioxide (CO2) fire extinguisher!

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2 About product
2.1 Overview of the robot system
As shown in Figure 2-1, in the Elephant series of robots, each robot system
consists of three main components: the robot body (also known as the
manipulator), the controller and the teach pendant.

1-The robot

2- Controller

3-Teach pendantFigure 2- 1 Robot system

The robot body is a mechanical body used to complete various tasks of therobot system, and mainly includes a robot casing, a driving device, atransmission unit, and an internal sensor. The main material of the robot casingis aluminum alloy. The robot's principle of motion is a combination of rotationalmotions of six joints. Using kinematics and dynamics analysis, the algorithm issolved to achieve the desired motion at the end of the robot.
The controller's structural realization of the robot control function is a key
part of determining the function and level of the robot. It is loaded with a powersource, a computer, etc., which can control the overall movement of the robot.
The teach pendant is the main interface of human-computer interaction,and its internal part is composed of a touch screen display, a control circuitboard and some components. The robot can be programmed and operated byusing a teach pendant.
In short, if the robot system is like a human, then the controller is like ahuman brain, controlling the robot body (like a human hand) to perform tasks,
and the teach pendant is the human-machine interface that the robot systemcommunicates with people.

2.2 Robot

2.2.1 Characteristics of the robot
The Elephant series robot have the advantages of short deployment time,12Shenzhen Elephant Robotics Technology Co., Ltd.

easy operation, safe use and convenient expansion of peripheral equipment,
which can greatly shorten the deployment time of the factory for automation
project transformation and reduce the total cost of deployment. The specificdescription is as follows:
1，Easy to deploy
In order to shorten the transformation cost and deployment time of theautomated production line, the Elephant Robotics's products are mainly oriented
to the upgrade and transformation of independent stations compared to the
traditional robotic deployment of the entire automated production line. The
customer or system integrator can choose the adapted end effector, radar orcamera to match the robot.
2，Easy to operate​ RoboFlow and our solutions help engineers design a stand-alone
workstation as soon as possible to install end-executing systems, stands,
cameras and other equipment.
3，Safe and reliable
Our security function is a top priority. Elephant series collaborative robots
have common safety collision detection, and also have Safety Equipment suchas Elephant Safety Vision, Lidar, and Grating to ensure a stable and reliable
safe working environment.
2.2.2 ModelAt present, the model of the Elephant series robot is only one type of
Elephant 5, and the model name is analyzed as shown in Table 2-1.
Table 2- 1 Model description table
Elephant
5
Elephant series
Load capacity 5kg

2.2.3 Introduction to the robot parts
The Elephant 5 single-arm collaborative robot is a robot with a load of 5kg
and a movable range of 810mm. It can be repeatedly positioned with anaccuracy of ±0.05mm. It can make production on an independent station: it canbe used for loading, unloading, testing, testing and packaging. The Elephant 5
robot can work safely with the workers. The schematic view and side view of
the robot body are shown in Figure 2-2.
The mechanical body of the Elephant 5 robot can be thought of as an openchain multi-link mechanism. The start link is the base of the robot, the end link
is connected to the end effector, and the adjacent links are connected by a joint.
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The Elephant 5 robot is a 6-degree-of-freedom industrial robot consisting of 6
links and 6 joints (axes). When numbered, the base is called the link 0 and is notincluded in the six links. The link 1 is connected to the base by the joint 1, thelink 2 is connected to the link 1 through the joint 2, and so on.

Figure 2- 2 Schematic diagram of the robot

The flange can be used to connect an end effector, such as an electricgripper or a pneumatic suction cup.

2.3 Scope of work
The working space of the Elephant 5 robot is shown in Figure 2-3. The
effective range of the robot is 810mm. Please measure the actual range of robot
motion before using the robot to avoid the possibility of insufficient arm length
or collision.

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Figure 2- 3 Range of motion of the robot

2.4 Active load
The active load schematic diagram of the Elephant 5 robot is shown in
Figure 2-4. The active load representation is shown in Figure 2-5. As the load
moves further and further away from the J6 flange position, its active load will
become smaller and smaller.

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Figure 2- 4 Load representation

Figure 2- 5 Active load

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2.5 Technical Parameter TableThe specifications of the Elephant 5 robot are shown in Table 2-2.

PayloadReach
Degrees of freedom
Working range

Table 2- 2 Technical Parameter
Elephant 5 Robot
5kg
810mm
6
J1/J4/J6:±180°
J2/J3/J5:±120°

Axis maximum speed
WeightPosition repeatability

225°/sec
23kg±0.05mm

Dimensions robot base
Programming mode
IP classification
Power consumption

φ180mmGraphical programming
IP42
260W（Typical）

Materials

Aluminium alloy，ABS，Rubber

Operating temperature range

0-50℃

Collaboration operation

Test in accordance with：EN ISO 13849:2006 PL d
EN ISO 10218-1: 2011-Clause 5.4.3

Noise
Robot mounting
Relative humidity
Size（L×W×H）
WeightPower supply
IP classification
Certificate
Interface and openness
I/O ports
I/O power supply
Communication
Size（L×W×H）<70dB
Any angle
5%-95%
Controller
545mm×285mm×433mm
25kg
AC 110-240V，50-60Hz
IP40
CE certificate
SDK(Python, C++,JAVA),API,ROS
Digital Input:16
Digital Ouput:16
24V 2A
TCP/IP
Teach Pendant
255mm×230mm×90mm
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WeightScreen resolution
IP classification
Screen size

1.8kg
1024×768
IP20
10.4ʺ

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3 Environment and installation
3.1 Transportation and storage
Since the robot is a precision device, please pay special attention to theprotection of the device during transportation.
Avoid applying external force to the robot's body and motor.
When transporting the robot over long distances, it is necessary to fix it to thehandling device to prevent the robot from tipping over. If necessary, use thepackaging at the time of delivery.
If the robot produces condensation during transportation/storage, turn the power onafter removing condensation.

When transporting before installation, in principle, lifting equipment suchas bridge crane should be used. Since the mass of the main body is not heavy,
manual handling can also be considered without lifting equipment. Pay attention
to safety when handling by hand, and take it with care to avoid damage to theequipment.
Please use heavy lifting equipment such as driving as much as possible, and be
careful of the people standing around to prevent the machine from rolling over.
When carrying the Elephant 5 robot manually, the number of personnel must not
be less than two.
The Elephant 5 robot is a precision device, so avoid excessive vibration and shock
when handling.
The weight of the Elephant 5 robot body is 23 kg.
If the sling is used to lift the robot, in order to avoid the appearance damage of therobot, place a thick cloth in the place where the sling is in direct contact, and try to
avoid the person standing under the robot body being lifted.
The robot cable and power must be disconnected before handling.

The storage environment temperature of the robot is +0°~+50°, and a
special person shall be responsible for keeping it.

3.2 Open box examination
When the packing box is in place, please confirm that the robot package is
intact. If there is any damage, please contact the logistics company and ourcompany in time.
After unpacking, check the actual items in the box according to the list ofitems.
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3.3 Working environment and conditions
Please set up the robot system in the environment that meets therequirements stated in table 3-1, in order to play / maintain the performance ofthe machine and use it safely.
Temperature
Relative humidity
Indoor and outdoor
requirements

Table 3- 1 Working environment and conditions-10℃~+50℃
20%~70%

Other environmental
requirements

Indoor
- Avoid sun exposure.
- Keep away from dust, oil smoke, salt, iron filings, etc..
- Keep away from flammable, corrosive liquids and gases.
- Do not come into contact with water.
- Do not transmit shocks, vibrations, etc.
- Keep away from sources of strong electromagnetic
interference.

3.4 Installation
3.4.1 Installation requirements
The actual weight of the Elephant 5 robot is 23 kg. Considering the
movement of the robot, the center of gravity will move as the robot moves.
Therefore, the robot needs to be fixed on a solid base to be used normally. Baseweight requirements: fixed base, or mobile base.
 The installation angles of the robot include vertical, inverted, side
mounted angles, etc.
 Table 3-1 shows the installation environment.
 The installation position must not be less than the working range of therobot, as shown in Figure 2-3.
3.4.2 Installation
1，Interface size of robot base
The fixing hole of the base is the interface between the fixed robot andother bases or planes. It is 4 through holes with a diameter of 8mm. It can be
fixed with M8 bolts (equipped with M8 bolts and matching gaskets and nuts inthe package). The bolt specifications are shown in Table 3-2:

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Table 3- 2 Specifications of robot base fixing screw
Bolt specification
M8
Select based on the thickness of the platform of the base
Bolt length
mounting robot
Strength
12.9
Tightening torque
28Nm (recommended using a torque wrench for fastening)

The specific hole size is shown in Figure 3-1. Make sure that there is acorresponding threaded hole on the fixed base before installing.

Figure 3- 1 The specific hole size2，

Mount the robot on the base
Before you officially install, please confirm: The environment to be installed complies with the requirements ofTable 3-1.
 The installation position is not less than the working range of the robot,
and there is enough space for installation, use, maintenance and repair.
 Place the stand in the proper position.
 Installation related tools are ready, such as screws, wrenches, etc.
After confirming the above, move the robot to the mounting surface of thebase, adjust the position of the robot, and align the fixing hole of the robot basewith the hole on the mounting surface of the base.

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When adjusting the position of the robot on the mounting base, please avoid
pushing the robot directly on the mounting surface of the base to avoid scratches.
When manually moving the robot, please try to avoid applying external force tothe weak part of the robot body to avoid unnecessary damage to the robot.

After aligning the holes, align the screws with the holes and tighten.
As long as the robot is not yet firmly mounted on the base, the robot may be indanger of falling over. Please keep the balance of the robot.

3，Place controller, teach pendant
The outline of the controller as shown in Figure 3-2.

Figure 3- 2 Controller dimensions

Please determine the placement position according to the actual size of thecontroller. Note that there should be no items to block the cooling fan of thecontroller, so as not to affect the heat dissipation effect. A better heat dissipation
effect is beneficial to improve the working life of the controller.
There are four foot cups in the base of the robot controller for smoothplacement of the controller. For the position of the specific cup, please refer to22Shenzhen Elephant Robotics Technology Co., Ltd.

the following figure. Please place the controller smoothly to prevent themachine from tilting and injuring people or objects.
The teach pendant can be hung on the side of the robot controller or placed
on top of the controller.
When placing the robot controller, be careful not to keep its distance from therobot body beyond the length of the connecting cable.
Choose the placement position of the controller, try to avoid possible problems
such as the controller being bumped or close to the wall not conducive to heatdissipation.

Figure 3- 3 Installation diagram

4，Install the end effector to the robot flange
The end effector is a device specially designed and installed at themechanical interface for the robot to perform its tasks. For example, grippers,
wrenches, welding torches, spray guns, etc.. The specific flange size is shown in
Figure 3-4.

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Figure 3- 4 Flange size

To install the end effector to the robot flange, there are two cases. One isthat the end effector interface corresponds to the flange mechanical interface
size; the other is to use the adapter that meets the size requirements of theconnection interface for connection.

3.5 Electrical connections
3.5.1 Cable connection
There are four cable lines used in the robot system. The specificinformation is shown in Table 3-3.
Type
Controller power
cord
Teach pendant
Robot power line
Robot signal line

Table 3- 3 Main cables of the robot
Connection
LengthUse description
External power
Power supply to the entire robot
2m
supply - controller
system.
ProvidecontrollerController - teach4m
demonstration
information
pendant
exchange channels.
Controller-robot
4m
Mainly to drive the robot motor.
It is to collect and analyze theController-robot
4m
encoder information.

The original cable must be used.
The cable interface is generally easy to damage. Do not use brute force orvigorously shake when plugging or unplugging. It is easy to cause the interface toloose or deform. Please insert and remove it carefully after alignment.
24Shenzhen Elephant Robotics Technology Co., Ltd.

Be sure to make replacement after turning off the power to the controller andrelated equipment and unplugging the power cord. If the work is performed while
the power is on, it may cause electric shock or malfunction.
Be sure to connect the AC power cable to the power plug. Do not connect directly
to the factory power supply. Turn off the power to the robot system by unplugging
the power cord. It is extremely dangerous to work when the AC power cable isconnected to the factory power supply, which may result in electric shock andmalfunction of the robot system.
Be careful not to bend the cable forcibly to avoid applying a load to the cable.
Also, do not place heavy objects on the cable and forcibly bend or pull the cable.
Failure to do so may result in damage to the cable, disconnection, or poor contact,
electric shock or improper system operation.
Before wiring, turn off the power of the controller and related devices and pull up
the warning sign (eg, do not turn on the power). Wiring under power-on conditions
is extremely dangerous and may result in electric shock and malfunction of therobot system.
Please ensure that the ground wire connection is reliable, otherwise it may cause
fire or electric shock.

3.6 System startup debugging
After the installation and connection work is completed, user need to plugin the power cord, turn on the power switch, press the system start button of theteach pendant. After that, user should observe whether the display button of theteach pendant is lit. If the light is on, it means the installation is successful, you
can go to the next step. Otherwise user need to check if an important step ismissing. If it is unsuccessful according to the manual, the malfunction may becaused by a malfunction during transportation. Do not disassemble the parts by
yourself. Please contact a professional for disposal.
Robot system boot flow chart as shown in Figure 3-5. Please strictly follow
the manual, otherwise the warranty will not be available if the robot is damaged
due to improper operation.

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Figure 3- 5 Robot system boot flow chart

3.7 IO Board
3.7.1 IO board introduction
Figure 3-6 shows the IO board port of the Elephant 5 robot. Port details areshown in Tables 3-4~8.

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1- Serial port
5- Digital input 8~11
9- Ethernet interface
13- Digital output
12~15

2- External control
port
6- Digital input
12~15
10- Digital output
0~3
14- DC power port

3- Digital input 0~3

4- Digital input 4~7

7- External E-STOP port

8-USB port

11- Digital output 4~7

12- Digital output
8~11

Figure 3- 6 IO board port description

The Elephant 5 robot provides common communication interfaces, powerinterfaces, general purpose IO ports, and dedicated IO ports. Among them, theuniversal IO port includes 16 digital input signals and 16 digital output signals
for interaction with other devices, and together with other devices constitute animportant part of the automation system.
For example, the user can use the digital output signal to control theelectric jaws installed on the output flange, or connect to the PLC for signal
interaction.
1，Communication port
As shown in Table 3-4, the IO board provides three communication
methods, namely serial communication, USB communication, and Ethernet
network port communication.

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No.

1

Table 3- 4 IO port description table 1（Communication port）
Type
Port
Definition
Description

Serial port0

GND

Signal ground（RS232）

1

232RX

Receive data（RS232）

2

232TX

Send data（RS232）

3

485D+

Receive data（RS485）

4

485D-

Send data（RS485）

8

USB port

-

USB1
USB2

USB port 1
USB port 2

9Ethernet interface-

Ethernet

Ethernet interface

1) Serial communication: The serial port sends and receives bytes in bits.
It’s simple and able to communicate over long distances.
In this IO board, serial communication is divided into RS232 and RS485.
The former occupies the first three ports of the terminal block, and the latteroccupies the last two ports. RS232 is full-duplex, the serial port can receive data
while using one line to send data while using another line. RS485 is half-duplex,
and only one point can be sent at any time. Therefore, the transmitting circuit
must be controlled by an enable signal.
RS485 and RS232 are only differences in the physical protocol ofcommunication (interface standard) . RS485 adopts differential transmissionmode, and RS232 is single-ended transmission mode. But the communication
program doesn't have much difference.
Users can choose one according to actual needs.
2) USB port
Users can use the USB interface to copy program files, or use the USB
interface to connect peripherals such as mice and keyboards.
3) Ethernet interface
Users can use the Ethernet interface for communication between the PC
and the robot system, or for Ethernet communication with other devices.
2，Control signal port
As shown in Table 3-5, the IO board provides the control signal port.

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No.

2

7

Table 3- 5 IO port description table 2（Control signal port）
Type
Port
Definition
Description

External control port

External emergency
stop port

0

SS1Emergency stop control signal 1

1

SS2

Emergency stop control signal 2

2

START

START

3

STOP

STOP

4

COM0

Common port 0

0

Null

Undefined

1

ES1+

2

ES1-

External emergency stop control
signal 1

3

ES2+

4

ES2-

External emergency stop control
signal 2

With these ports, external devices can control the system's emergency stop
loop. It is also possible to control the start and stop of the program. These ports
makes it easy for the user to control the robot system as a link in the automatic
control system.
3，Digital input ports
As shown in Table 3-6, there are general-purpose digital input ports. The
Elephant 5 robot provides 16 digital input signals.
No.

3

4

5

6

Table 3- 6 IO port description table 3（Digital input ports）
Type
Port
Definition
Description0
IN0Digital input signal 01
IN1
Digital input signal 1
Digital input port
2
IN2
Digital input signal 2
0~3
3
IN3
Digital input signal 3
4
COM 1
Common port 1
0
IN4
Digital input signal 41
IN5Digital input signal 5
Digital input port
2
IN6
Digital input signal 6
4~7
3
IN7
Digital input signal 7
4
COM 2
Common port 20IN8Digital input signal 81
IN9Digital input signal 9Digital input port
2
IN10
Digital input signal 10
8~11
3
IN11
Digital input signal 11
4
COM 3
Common port 30IN12Digital input signal 12
Digital input port
12~15
1
IN13
Digital input signal 1329Shenzhen Elephant Robotics Technology Co., Ltd.

2

IN14

3

IN15

4

COM 4

Digital input signal 14
Digital input signal 15
Common port 4

It should be noted that the input common terminal needs to be connected to
the DC 24V power supply. The input port can be active high or active low
depending on the common configuration.
4，Digital output ports
As shown in Table 3-7, there are general-purpose digital output ports. The
Elephant 5 robot provides 16 digital output signals.
Unlike the input port, the internal DC 24V provides 24V directly. The
output is valid at 0V. The peripherals form a complete loop by connecting thetwo ends(output signal and common port), and the peripherals can be controlled
by controlling the state of the outputs.
No.

10

11

12

Table 3- 7 IO port description table 4（Digital output ports）
Type
Port
Definition
Description

Digital output port
0~3

Digital output port
4~7

Digital output port
8~11

0

24V

DC 24V1

OUT0

Digital output signal 0

224V

DC 24V3

OUT1

Digital output signal 1

424V

DC 24V

5

OUT2

Digital output signal 2

624V

DC 24V

7

OUT3

Digital output signal 3

024V

DC 24V1

OUT4

Digital output signal 4

224V

DC 24V3

OUT5

Digital output signal 5

424V

DC 24V

5

OUT6

Digital output signal 6624V

DC 24V7

OUT7

Digital output signal 7

024V

DC 24V1

OUT8Digital output signal 8

224V

DC 24V3

OUT9Digital output signal 930

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13

Digital output port
12~15

4

24V

DC 24V

5

OUT10

Digital output signal 10

624V

DC 24V

7

OUT11

Digital output signal 11024V

DC 24V1

OUT12Digital output signal 12

2

24V

DC 24V3

OUT13

Digital output signal 13

424V

DC 24V

5

OUT14

Digital output signal 14

624V

DC 24V7

OUT15

Digital output signal 15

5，DC power port
As shown in Table 3-8, the IO board provides an internal DC 24V for theuser to use.
No.

Table 3- 8 IO port description table 5（DC power port）
Type
Port
Definition
Description
0

14

DC power port

1

24V
24V

2

24V

3

24V

4
5

GND
GND

6

GND

7

GND

Internal DC power supply 24VInternal DC power supply GND

3.7.2 IO port principle and application
1，Digital input port
As shown in Figure 3-7, the input signal is driven through the currentlimiting resistor R to allow the internal circuit to detect it. The difference
between the PNP input and the NPN input is that one end of the PNP input isconnected to 0V, and one end of the NPN input is connected to 24V.

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Figure 3- 7 Digital input port schematic

Figure 3-8 shows an example of an input connection application. When thecommon port is connected to 24V, once an external device inputs 0V, the input
signal is in the High state, otherwise it is in the Low state. vice versa.

Figure 3- 8 Input application example diagram

2，Digital output port
As shown in Figure 3-9, the output is an NPN output. When the control
signal is high, the triode is activated and the output is connected to GND. Whenthe control signal is low, the triode is blocked and the output is in a floatingstate.

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Figure 3- 9 Digital output port schematic

Figure 3-10 shows an example of an output connection application.

Figure 3- 10 Output application example diagram

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4 Calibration
If the parts of the robot (motor, reducer, timing belt, etc.) are replaced,
there will be a deviation between the origin stored by each motor encoder andthe origin stored by the controller, and the correct positioning cannot be
performed. The origin is the reference of the robot coordinate system. Without
the origin, the robot cannot judge its position. Therefore, in order to obtain thehighest possible absolute positioning accuracy, the robot must be calibrated (theoperation where the two origin positions are the same is called calibration) .
Generally, recalibration is required in the following cases: After replacing the parts of the robot (motor, reducer, timing belt, etc.).
 Collision with the work-piece or environment.
 Move the robot joints without being under the control of the controller.
 Replace the encoder data backup battery.
 Other conditions that may cause zero point loss.
The mechanical origin of the robot is shown in Figure 4-1. The calibration
scale of J6 is not shown in the figure because J6 can set any position as thecalibration position.

Figure 4- 1 Mechanical origin posture34

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5 Maintenance
5.1 On the safety of maintenance
When the robot has been running for a period of time, it is necessary to
carry out necessary maintenance to ensure that the robot's function is normal.
 Be sure to perform robot maintenance by trained personnel.
 Personnel trained in safety refer to those that have been regulated bynational laws and regulations.
 Personnel who are trained in the safety when engaged in industrial
robot-related business (training on knowledge, operation, teaching, etc.
of industrial robots, knowledge of business operations such as
inspections, and related laws and regulations).
 The company's training is for those who have completed theinstallation training and maintenance training.
Before maintenance, please read “Safety on Maintenance”, this manual andrelated manuals, and perform maintenance based on a thorough understandingof safety maintenance methods.
Do not change any information in the software security configuration (such as
force limits). If the safety parameters change, the entire robot system should beconsidered a new system, which means that all safety audit processes, such as risk
assessment, must be updated.
Do not remove any parts unless otherwise stated in this manual. The maintenancesteps shall be strictly adhered to the content. If wrong disassemble or maintenanceis performed, not only will the robot system malfunction, but it may also cause
serious safety problems.
Be sure to check the robot movement after replacing the parts outside the safety
fence. Otherwise, the robot before the action confirmation may perform
unexpected actions and may cause serious safety problems.
All disassembled robots need to be recalibrated.
If you have not received training, keep away from the robot when the power is on.
Also, do not enter the action area. Even if you see that the robot seems to stopmoving, the robot that is powered on may accidentally operate and may cause
serious safety problems.
Before entering the normal operation, please confirm that the emergency stop
switch and the safety guard switch are in normal operation. If the switch does notoperate normally, the safety function cannot be performed in an emergency, which
may result in serious injury or serious damage, which is very dangerous.

35Shenzhen Elephant Robotics Technology Co., Ltd.

Be sure to perform maintenance, replacement, and wiring work after turning off
the power to the controller and related equipment and unplugging the power cord.
Failure to do so may result in electric shock or malfunction.

5.2 Maintenance plan
In order for the robot to maintain efficient performance over the long term,
regular maintenance is required. The maintenance personnel must prepare an
overhaul plan and strictly implement it. The maintenance plan for the Elephantseries robot is shown in Table 5-1.
Table 5- 1 Maintenance schedule
No.

Equipment

Routine1

Robot appearance√

2

Cable interface

3

Motor, reducer
Cable
external
harnesinternalssurfaceScrewinternal

4

Contents

Inspection

5
6
7
8

Clean

Whole robot

9

Replacement

Lubricating oil

10

Battery

1
month

3
months6months

12 months

√
√
√
√
√
√
√
Replace when the gear unit needs to be replaced.
When the battery low warning appears.

5.3 Who to contact
1，System integrator
You can directly contact the system integrator responsible for installingand commissioning the robot.
2，Supplier
You can contact the supplier of Elephant Robotics in your region. For
specific supplier information, please visit the official website:www.elephantrobotics.cn.
3，Official website
You can check out on the official website of the Elephant Robotics(www.elephantrobotics.cn) for more information.

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6 RepairWhen the robot malfunctions, do not continue to operate. Please
immediately contact the operator who has received the prescribed training toperform fault analysis, so as to clearly grasp the phenomenon and determine
what components are abnormal.
Matters on repair, inspection, adjustment, etc. of the robot must be carriedout by an authorized system integrator or agent. Please contact a professional
for disposal. Do not disassemble the robot at will. See section 5.3 for contact
details.
When contacting, please prepare the following items in advance: Controller name, serial number.
 Robot name, serial number.
 Description of problem (preferably with pictures).

37Shenzhen Elephant Robotics Technology Co., Ltd.

Appendix 1 CE Qualification

38