This manual is OMRON's original instructions describing the setup, operations, and user maintenance of the i4H robot robot (herein also referred to as ...
Thank you for purchasing the i4H robot. This manual is OMRON's original instructions describing the setup, operations, and user maintenance.
2 gen 2021 — Ap- propriate safety measures should be taken, such as ear protection and display of a warning sign. • Any moving robot requires some distance to stop. This ...
i4H Robots with EtherCAT User's Manual i4-650H i4-750H i4-850H I661-E-02 NOTE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication. Trademarks Company names and product names in this document are the trademarks or registered trademarks of their respective companies. Copyrights Microsoft product screen shots reprinted with permission from Microsoft Corporation. Introduction Introduction Thank you for purchasing the i4H robot. This manual is OMRON's original instructions describing the setup, operations, and user maintenance of the i4H robot robot (herein also referred to as robot). Please read this manual and make sure you understand the functionality and performance of the robot before attempting to use it. Keep this manual in a safe place where it will be available for reference during operation. Intended Audience This manual is intended for the following personnel, who must also have knowledge of factory automation (FA) systems and robotic control methods. · Personnel in charge of introducing FA systems. · Personnel in charge of designing FA systems. · Personnel in charge of installing and maintaining FA systems. · Personnel in charge of managing FA systems and facilities. Applicable i4H Robot Models The following table lists all applicable i4H SCARA robot series models along with their specifications. Product i4H SCARA robot series Models i4-650H Standard i4-650H Long Quill i4-650H Inverted i4-650H Inverted Long Quill i4-750H Standard i4-750H Long Quill i4-750H Inverted i4-750H Inverted Long Quill i4-850H Standard i4-850H Long Quill i4-850H Inverted i4-850H Inverted Long Quill Units Unless otherwise noted, length dimensions are in millimeters and all units are metric. i4H Robots with EtherCAT User's Manual (I661) 1 Manual Information Manual Information Page Structure The following page structure is used in this manual. A 5 Installation B C CD E 5-1 Unpack This section provides details on how to unpack the Industrial Panel PC. 5-1-1 Unpack Procedure 1 Check the package for damage. If there is any visible damage: · Take photos of the package and save them. · Inform your supplier immediately. 2 Open the package. Ensure not to damage the contents. 3 Ensure that all items are present. Additional Information Refer to 5-1-2 Items Supplied with the Product for the items supplied. 5-1 Unpack B 5 G C 5-1-1 Unpack Procedure F NY-series User's Manual (W555) 5 - 3 H Note: This illustration is provided as a sample. It will not literally appear in this manual. Item A B C D Explanation Level 1 heading Level 2 heading Level 3 heading Step in a procedure Item E F G H Explanation Special Information Manual name Page tab with the number of the main section Page number Special Information Special information in this manual is classified as follows: 2 i4H Robots with EtherCAT User's Manual (I661) Manual Information Precautions for Safe Use Precautions on what to do and what not to do to ensure safe usage of the product. Precautions for Correct Use Precautions on what to do and what not to do to ensure proper operation and performance. Additional Information Additional information to read as required. This information is provided to increase understanding or make operation easier. Version Information Information on differences in specifications and functionality between different versions. i4H Robots with EtherCAT User's Manual (I661) 3 Manual Information 4 i4H Robots with EtherCAT User's Manual (I661) Sections in this Manual 1 Overview 2 Specifications 3 Installation 4 Operation 5 Troubleshooting 6 Maintenance A Appendices Sections in this Manual 1 1 2 3 4 5 6 A i4H Robots with EtherCAT User's Manual (I661) 5 CONTENTS CONTENTS Introduction .............................................................................................................. 1 Intended Audience...........................................................................................................................................1 Applicable i4H Robot Models...........................................................................................................................1 Units ................................................................................................................................................................. 1 Manual Information.................................................................................................. 2 Page Structure.................................................................................................................................................2 Special Information ..........................................................................................................................................2 Sections in this Manual ........................................................................................... 5 Terms and Conditions Agreement........................................................................ 10 Warranty and Limitations of Liability ..............................................................................................................10 Application Considerations ............................................................................................................................ 11 Disclaimers .................................................................................................................................................... 11 Safety Precautions................................................................................................. 13 Definition of Precautionary Information..........................................................................................................13 Symbols .........................................................................................................................................................13 Dangers .........................................................................................................................................................14 Warnings ........................................................................................................................................................ 15 Cautions ......................................................................................................................................................... 18 Precautions for Safe Use ...................................................................................... 19 Precautions for Correct Use ................................................................................. 21 Regulations and Standards .................................................................................. 23 Related Manuals..................................................................................................... 24 Glossary.................................................................................................................. 25 Revision History..................................................................................................... 26 Section 1 Overview 1-1 Intended Use ..........................................................................................................................1-2 1-2 Robot Features.......................................................................................................................1-3 1-2-1 Robot Integrated System ............................................................................................................1-3 1-2-2 Basic Robot Components ...........................................................................................................1-4 1-2-3 Other Components ......................................................................................................................1-6 1-2-4 Front Panel..................................................................................................................................1-7 1-2-5 Connectors ..................................................................................................................................1-9 1-3 Information Labels...............................................................................................................1-12 1-3-1 Robot Label ...............................................................................................................................1-12 1-3-2 Controller Label .........................................................................................................................1-12 1-4 Robot Configurations ..........................................................................................................1-14 1-4-1 i4-650H......................................................................................................................................1-14 1-4-2 i4-750H......................................................................................................................................1-14 1-4-3 i4-850H......................................................................................................................................1-14 1-5 Model Numbers ....................................................................................................................1-15 6 i4H Robots with EtherCAT User's Manual (I661) CONTENTS 1-5-1 1-5-2 Robot Model Numbers ..............................................................................................................1-15 Controller Model Numbers ........................................................................................................1-15 1-6 Optional Hardware ...............................................................................................................1-16 1-6-1 IO Blox ......................................................................................................................................1-16 1-6-2 T20 Pendant..............................................................................................................................1-16 1-6-3 IPC Application Controller .........................................................................................................1-17 1-6-4 XIO Termination Block...............................................................................................................1-17 1-6-5 Optional Cables.........................................................................................................................1-18 1-6-6 eCobra Mount Adapter ..............................................................................................................1-20 1-6-7 Camera Mounting Bracket and Adapter ....................................................................................1-20 1-6-8 eCobra Tool Flange ...................................................................................................................1-21 Section 2 Specifications 2-1 Physical Specifications .........................................................................................................2-2 2-1-1 Robot Overall Dimensions ..........................................................................................................2-2 2-1-2 Cable Clearances........................................................................................................................2-6 2-1-3 Mounting Flange Dimensions......................................................................................................2-6 2-1-4 Tool Flange Dimensions ..............................................................................................................2-7 2-1-5 Front Panel Dimensions ..............................................................................................................2-7 2-1-6 eCobra Mount Adapter Dimensions ............................................................................................2-7 2-1-7 Camera Mounting Bracket and Adapter Dimensions ..................................................................2-8 2-1-8 Robot Weights.............................................................................................................................2-8 2-2 Performance Specifications................................................................................................2-10 2-2-1 General Performance Information .............................................................................................2-10 2-2-2 Stopping Distances and Times..................................................................................................2-10 2-3 Electrical Specifications......................................................................................................2-14 2-3-1 Power Supply Specifications .....................................................................................................2-14 2-3-2 XIO I/O Specifications ...............................................................................................................2-14 2-4 Environmental Specifications.............................................................................................2-16 2-5 Other Specifications ............................................................................................................2-17 2-5-1 Connector and Port Specifications ............................................................................................2-17 2-5-2 Mounting Screws and Torques ..................................................................................................2-17 Section 3 Installation 3-1 Robot Installation Procedure................................................................................................3-2 3-2 Mounting the Robot ...............................................................................................................3-3 3-2-1 Robot Mounting Surface .............................................................................................................3-3 3-2-2 Mounting Procedure ....................................................................................................................3-3 3-3 Installing End-of-Arm Tooling...............................................................................................3-5 3-4 Installing Optional Equipment ..............................................................................................3-6 3-4-1 Mounting External Equipment to the Robot ................................................................................3-6 3-4-2 Tool EtherCAT Connector Wiring ................................................................................................3-6 3-4-3 USER Connector Wiring .............................................................................................................3-7 3-5 Adjustable Hardstop Details .................................................................................................3-8 3-5-1 Joint 1 Adjustable Hardstops ......................................................................................................3-8 3-6 System Cable Installation ...................................................................................................3-10 3-6-1 System Cable Overview ............................................................................................................3-10 3-6-2 System Cable Installation Procedure ........................................................................................3-12 3-7 Connecting Digital I/O .........................................................................................................3-13 3-7-1 XIO Connector Signals and Wiring ...........................................................................................3-13 3-7-2 IO Blox Connections .................................................................................................................3-17 3-8 Installing Safety Equipment................................................................................................3-19 3-8-1 Installing the Front Panel ..........................................................................................................3-19 i4H Robots with EtherCAT User's Manual (I661) 7 CONTENTS 3-8-2 Safety Circuits ...........................................................................................................................3-20 3-9 Setting the EtherCAT Node ID ............................................................................................3-27 3-9-1 EtherCAT Node ID Setting Example .........................................................................................3-27 3-10 Supplying Power and Ground ............................................................................................3-29 3-10-1 Grounding the System ..............................................................................................................3-29 3-10-2 DC Connections ........................................................................................................................3-30 3-10-3 AC Connections ........................................................................................................................3-31 3-11 Verifying Installation............................................................................................................3-32 3-11-1 Mechanical Checks ...................................................................................................................3-32 3-11-2 System Cable Checks ...............................................................................................................3-32 3-11-3 Safety Equipment Checks .........................................................................................................3-32 3-11-4 Switch Position Checks .............................................................................................................3-34 Section 4 Operation 4-1 Payload and Acceleration Considerations ..........................................................................4-2 4-2 Robot Control Modes ............................................................................................................4-3 4-2-1 Manual Mode ..............................................................................................................................4-3 4-2-2 Automatic Mode ..........................................................................................................................4-3 4-2-3 Operation Mode ..........................................................................................................................4-4 4-2-4 Host Mode ...................................................................................................................................4-4 4-2-5 Service Mode ..............................................................................................................................4-5 4-3 Enabling and Disabling the Robot .......................................................................................4-6 4-3-1 Enabling Robot High Power ........................................................................................................4-6 4-3-2 Disabling High Power ..................................................................................................................4-7 4-4 LED Light Ring .......................................................................................................................4-8 4-5 LCD Display............................................................................................................................4-9 4-5-1 LCD Display Status Messages....................................................................................................4-9 4-6 Brake Operation ...................................................................................................................4-10 4-6-1 Built-in Brake Release Button ...................................................................................................4-10 4-6-2 Remote Brake Release ............................................................................................................. 4-11 4-7 Manually Jogging the Robot...............................................................................................4-12 Section 5 Troubleshooting 5-1 Fault Detection .......................................................................................................................5-2 5-2 Emergency Stop Troubleshooting .......................................................................................5-3 5-3 Error Messages ......................................................................................................................5-4 Section 6 Maintenance 6-1 Field-replaceable Items .........................................................................................................6-2 6-2 Periodic Maintenance ............................................................................................................6-3 6-2-1 Periodic Maintenance Overview..................................................................................................6-3 6-2-2 Checking Safety Functions .........................................................................................................6-3 6-2-3 Checking Fastener Torques ........................................................................................................6-4 6-2-4 Checking Safety and Warning Labels .........................................................................................6-5 6-2-5 Checking for Oil Leaks ................................................................................................................6-5 6-2-6 Lubricating Joint 3 .......................................................................................................................6-5 6-2-7 Replacing Encoder Batteries.......................................................................................................6-6 6-2-8 Harmonic Drive Oil Change ........................................................................................................6-8 6-2-9 Cleaning the Robot .....................................................................................................................6-8 8 i4H Robots with EtherCAT User's Manual (I661) CONTENTS 6-3 Non-periodic Maintenance ....................................................................................................6-9 6-3-1 Replacing the Tool Flange...........................................................................................................6-9 6-3-2 Replacing the iCS-ECAT Amplifier Chassis ..............................................................................6-10 6-3-3 Replacing the Outer Link Cover ................................................................................................6-14 Appendix A-1 Repacking the Robot for Transport..................................................................................... A-2 A-2 Transportation and Storage Considerations...................................................................... A-3 A-3 I/O Signal Numbering ........................................................................................................... A-4 A-3-1 Input Signal Numbering.............................................................................................................. A-4 A-3-2 Output Signal Numbering ........................................................................................................... A-5 A-4 Cable Pinouts ........................................................................................................................ A-7 A-4-1 XSYSTEM Cable Pinouts........................................................................................................... A-7 A-4-2 XBELTIO Adapter Cable Pinouts ............................................................................................... A-8 A-4-3 Belt Encoder Y-adapter Cable Pinouts....................................................................................... A-9 A-5 Parts List.............................................................................................................................. A-11 Index i4H Robots with EtherCAT User's Manual (I661) 9 Terms and Conditions Agreement Terms and Conditions Agreement Warranty and Limitations of Liability Warranty · Exclusive Warranty Omron's exclusive warranty is that the Products will be free from defects in materials and workmanship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, expressed or implied. · Limitations OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. Omron further disclaims all warranties and responsibility of any type for claims or expenses based on infringement by the Products or otherwise of any intellectual property right. · Buyer Remedy Omron's sole obligation hereunder shall be, at Omron's election, to (i) replace (in the form originally shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-complying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal to the purchase price of the non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity or any other claims or expenses regarding the Products unless Omron's analysis confirms that the Products were properly handled, stored, installed and maintained and not subject to contamination, abuse, misuse or inappropriate modification. Return of any Products by Buyer must be approved in writing by Omron before shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the use of Products in combination with any electrical or electronic components, circuits, system assemblies or any other materials or substances or environments. Any advice, recommendations or information given orally or in writing, are not to be construed as an amendment or addition to the above warranty. See http://www.omron.com/global/ or contact your Omron representative for published information. Limitations of Liability OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted. 10 i4H Robots with EtherCAT User's Manual (I661) Terms and Conditions Agreement Application Considerations Suitability for Use Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the Product in the Buyer's application or use of the Product. At Buyer's request, Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product. This information by itself is not sufficient for a complete determination of the suitability of the Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer's application, product or system. Buyer shall take application responsibility in all cases. NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM. Programmable Products · Omron Companies shall not be responsible for the user's programming of a programmable Product, or any consequence thereof. · Omron Companies shall not be responsible for the operation of the user accessible operating system (e.g. Windows, Linux), or any consequence thereof. Disclaimers Performance Data Data presented in Omron Company websites, catalogs and other materials is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of Omron's test conditions, and the user must correlate it to actual application requirements. Actual performance is subject to the Omron's Warranty and Limitations of Liability. Change in Specifications Product specifications and accessories may be changed at any time based on improvements and other reasons. It is our practice to change part numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the Product may be changed without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omron's representative at any time to confirm actual specifications of purchased Product. i4H Robots with EtherCAT User's Manual (I661) 11 Terms and Conditions Agreement Errors and Omissions Information presented by Omron Companies has been checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical or proofreading errors or omissions. 12 i4H Robots with EtherCAT User's Manual (I661) Safety Precautions Safety Precautions Definition of Precautionary Information The following notation is used in this manual to provide precautions required to ensure safe usage of the i4H robot. The safety precautions that are provided are extremely important to safety. Always read and heed the information provided in all safety precautions. The following notation is used. DANGER Identifies an imminently hazardous situation which, if not avoided, is likely to result in serious injury, and might result in fatality or severe property damage. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Additionally, there may be severe property damage. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage. Symbols The circle and slash symbol indicates operations that you must not do. The specific operation is shown in the circle and explained in text. This example indicates prohibiting disassembly. The triangle symbol indicates precautions (including warnings). The specific operation is shown in the triangle and explained in text. This example indicates a precaution for electric shock. The triangle symbol indicates precautions (including warnings). The specific operation is shown in the triangle and explained in text. This example indicates a general precaution. The filled circle symbol indicates operations that you must do. The specific operation is shown in the circle and explained in text. This example shows a general precaution for something that you must do. The triangle symbol indicates precautions (including warnings). The specific operation is shown in the triangle and explained in text. This example indicates a precaution for high temperatures. i4H Robots with EtherCAT User's Manual (I661) 13 Safety Precautions Dangers DANGER General An i4H robot can cause serious injury or death, or damage to itself and other equipment, if the following safety precautions are not observed: · All personnel who install, operate, teach, program, or maintain the system must read this guide, read the Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot. · All personnel who design the robot system must read this guide, read the Robot Safety Guide, and must comply with all local and national safety regulations for the location in which the robot is installed. · The robot system must not be used for purposes other than described in 1-1 Intended Use on page 1-2. Contact your local Omron support if you are not sure of the suitability for your application. · The user is responsible for providing safety barriers around the robot to prevent anyone from accidentally coming into contact with the robot when it is in motion. · Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed. · When the robot or robotic equipment is not investigated in conjunction with a system work cell, the instructions shall call attention to the following: the interlocked portion of barrier shall be installed, applied, and maintained so that it has the capability of being easily unlocked from the inside of the safeguarded space, with or without power available, when the possibility of full body access exists. i4H robots are not collaborative robots. They require a dedicated work area that will prevent personnel from coming into contact with them during operation. The normal and intended use of these robots does not create hazards. These robots have been designed and constructed in accordance with the relevant requirements of IEC 60204-1. These robots are intended for use in parts assembly and material handling for payloads up to 15.0 kg. Refer to the Robot Safety Guide (Cat. No. I590) for details on the intended use of our robots. These robots are intended for industrial use only. Perform a risk assessment before using. These robots are not intended for: · Use in the presence of ionizing or non-ionizing radiation. · Use in potentially explosive atmospheres. · Use in medical or life saving applications. · Use in a residential setting. Installation The robot system must be installed with user-supplied interlock barriers. The interlocked barriers must open the E-Stop circuit in the event of personnel attempting to enter the work cell when High Power is enabled. Failure to install suitable guarding or interlocks could result in injury or death. We strictly prohibit installation, commissioning, or operation of any robot without adequate safeguards. These must be compliant with applicable local and national standards. 14 i4H Robots with EtherCAT User's Manual (I661) Safety Precautions The placement of safety controls shall avoid requiring a person to enter a hazardous area to actuate them. Controls shall be located outside of the safeguarded space, except for certain controls such as emergency stops or a teach pendant, where based on a risk assessment they may be located within the safeguarded space. After installing the robot, you must test it before you use it for the first time. Failure to do this could cause death, serious injury, or equipment damage. Failure to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or fatality of a person touching the end-effector during an electrical fault. Any High Power push-buttons must be installed outside of the robot's workspace. Warnings WARNING General The instructions for operation, installation, and maintenance given in this document must be strictly observed. If air pressure is present, disconnect it from the robot when servicing end-of-arm tooling or other pneumatic components to prevent unsecured pneumatic air lines from accidentally injuring personnel. Do not move the robot links if the robot is not secured. Failure to comply could result in the robot falling and causing either personnel injury or property damage. Installation Ensure that installation and post-installation checks of the product are performed by personnel in charge who possess a thorough understanding of the machinery to be installed. The AC power installation must be performed by a skilled, and instructed person. For more information on this refer to the Robot Safety Guide. During the AC power installation, unauthorized third parties must be prevented from turning the power on through the use of fail-safe lockout measures. Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system. i4H Robots with EtherCAT User's Manual (I661) 15 Safety Precautions Provide appropriately-sized Branch Circuit Protection and Lockout / Tagout Capability in accordance with the National Electrical Code and any local codes. Use a crane and straps to lift the robot by the inner arm and controller handle. Never lift the robot by the quill. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage. If you supply your own Front Panel, its design must comply with the requirements of IEC 60204-1 and ISO 13849. The E-Stop's push button must comply with ISO 13850 (Clause 5.5.2). Disabling the High Power button violates IEC 60204-1. Do not alter its functionality. If a robot is mounted to a surface with inadequate stiffness, damage to the z-axis quill or other mechanical components can result from excessive oscillation during operation. The robot can fall over if it is not properly secured with mounting hardware. The robot must be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create trapping or pinch points. It must be installed in accordance with Standard for Robots and Robotic Devices Safety Requirements for Industrial Robots Part 2: Robot Systems and Integration, ISO 10218-2. Ensure that interconnecting cables or pneumatic lines are routed away from the robot workspace. To reduce the risk of fire or electric shock, install the robot in a controlled environment relatively free of contaminants. Do not remove the shipping brackets or move the robot links until the robot has been secured to its mounting surface. Failure to comply could result in the robot falling and causing either personnel injury or property damage. Operation Before starting the operation of equipment, always confirm that the safety equipment of the robot works properly. If a malfunction of the safety equipment is detected, follow the troubleshooting procedure. Use the total weight of the end-of-arm tooling and the payload to stay within the payload rating of the robot. Ensure that the system never exceeds that maximum payload. Perform a full risk assessment which includes the end-of-arm tooling and any payload to prevent crushing, shearing, payload ejection, entanglement, stabbing or puncture hazard. Releasing a brake may cause the quill, tool flange, end-of-arm tooling, and payload to drop. To prevent possible injury to personnel or damage to the equipment, make sure that the equipment is supported when releasing the brake and verify that the end-of-arm tooling and payload are clear of all obstructions. 16 i4H Robots with EtherCAT User's Manual (I661) Safety Precautions All signals that pass-through the USER connectors are not associated with any robot controls, emergency stop circuits, or robot power. Implement appropriate safety measures to ensure that these signals are not active during emergency stop conditions or while the robot is powered OFF. In Automatic mode, the robot can move unexpectedly. Ensure all personnel remain clear of the cell when Automatic mode is enabled. If an operator is going to be in the work cell with the switch in Manual mode, the operator must carry an enabling device such as the T20 pendant. Whenever possible, perform Manual mode operations with all personnel outside the workspace. The stopping time and distance, or angle, of a robot joint from initiation of a stop signal is not negligible and must be taken into account when designing and applying safeguarding devices. Never connect or disconnect system cables while power is applied to the robot. Failure to comply may cause unexpected behavior and can result in personnel injury and equipment damage. Never run a robot system with all jumpers installed. This would leave the system with no E-Stops. Do not use the robot in hazardous environments (explosive gas, and oil mist). The robot shall be operated within its specified temperature range to ensure proper operation. The robot's physical hardstop devices are not intended to withstand repeated use. If this occurs, the hardstop may become damaged. Implement proper programming and configuration of joint range limits to prevent hardstop impacts. Maintenance Do not use organic solvents to clean any part of the robot unless directed in the cleaning instructions. Organic solvents might damage electronics resulting in an unsafe operating state that could cause injury or damage to equipment. You must perform the Lockout and tagout procedure prior to servicing the robot. The access covers on the robot are not interlocked. You must turn OFF and disconnect the power before the covers of the robot are removed. The procedures and replacement of the parts mentioned in this manual must be performed only by the skilled or instructed persons. i4H Robots with EtherCAT User's Manual (I661) 17 Safety Precautions Cautions CAUTION The design and installation of the complete system must comply with the safety standards and regulations in the country of use. The integrators of the robot should understand the safety laws and regulations in their countries and prevent major hazards from occurring in the complete system. 18 i4H Robots with EtherCAT User's Manual (I661) Precautions for Safe Use Precautions for Safe Use · The Joint 3 quill and the tool flange are not grounded to protective earth. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment or tooling to the ground point on the robot base. · Output 8 can be assigned to indicate the robot's High Power state. When High Power is enabled, this output will turn ON. When High Power is not enabled, this output will be OFF. This is not a safety-rated means of indicating a High Power state and should only be used for monitoring the robot status. Use the Sysmac Studio to make this configuration if needed. · Do not apply the AC power until all installation steps are complete and verified and all safety measures are in place. · High power cannot be enabled unless all safety circuits are satisfied. · The LED light ring does not reflect the robot's High Power status. To see the robot's High Power status, use the Front Panel indicator or a user-supplied indicator connected to the XFP connector. · The braking mechanism operates passively. If 24 VDC Control Power is removed from the system, the brake mechanism will automatically activate. 24 VDC Control Power must be supplied to release the brake. To prevent possible damage to the equipment, remove any payload from the end-of-arm tooling, make sure that Joint 3 is supported while releasing the brake, and verify that the end-of-arm tooling or other installed equipment is clear of all obstructions. · To comply with ISO 10218-1 when using a remote brake release button, ensure the brake release button displays a warning label to indicate that the z-axis of the robot may fall due to gravity if the brake is released. · The High Power indicator must be operational to satisfy safety requirements. · You can contribute to resource conservation and protecting the environment by the proper disposal of Waste Electronics and Electrical Equipment (WEEE). All electrical and electronic products should be disposed of separately from the municipal waste system according to local ordinances using designated collection facilities. · The product contains lithium batteries with a perchlorate content of 6ppb or higher. When exporting an end product containing the product to or shipping through California, USA, label all packing and shipping containers appropriately. Special handling may apply. Refer to https://dtsc.ca.gov for more information. · Dispose of any battery that has been dropped or otherwise subjected to excessive shock. Batteries that have been subjected to shock may leak if they are used. · Batteries may leak, rupture, heat, or ignite. Never short-circuit, charge, disassemble, heat, or incinerate a battery or subject it to strong shock. · Any person who programs, teaches, operates, maintains, or repairs robots or robot systems shall be trained and can demonstrate competence to safely perform the assigned task. · Any person who programs, teaches, operates, maintains, or repairs robots or robot systems shall be trained on responding to emergency or abnormal situations. · Do not connect user-supplied Manual / Automatic contacts or other control signals in parallel with the Front Panel switch contact. This would violate the Single Point of Control principle and might allow Automatic mode to be selected while an operator is in the cell. i4H Robots with EtherCAT User's Manual (I661) 19 Precautions for Safe Use · Acoustic emission from these robots may be up to 80 dB (A) at 1 m distance under worst-case conditions. Typical values will be lower, depending on payload, speed, acceleration, and mounting. Appropriate safety measures should be taken, such as ear protection and display of a warning sign. · Any moving robot requires some distance to stop. This requires more distance at high operating speeds or heavier payloads. When stopping a robot, make sure that there is no interference with other equipment. · Do not expose the shipping container to excessive shock and vibration. This could damage the robot. · Using improper lubrication products on the robot may damage it. · After an operator places the robot in Manual mode using the Front Panel key switch, they should remove the key for safety purposes. · If the supplied Front Panel is not used, a High Power indicator light must be present in the system. This indicator light must be amber in color. It must be either mounted to the robot or integrated into the work cell where it is visible from all approaches or entry points. · If a supplementary audible means of robot operation is provided, it shall exceed the ambient noise at the end-use application. · During manual operation, ensure all persons are a safe distance away from the robot workspace. · To stop the robot in an emergency, press any E-stop button and then follow the internal procedures of your company or organization defined for an emergency situation. · If a fire occurs on the robot, use a CO2 type fire extinguisher. · In case of entrapment of a person by the robot or any other emergency or abnormal situation, you can manually move the inner and outer links to a safe position while the High Power is disabled. A brake device prevents Joints 3 and 4 from moving when High Power is disabled and can only be released while 24 VDC Control Power is present. · Prior to placing the robot in Automatic Mode, all safeguards must be returned to their safe state. · After the robot is placed in Manual mode using the Front Panel key switch, the key should be removed for safety purposes. 20 i4H Robots with EtherCAT User's Manual (I661) Precautions for Correct Use Precautions for Correct Use · Robot motion is not possible until AC power is supplied High Power and has been enabled. · This equipment must be shipped and stored in a temperature-controlled environment, within the range 25 to +55° C. The recommended humidity range must be 5 to 90%, non-condensing. It should be shipped and stored in the supplied packaging, which is designed to prevent damage from normal shock and vibration. · Robot must be operated within its specific temperature ratings to ensure proper operation. · Placing the robot on its side for extended periods of time can cause oil leaks from the harmonic drive units. Limit the amount of time the robot is placed on its side. · Control power must be present before High Power can be enabled. · The T20 pendant can only control the robot it is directly connected to. · Either a Front Panel or equivalent circuits are required to enable High Power to the robot. · If the Front Panel High Power ON / OFF indicator fails, you might incorrectly assume that High Power is OFF, and the robot is safe. To prevent this, a failed indicator causes an error (-924) *Front panel HIGH POWER lamp failure* and locks out the High Power enabling until you replace the indicator. · It is recommended to use an 18 mm (minimum) thick steel plate with a maximum surface roughness of 25 m that is properly secured to the floor or wall as a robot mounting surface. Mounting surface flatness must not exceed 5 mm. · The mounting surface should be clean and prepared according to the information provided in the manual before attempting to mount the robot. · Do not over-tighten the tool flange setscrew. This will cause off-center alignment of the tool flange on the quill. · Always reduce joint motion limits with software configuration settings when hardstops are used to restrict range of motion. · Never release the z-axis brake while the quill clamp collar is loose or removed. This can allow the quill to fall out of the robot. · If Teach Pendant cabling is installed, the jumper plug or the Teach Pendant must be connected to satisfy safety circuits and allow High Power to be enabled. · Do not disable or bypass the High Power button. This will violate IEC 60204-1. · Operating the robot outside of the payload and speed constraints described in this document can damage or reduce the service life of the z-axis quill. · If a Front Panel is not present, the High Power indicator and High Power button signals can be accessed with the XFP system cable connector. · Attempting to release the brake while High Power is ON will automatically disable High Power. If the robot is moving, this will cause it to stop abruptly. · Only replace items on the robot system with the parts supplied by OMRON. · Only use the recommended grease on the joint 3 quill (part number 90401-04029). Refer to the provided Safety Data Sheet for proper handling. · When removing and replacing the tool flange, you must reinstall it in the same position to avoid losing the calibration for the robot. · Use surge suppression when switching inductive loads such as relays to prevent damage to the output circuits. · Any externally mounted equipment is considered robot payload. Consideration to the payload attached to the Tool Flange should be made when mounting external equipment to the robot. i4H Robots with EtherCAT User's Manual (I661) 21 Precautions for Correct Use · Avoid rotating the quill / Joint 4 when the brake is released. This could result in an out-of-range condition and may prevent program execution. · All fastener torque values provided must be applied within ±5%. · Do not remove factory-installed Joint 1 hardstops. · Follow appropriate ESD procedures when removing or replacing the iCS-ECAT amplifier chassis. · If a solenoid valve kit is present, pneumatic pass-through ports are repurposed for valve air supply and exhaust. · Robot joints 1 and 2 have no brake mechanism and can be manually moved when power is not present. · If any damage is detected before unpacking the robot, request that the carrier's agent be present when you unpack the container. · If the robot mounting structure is not designed with adequate stiffness, robot performance will not meet the specified values. · When adjusting Joint 1 hardstops, do not let screws or other objects drop into the robot body. · Keep a minimum of 300 mm clearance behind the robot to avoid unmounting of the robot in case of iCS-ECAT amplifier chassis replacement and to allow for easy switch setting access. · The NJ501 Robot Integrated CPU Unit must be connected to the robot for normal operation. 22 i4H Robots with EtherCAT User's Manual (I661) Regulations and Standards Regulations and Standards The OMRON i4H robot series are compliant to the following standard: Regulations and Standards Regulation/Standard 2006/42/EC 2014/30/EU EN ISO 12100 EN ISO 13849-1 EN ISO 10218-1 EN 60204-1 EN 61000-6-4 EN 61000-6-2 Description Machinery Directive. EMC Directive. Safety of Machines - General Principles for Design Risk Assessment and Reduction. Safety of Machines - Safety Related Parts of Control Systems SRP/CS - Part 1. Robots for Industrial Environments - Safety Requirements - Part 1: Robot. Safety of Machinery - Electrical Equipment of Machines - Part 1 General Requirements. EMC - Part 6-4: Emissions Standard for Industrial Environments. EMC - Part 6-2: Immunity Emissions Standard for Industrial Environments. i4H Robots with EtherCAT User's Manual (I661) 23 Related Manuals Related Manuals Use the following related manuals for reference. Manual Title Automated Control Environment (ACE) Version 4 User's Manual (Cat. No. I633) IPC Application Controller User's Manual (Cat. No. I632) NJ-series Robot Integrated CPU Unit User's Manual (Cat. No. O037) Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) Sysmac Studio Version 1 Operation Manual (Cat. No. W504) T20 Pendant User's Manual (Cat. No. I601) Robot Safety Guide (Cat. No. I590) eV+3 Keyword Reference Manual (Cat. No. I652) eV+3 User's Manual (Cat. No. I651) Description Instruction for the use of the ACE Version 4 software. Describes the IPC Application Controller. Describes the settings and operation of the CPU Unit and programming concepts for OMRON robot control. Describes the operating procedures of the Sysmac Studio for Robot Integrated CPU Unit. Describes the operating procedures of the Sysmac Studio. Describes the setup, operation, and user maintenance for the Teaching Pendant T20. Describes how to use the OMRON robot safely. Provides reference to eV+ Keyword use and functionality. Provides a description of the eV+ programming language and functionality. 24 i4H Robots with EtherCAT User's Manual (I661) Glossary Glossary Term / Abbreviation Application Controller Automatic Mode Control Power End-of-arm Tooling Emergency Stop Hardstop High Power Joint LED Light Ring Link Manual Mode SCARA T20 Pendant Quill Work Envelope Workspace Description Industrial PC that provides additional functionality to the robot to execute PackManager and Robot Vision Manager applications. Operating state of the robot during normal conditions. In this mode, program execution will control the robot up to the maximum allowable speed. 24 VDC supply that energizes control and other non-servo motor circuits. Any device mounted to the robot's tool flange intended for performing work during robot operation. An action or device used to immediately stop the robot. This may be referred to as emergency stop, E-stop, or ESTOP. Physical limit that restricts the range of motion for a robot axis. AC supply that energizes all internal servo motors to allow robot motion. Mechanical robot component that connects its moving parts. Multi-colored light ring on Joint 1 that provides a visual indication of the robot operating state. Mechanical robot component that moves in a radial motion. Operating state of the robot during commissioning, position teaching, and other setup operations. Selective Compliance Assembly Robot Arm Optional, handheld device used to manually jog the robot, teach locations, and debug programs without a PC. This is also referred to as a Teach Pendant or a pendant. Mechanical robot component that provides motion in the z-axis and rotary motion for the tool flange. This is a ball-screw mechanism. Working area that is accessible by the robot considering any end-of-arm tooling and part shapes that are attached. Total area that the robot occupies considering all capable range of motion. i4H Robots with EtherCAT User's Manual (I661) 25 Revision History Revision History A manual revision code appears as a suffix to the catalog number on the front and back covers of the manual. Cat. No. I661-E-02 Revision code Revision code Date Revised content 02 January 2021 Minor modifications 01 December 2020 Original production 26 i4H Robots with EtherCAT User's Manual (I661) Overview 1 1 1-1 Intended Use................................................................................................... 1-2 1-2 Robot Features ............................................................................................... 1-3 1-2-1 Robot Integrated System................................................................................. 1-3 1-2-2 Basic Robot Components................................................................................ 1-4 1-2-3 Other Components .......................................................................................... 1-6 1-2-4 Front Panel...................................................................................................... 1-7 1-2-5 Connectors ...................................................................................................... 1-9 1-3 Information Labels ....................................................................................... 1-12 1-3-1 Robot Label ................................................................................................... 1-12 1-3-2 Controller Label ............................................................................................. 1-12 1-4 Robot Configurations .................................................................................. 1-14 1-4-1 i4-650H.......................................................................................................... 1-14 1-4-2 i4-750H.......................................................................................................... 1-14 1-4-3 i4-850H.......................................................................................................... 1-14 1-5 Model Numbers ............................................................................................ 1-15 1-5-1 Robot Model Numbers .................................................................................. 1-15 1-5-2 Controller Model Numbers ............................................................................ 1-15 1-6 Optional Hardware ....................................................................................... 1-16 1-6-1 IO Blox........................................................................................................... 1-16 1-6-2 T20 Pendant.................................................................................................. 1-16 1-6-3 IPC Application Controller ............................................................................. 1-17 1-6-4 XIO Termination Block................................................................................... 1-17 1-6-5 Optional Cables............................................................................................. 1-18 1-6-6 eCobra Mount Adapter .................................................................................. 1-20 1-6-7 Camera Mounting Bracket and Adapter ........................................................ 1-20 1-6-8 eCobra Tool Flange ....................................................................................... 1-21 i4H Robots with EtherCAT User's Manual (I661) 1-1 1 Overview 1-1 Intended Use The i4H robot is a selective compliance assembly robot arm (SCARA) for use within factory environments. It is designed to perform automated motion control typically used with material handling operations. The i4H robot is capable of high speed, high-precision motion for payloads up to 15 kg. Its durable design and flexible programmability make it ideal for a wide variety of robotic applications. 1-2 i4H Robots with EtherCAT User's Manual (I661) 1-2 Robot Features 1-2-1 Robot Integrated System 1 Overview 1-2 Robot Features This section provides information about the features of the i4H robot series. The following items sum- marize the main features of this robot. · High speed, precision, and payloads are possible with a robust mechanical design. · EtherCAT communications are built-in for easy integration with other networked devices. · Various configurations allow a wide variety of mounting options. 1 · A multi-colored LED light ring provides a highly visible indication of the general robot status. · An LCD display on the base of the robot provides detailed information about robot operational sta- tus. · Mounting points are available on the exterior of the robot for items such as pneumatic valves or oth- er hardware. · Pass through electrical and pneumatic ports are available from the base of the robot to the outer link. · The Primary Interface Panel provides a central location for all cables and connections and a Secon- dary Interface Panel provides connections for end-of-arm tooling and other hardware. · Built-in, optically isolated I/O provides 17 inputs and 12 outputs. · Adjustable hardstops are integrated into the robot body. 1-2-1 Robot Integrated System The Robot Integrated CPU Unit provides the functionality of previous OMRON PLCs and also the functionality that is required for robot control. Control of I/O devices on high-speed EtherCAT can be applied to robots, safety devices, vision systems, motion equipment, discrete I/O, and more. Built-in EtherCAT communications allow this robot to operate together with EtherCAT slaves, other Sysmac products, and the Sysmac Studio software to achieve optimal functionality and ease of operation. Precautions for Correct Use The NJ501 Robot Integrated CPU Unit must be connected to the robot for normal operation. i4H Robots with EtherCAT User's Manual (I661) 1-3 1 Overview Vision sensor Application Controller NA-series PT Server Relational database EtherNet/IP Robot Integrated CPU Unit NJ501-R EtherCAT Camera Sysmac Studio USB OMRON robot Safety devices Front Panel Encoder, digital I/O 1S-series Servo Drives G5-series Servo Drives (with built-in EtherCAT communications) Slave Terminal FH-series Vision Systems I/O control external devices Teaching pendant T20 Robots controllable by NJ Robotics function 1-2-2 Basic Robot Components The robot consists of the following components that are referred to throughout this manual. Use the information below to identify the robot's basic components. Mechanical Components Use the image below to identify the robot's mechanical components. Outer Link Inner Link Quill Tool Flange Base Axes of Motion Use the following diagrams to understand the robot's 4 axes of motion. 1-4 i4H Robots with EtherCAT User's Manual (I661) 1-2 Robot Features 1 Overview Joint 2 + - + Joint 1 - + Joint 4 - Joint 3 1 (Z-axis) + Interface Panels Use the information below to identify the robot's interface panels and their functions. Secondary Interface Panel 1-2-2 Basic Robot Components Primary Interface Panel Primary Interface Panel The Primary Interface Panel is located on the base of the robot and provides access to the following items. i4H Robots with EtherCAT User's Manual (I661) 1-5 1 Overview Pneumatic Pass-through Ports (4) USER Connector Mode Switches EtherCAT Status LEDs EtherCAT Node Switches XBELTIO XIO Connector Connector High Power Connector Control Power Connector EtherCAT Ports Chassis Ground XSYSTEM Connector Secondary Interface Panel The Secondary Interface Panel is located on top of the outer link and provides access to the following items. USER Connector Reserved for future use Tool EtherCAT Connector Pneumatic Pass-through Ports 1-2-3 Other Components Other components are located on the robot as shown in the following image. 1-6 i4H Robots with EtherCAT User's Manual (I661) 1 Overview 1-2 Robot Features 1-2-4 Front Panel LCD Display Brake Release Button LED Light Ring Indicator 1 1-2-4 Front Panel The Front Panel is a device that provides remote control and status functions when mounted a safe distance outside of the robot workspace. The Front Panel provides the following functions. · Setting the robot mode to Manual or Automatic mode. Refer to 4-2 Robot Control Modes on page 4-3 for more information. · Indicating the robot High Power and Control Power state. · Enabling robot High Power. Refer to 4-3-1 Enabling Robot High Power on page 4-6 for more in- formation. · Activating an emergency stop and disabling robot High Power. If Front Panel signals need to be relocated, refer to XFP Wiring Diagram on page 3-23 for internal circuit details. Precautions for Safe Use If the supplied Front Panel is not used, a High Power indicator light must be present in the system. This indicator light must be amber in color. It must be either mounted to the robot or integrated into the work cell where it is visible from all approaches or entry points. Precautions for Correct Use · Either a Front Panel or equivalent circuits are required to enable High Power to the robot. Refer to XFP Wiring Diagram on page 3-23 for more information. · If the Front Panel High Power ON / OFF indicator fails, you might incorrectly assume that High Power is OFF, and the robot is safe. To prevent this, a failed indicator causes an error (-924) *Front panel HIGH POWER lamp failure* and locks out the High Power enabling until you replace the indicator. Refer to the eV+3 User's Manual (Cat. No. I651) for more information about error handling. Refer to High Power Indicator Check Procedure on page 3-34 for information about High Power indicator operation verification. i4H Robots with EtherCAT User's Manual (I661) 1-7 1 Overview Additional Information · The Front Panel is supplied with an extension cable that must be used to connect it to the XFP connector on the XSYSTEM cable. Refer to 3-8-1 Installing the Front Panel on page 3-19 for more information. · Design of the factory-supplied Front Panel E-Stop is in accordance with the requirements of IEC 60204-1 and ISO 13849. WARNING · If you supply your own Front Panel, its design must comply with the requirements of IEC 60204-1 and ISO 13849. The E-Stop's push button must comply with ISO 13850 (Clause 5.5.2). · If an operator is going to be in the work cell with the switch in Manual mode, the operator must carry an enabling device such as the T20 pendant. · Whenever possible, perform Manual mode operations with all personnel outside the workspace. · Disabling the High Power button violates IEC 60204-1. Do not alter its functionality. · In Automatic mode, the robot can move unexpectedly. Ensure all personnel remain clear of the cell when Automatic mode is enabled. Mode Selection Switch Control Power LED Indicator High Power Enable Button High Power Indicator Emergency Stop Button Use the information in the table below to understand Front Panel item details. Item Description Control Power LED Indicator Provides an indication that the robot is receiving 24 VDC Control Power with a green LED. Mode Selection Switch Controls the robot's operating mode. The left position selects Manual mode. The right position selects Automatic mode. Refer to 4-2 Robot Control Modes on page 4-3 for more information. High Power Indicator Provides an indication of the robot's High Power state with an amber LED. Refer to 4-3 Enabling and Disabling the Robot on page 4-6 for more information. High Power Enable Button Button to request robot High Power. Emergency Stop Button*1 Button for emergency stopping of the robot. *1. This switch is a dual-channel, passive E-stop device that supports Category 3 CE safety requirements. 1-8 i4H Robots with EtherCAT User's Manual (I661) 1 Overview 1-2 Robot Features 1-2-5 Connectors 1-2-5 Connectors This section describes all connectors on the robot. USER Connectors The USER connectors provide pass-through electrical signals from the base of the robot to the end of the arm. 1 Pass-through electrical signals are typically used for end-of-arm tooling sensing and control. All USER connector pin associations between the Primary Interface Panel and the Secondary Inter- face Panel are one-to-one. For example, pins 1 through pins 19 of the USER connector on the Pri- mary Interface Panel are directly connected to pins 1 through 15 of the USER connector on the Sec- ondary Interface Panel. CAUTION All signals that pass-through the USER connectors are not associated with any robot controls, emergency stop circuits, or robot power. Implement appropriate safety measures to ensure these signals are not active during emergency stop conditions or while the robot is powered OFF. Additional Information There are no twisted-pair conductors between the USER connectors on the Primary Interface Panel and the Secondary Interface Panel. Data communication is not recommended for these connectors. Refer to 2-5-1 Connector and Port Specifications on page 2-17 for more information about the USER connector signal specifications. Control Power Connector The Control Power connector is used to supply 24 VDC to the robot logic circuits. When power is supplied to this connector, the robot will boot up and control functions such as programming and configuration are possible. A mating connector is supplied with the robot. Additional Information Control power is user-supplied. Refer to 2-3-1 Power Supply Specifications on page 2-14 for information about Control Power specifications. Refer to 3-10-2 DC Connections on page 3-30 for information about Control Power wiring. Precautions for Correct Use Robot motion is not possible until High Power is supplied and has been enabled. Refer to 4-3 Enabling and Disabling the Robot on page 4-6 for more information. High Power Connector The High Power connector is used to supply 200 to 240 VAC to the internal servo amplifiers. i4H Robots with EtherCAT User's Manual (I661) 1-9 1 Overview When power is supplied to this connector and High Power has been enabled, the robot is ready to move. A mating connector is supplied with the robot. Additional Information High Power is user-supplied. Refer to 2-3-1 Power Supply Specifications on page 2-14 for information about High Power specifications. Refer to 3-10-3 AC Connections on page 3-31 for information about High Power wiring. Precautions for Correct Use Control Power must be present before High Power can be enabled. XSYSTEM Connector The XSYSTEM connector provides connections to external equipment such as a Front Panel, Teach Pendant, and user-supplied safety devices. An Ethernet connector is also provided for direct communication with a PC while in Service Mode. The robot is supplied with an XSYSTEM cable and jumper plugs. This cable provides connections for a Front Panel, Teach Pendant, and other user-supplied safety devices. · The part number for the XSYSTEM cable is 13322-100. · The length of this cable is 1.8 m. Additional Information Refer to 3-6-1 System Cable Overview on page 3-10 for more information. XBELTIO Connector The XBELTIO connector provides access to the following signals. · Belt encoder inputs 1 and 2 · Expansion I/O · RS-232 Additional Information Refer to Optional Connections on page 3-11 for more information. XIO Connector The XIO connector provides access to built-in I/O of the robot (12 inputs, 8 outputs). Additional Information Refer to the 3-7-1 XIO Connector Signals and Wiring on page 3-13 for more information about XIO connector wiring. 1-10 i4H Robots with EtherCAT User's Manual (I661) 1-2 Robot Features 1 Overview Pneumatic Pass-through Ports The pneumatic pass-through ports provide pass-through air lines from the Primary Interface Panel to the Secondary Interface Panel. Pneumatic pass-through ports are typically used for end-of-arm tooling control. Tool EtherCAT Connector 1 This connector provides EtherCAT communications to user-supplied devices that can be mounted to the outer link or end-of-arm tooling. This connector provides an extension of the EtherCAT network. Additional Information Refer to 3-4-2 Tool EtherCAT Connector Wiring on page 3-6 for more information. 1-2-5 Connectors i4H Robots with EtherCAT User's Manual (I661) 1-11 1 Overview 1-3 Information Labels The information labels contain relevant information about the robot and the controller. The following examples will be different from your product label. 1-3-1 Robot Label The robot label is described below. 1 RS 4 - XXXXXXX 2 INDUSTRIAL ROBOT Model : i4 - 650 H 4 Wei ght : #.# kg (## .# lb ) Max . Payload : #.# kg (## .# lb ) Max Reach : ### mm MSIP - REM - OAT - I4 H Option : Input : 1Phase 200 - 240 VAC Compliance 3 5 50 / 60 Hz 12 A Input : 24 VDC +/- 10 % 8A Shor t Circuit Rating : 200A M / N : ##### - ### Rev # SN : SSS - XXXXX 6 Lot No .: DDMYYFF Enc losure : IP20 QR CO DE 4225 Hacienda Drive , Pleasanton , CA 94588 USA Omron Roboti cs & Safety Techno logies , Inc . Item Name Description 1 Part number *1 The robot part number is displayed. 2 Product type The product type is displayed. 3 Alerts and compliance General alerts and compliance information is displayed. 4 Robot information The robot model, weight, maximum payload, and maximum reach is displayed. 5 Electrical information General electrical power supply information about the robot is dis- played. 6 Production information The following information is provided. · M/N indicates the model number and revision level. · SN indicates the serial number. · Lot. No. indicates the lot number in the format of DDMYYFF. Month number 1 to 9 for January to September, X for October, Y for Novem- ber, and Z for December. FF is reserved for internal use. · Product origin information is displayed. *1. Refer to 1-5 Model Numbers on page 1-15 for model information. 1-3-2 Controller Label The controller label is described below. 1-12 i4H Robots with EtherCAT User's Manual (I661) 1-3 Information Labels 1-3-2 Controller Label 1 Overview 1 2 X XX X X - X XX CONTROLL ER Mode l : i4H -iCS ECAT 4 Input : 1Pha se 200 - 240 VAC 50 / 60 Hz 12 A Input : 24 VDC +/- 10 % 8A Short Cir cuit Rating : 200A 5 3 MAC ADD RESS : PORT 1 XX XXX XXX XXX X QR PORT 2 XX XXX XXX XXX X 6 SN : XX X - XX XXX XX Lo t No.: DD MYYF F CO DE 1 4225 Ha cie nda Dr iv e , Ple asanton , CA 94588 USA Omr on Robotics & Safe ty Te chnologies , Inc . Item Name Description 1 Part number *1 The controller part number is displayed. 2 Product type The product type is displayed. 3 Alerts and compliance General alerts and compliance information is displayed. 4 Controller information The controller model and general electrical power supply information is displayed. 5 MAC Address MAC address for the EtherCAT port 1 and port 2 (IN and OUT) 6 Production information The following information is provided. · SN indicates the serial number. · Lot. No. indicates the lot number in the format of DDMYYFF. Month number 1 to 9 for January to September, X for October, Y for Novem- ber, and Z for December. FF is reserved for internal use. · Product origin information is displayed. *1. Refer to 1-5 Model Numbers on page 1-15 for model information. i4H Robots with EtherCAT User's Manual (I661) 1-13 1 Overview 1-4 Robot Configurations The i4H robot is offered in a variety of configurations with different work envelopes and z-axis stroke lengths. 1-4-1 i4-650H The i4-650H has a reach of 650 mm and is offered in the following configurations. i4-650H Standard i4-650H Long Quill i4-650H Standard Inverted i4-650H Long Qull Inverted 1-4-2 i4-750H The i4-750H has a reach of 750 mm and is offered in the following configurations. i4-750H Standard i4-750H Long Quill i4-750H Standard Inverted i4-750H Long Qull Inverted 1-4-3 i4-850H The i4-850H has a reach of 850 mm and is offered in the following configurations. i4-850H Standard i4-850H Long Quill i4-850H Standard Inverted i4-850H Long Qull Inverted 1-14 i4H Robots with EtherCAT User's Manual (I661) 1-5 Model Numbers 1-5-1 Robot Model Numbers 1 Overview 1-5 Model Numbers Models numbers and descriptions associated with the robot are provided below. 1-5-1 Robot Model Numbers The table below provides all robot model numbers and descriptions. 1 Model Number RS4-2066502 RS4-2066504 RS4-2066702 RS4-2066704 RS4-2067502 RS4-2067504 RS4-2067702 RS4-2067704 RS4-2068502 RS4-2068504 RS4-2068702 RS4-2068704 Reach 650 mm 750 mm 850 mm Z-axis Stroke 210 mm 410 mm 210 mm 410 mm 210 mm 410 mm 210 mm 410 mm 210 mm 410 mm 210 mm 410 mm Mounting Orientation Standard Inverted Standard Inverted Standard Inverted 1-5-2 Controller Model Numbers The table below provides all robot controller model numbers and descriptions. iCS-ECAT Model Number Description Controller with EtherCAT communications support. i4H Robots with EtherCAT User's Manual (I661) 1-15 1 Overview 1-6 Optional Hardware The following optional hardware is available for the robot. 1-6-1 IO Blox IO Blox units are available to expand the I/O capacity of the robot. Each unit offers 8 inputs and 8 outputs. Up to 4 IO Blox units can be added to the robot. · The part number for an IO Blox unit connected directly to the robot is 90356-30200. · The part number for IO Blox units connected to another IO Blox unit is 90356-30100. Additional Information Refer to 3-7-2 IO Blox Connections on page 3-17 and the IO Box Users Guide (04638-000) for more information. 1-6-2 T20 Pendant The T20 pendant is an optional handheld device that allows you to manually jog the robot, teach locations, and view V+ programs without a PC. · The part number for the pendant kit is 10054-010. This kit includes the T20 Teach Pendant, an adapter cable (3 m), and a jumper plug. · The adapter cable includes a round, 17-pin connector that can be panel-mounted. It can be mount- ed to a surface with up to 6.5 mm of thickness and requires an M23 hole. Precautions for Correct Use The T20 pendant can only control the robot it is directly connected to. Additional Information Refer to 3-6-1 System Cable Overview on page 3-10 and the T20 Pendant User's Manual (Cat. No. I601) for more information. 1-16 i4H Robots with EtherCAT User's Manual (I661) 1-6 Optional Hardware 1-6-3 IPC Application Controller 1 Overview 1 1-6-3 IPC Application Controller The IPC Application Controller can be added to your system to execute PackManager and Robot Vision Manager applications. The Pack Manager application controls automated pick-and-place systems with cameras, conveyors, and robots based on the data that you set up in the Sysmac Studio. It is executed on the IPC Application Controller to control the process data and recipe data. The Robot Vision Manager application processes images captured by cameras based on the data that you set up in the Sysmac Studio. It is executed on the IPC Application Controller. Refer to the following manuals for more information. · Automated Control Environment (ACE) Version 4 User's Manual (Cat. No. I633) · IPC Application Controller User's Manual (Cat. No. I632) 1-6-4 XIO Termination Block The XIO Termination Block is used to connect digital I/O devices to the robot. This unit provides terminal block connection points for 12 inputs and 8 outputs. LED indicators are provided to indicate ON/OFF status. Each input has a switch to simulate input signals for troubleshooting or testing purposes. i4H Robots with EtherCAT User's Manual (I661) 1-17 1 Overview Use the XIO cable to connect the XIO Termination block to the robot. Refer to XIO Cable on page 1-19 for more information. · The part number for the XIO Termination Block is 90356-40100 (2 m cable included). · Refer to the Adept XIO Termination Block Installation Guide (00340-000) for more information. 1-6-5 Optional Cables This section provides information about optional cables that are available. 1-18 XIO Cable XIO Breakout Cable XBELTIO Adapter Cable Belt Encoder Y-adapter Cable EXPIO to IO Blox Cable i4H Robots with EtherCAT User's Manual (I661) 1 Overview 1-6 Optional Hardware 1-6-5 Optional Cables XBELTIO Adapter Cable The optional XBELTIO adapter cable connects to the XBELTIO connector on the Primary Interface Panel. It provides connections for belt encoder, force sensor, RS-232, and IO Blox signals. · The part number for this cable is 13463-000. · The length of this cable is 600 mm. Additional Information 1 Refer to A-4-2 XBELTIO Adapter Cable Pinouts on page A-8 for more information. Belt Encoder Y-adapter Cable The optional belt encoder Y-adapter cable connects to the XBELTIO adapter cable's BELT ENCODER connector. This cable provides individual connections for two belt encoder input signals. · The part number for this cable is 09443-000. · The length of this cable is 3 m. Additional Information Refer to A-4-3 Belt Encoder Y-adapter Cable Pinouts on page A-9 for more information. XIO Breakout Cable The optional XIO breakout cable connects to the XIO connector on the Primary Interface Panel and provides a method to connect I/O devices directly to the robot without using an XIO Termination Block unit. · This cable is not compatible with the XIO Termination Block. · This cable cannot be used together with an XIO cable. · The part number for this cable is 04465-000. · The length of this cable is 5 m. Additional Information Refer to 3-7-1 XIO Connector Signals and Wiring on page 3-13 for more information. XIO Cable The optional XIO cable connects to the XIO connector on the Primary Interface Panel. It is used to connect an XIO Termination Block to the system. · This cable cannot be used together with the XIO Breakout cable. · The part number for this cable is 03695-000. · The length of this cable is 2 m. Additional Information Refer to XIO Termination Block on page 3-16 for more information. i4H Robots with EtherCAT User's Manual (I661) 1-19 1 Overview EXPIO to IO Blox Cable The optional EXPIO to IO Blox cable connects to the XBELTIO adapter cable's FORCE/EXPIO connector. It allows a direct connection between this connector and optional IO Blox units. · The part number for this cable is 04677-030. · The length of this cable is 3 m. Additional Information Refer to 3-7-2 IO Blox Connections on page 3-17 for more information. 1-6-6 eCobra Mount Adapter An adapting plate is available that allows the robot to mount to a surface with an eCobra 600/800 hole pattern. This adapter is placed between the robot and the mounting surface and adapts the mounting holes on the surface to fit the robot mounting flange. · The part number of the eCobra mount adapter is 21636-000. · The mount adapter is made from 6061-T6 aluminum. Additional Information Using this adapter will add an additional 19 mm between the robot and the mounting surface. Refer to 2-1-6 eCobra Mount Adapter Dimensions on page 2-7 for more information. 1-6-7 Camera Mounting Bracket and Adapter A camera mounting bracket can be used to attach a camera to the robot outer link. This is fastened to the bottom of the outer link, near the z-axis quill exit. Use five M5 X 20 socket head cap screws with 2.5 N-m torque and Loctite 222 or equivalent thread locking compound when attaching the bracket to the robot. When attaching a Basler or Sentech camera, an adapter plate must be used to fasten the camera to the camera mounting bracket. The adapter plate is positioned between the bracket and the camera. Use four M3 X 10 socket head cap screws with 2.5 N-m torque and Loctite 222 or equivalent thread locking compound when attaching the plate to the adapter bracket. · The part number of the camera mounting bracket is 18908-000. · The part number of the adapter plate is 22295-000. · The adapter plate is made from 6061-T6 aluminum. · The bracket is made from 5052-H32 aluminum. 1-20 i4H Robots with EtherCAT User's Manual (I661) 1-6 Optional Hardware 1-6-8 eCobra Tool Flange 1 Overview · The weight of the camera mounting bracket is 120 grams. · The weight of the adapter plate is 37 grams. Additional Information Refer to 2-1-7 Camera Mounting Bracket and Adapter Dimensions on page 2-8 for more information. 1 1-6-8 eCobra Tool Flange An eCobra tool flange is available for the robot that allows reuse of end-of-arm tooling designed for an eCobra 600/800 robot. The eCobra tool flange has the same bolt pattern as the typical eCobra tool flange and it fits the Z-axis quill of the i4H SCARA robot series. To replace the standard tool flange that is supplied with the robot with the optional eCobra tool flange, use the same procedure found in 6-3-1 Replacing the Tool Flange on page 6-9. The part number of the eCobra tool flange is 19106-100F. i4H Robots with EtherCAT User's Manual (I661) 1-21 1 Overview 1-22 i4H Robots with EtherCAT User's Manual (I661) 2 Specifications 2 This section provides specifications for the robot's hardware, performance, electrical connections, installation environment, and other technical aspects of the system. 2-1 Physical Specifications ................................................................................. 2-2 2-1-1 Robot Overall Dimensions............................................................................... 2-2 2-1-2 Cable Clearances............................................................................................ 2-6 2-1-3 Mounting Flange Dimensions.......................................................................... 2-6 2-1-4 Tool Flange Dimensions .................................................................................. 2-7 2-1-5 Front Panel Dimensions .................................................................................. 2-7 2-1-6 eCobra Mount Adapter Dimensions ................................................................ 2-7 2-1-7 Camera Mounting Bracket and Adapter Dimensions ...................................... 2-8 2-1-8 Robot Weights ................................................................................................. 2-8 2-2 Performance Specifications ........................................................................ 2-10 2-2-1 General Performance Information ................................................................. 2-10 2-2-2 Stopping Distances and Times...................................................................... 2-10 2-3 Electrical Specifications .............................................................................. 2-14 2-3-1 Power Supply Specifications ......................................................................... 2-14 2-3-2 XIO I/O Specifications ................................................................................... 2-14 2-4 Environmental Specifications ..................................................................... 2-16 2-5 Other Specifications .................................................................................... 2-17 2-5-1 Connector and Port Specifications ................................................................ 2-17 2-5-2 Mounting Screws and Torques ...................................................................... 2-17 i4H Robots with EtherCAT User's Manual (I661) 2-1 2 Specifications 2-1 Physical Specifications This section provides physical specifications for the robot. 2-1-1 Robot Overall Dimensions Use the diagrams below to understand the robot's overall physical dimensions and work envelope. i4-650H Standard Dimensions Overall dimensions for the i4-650H Standard are provided below. 956 650 240 375 ±152° ±140° ±360° 240 776 880 210 418.5 i4-650H Long Quill Dimensions Overall dimensions for the i4-650H Long Quill are provided below. 956 650 240 375 ±152° ±140° ±360° 240 1080 776 418.5 410 2-2 i4H Robots with EtherCAT User's Manual (I661) 2-1 Physical Specifications 2-1-1 Robot Overall Dimensions 2 Specifications i4-650H Inverted Dimensions Overall dimensions for the i4-650H Inverted are provided below. 956 ±152° ±140° ±360° 518 488 240 375 210 240 650 2 i4-650H Inverted Long Quill Dimensions Overall dimensions for the i4-650H Inverted Long Quill are provided below. 956 173.5 ±152° ±140° ±360° 518 488 240 375 240 650 410 i4-750H Standard Dimensions Overall dimensions for the i4-750H Standard are provided below. 1056 750 240 375 ±152° ±140° ±360° 240 776 880 210 418.5 i4-750H Long Quill Dimensions Overall dimensions for the i4-750H Long Quill are provided below. i4H Robots with EtherCAT User's Manual (I661) 2-3 2 Specifications 1056 750 240 375 ±152° ±140° ±360° 240 776 1080 418.5 410 i4-750H Inverted Dimensions Overall dimensions for the i4-750H Inverted are provided below. 1056 ±152° ±140° 240 ±360° 518 488 375 210 240 750 i4-750H Inverted Long Quill Dimensions Overall dimensions for the i4-750H Inverted Long Quill are provided below. 1056 173.5 ±152° ±140° 240 ±360° 518 488 375 240 750 410 i4-850H Standard Dimensions Overall dimensions for the i4-850H Standard are provided below. 2-4 i4H Robots with EtherCAT User's Manual (I661) 2-1 Physical Specifications 2-1-1 Robot Overall Dimensions 2 Specifications 1156 850 240 475 ±152° ±140° ±360° 240 776 880 210 418.5 2 i4-850H Long Quill Dimensions Overall dimensions for the i4-850H Long Quill are provided below. 1156 850 240 475 ±152° ±140° ±360° 240 776 1080 410 418.5 i4-850H Inverted Dimensions Overall dimensions for the i4-850H Inverted are provided below. 1156 ±152° ±140° ±360° 240 518 488 475 240 210 850 i4-850H Inverted Long Quill Dimensions Overall dimensions for the i4-850H Inverted Long Quill are provided below. i4H Robots with EtherCAT User's Manual (I661) 2-5 2 Specifications 1156 ±152° ±140° ±360° 240 518 475 240 850 173.5 488 410 2-1-2 Cable Clearances There must be at least 183 mm of clearance from the Primary Interface Panel connectors to provide adequate space for cables. These clearances apply to all robot models. 2-1-3 Mounting Flange Dimensions The robot's mounting flange dimensions are provided below. Additional Information All hole locations are ± 0.12 mm. 4X Ø 14 THRU Ø 8 +0.02 13 0 280 2 22 +0.02 Ø 8 8 0 2-6 332 375 213 29 180 30 240 i4H Robots with EtherCAT User's Manual (I661) 2-1 Physical Specifications 2-1-4 Tool Flange Dimensions 2 Specifications 2-1-4 Tool Flange Dimensions The robot's tool flange dimensions are provided below. Geometry and tolerances meet ISO-9409-1-50-4-M6 (2004) requirements for manipulating industrial robots. 10 7 6.4 7 SLOT 5.08 M3 X 0.5 THRU 15° A 50 B.C. 23.699 +0.025 31.5 0 63 0 -0.046 2 58.70 3 X 90° 4 X M6 X 1.0 THRU 45° A 6 +0.013 0 THRU 2-1-5 Front Panel Dimensions The Front Panel dimensions are provided below. 152 140 Ø 4 41 125 76 89 56 16 5 2-1-6 eCobra Mount Adapter Dimensions The eCobra mount adapter dimensions are provided below. i4H Robots with EtherCAT User's Manual (I661) 2-7 2 Specifications 4X Ø 10.8 THRU M12 X 1.25 - 6H THRU 365 2X 347 324 +0.015 4X Ø8 0 THRU 2X 214 4X Ø 13.5 THRU Ø 20 13 2X 54 3X 44 2X 15 0 4X R25 19 0 4X 30 2X 40 70 170 2X 200 2X 210 240 2-1-7 Camera Mounting Bracket and Adapter Dimensions The camera mounting bracket dimensions are provided below. 77 105.5 42 73 125 6 2-1-8 Robot Weights Weights for the different robot models are provided in the following table. Robot Model i4-650H Standard i4-650H Inverted i4-650H Long Quill i4-650H Inverted Long Quill i4-750H Standard i4-750H Inverted i4-750H Long Quill i4-750H Inverted Long Quill i4-850H Standard i4-850H Inverted 50.4 kg 50.8 kg 50.9 kg 51.3 kg 51.6 kg Weight 2-8 i4H Robots with EtherCAT User's Manual (I661) 2-1 Physical Specifications Robot Model i4-850H Long Quill i4-850H Inverted Long Quill 2 Specifications 52.0 kg Weight 2 2-1-8 Robot Weights i4H Robots with EtherCAT User's Manual (I661) 2-9 2 Specifications 2-2 Performance Specifications The following sections provide robot performance specifications. 2-2-1 General Performance Information The following table provides general performance information for the robot. Item i4-650H i4-750H i4-850H Maximum Payload*1 15 kg Reach 650 mm 750 mm 850 mm Joint Range Joint 1 ±152° Joint 2 ±140° Joint 3 · 210 mm · 410 mm (long quill model) Joint 4 ±360° Joint 4 Moment of Inertia 0.5 kg-m2 maximum Downward Push Force burst 600 N with no load*2 Cycle Time*3*4 0.48 s 0.54 s Repeatability at 100% speed · X, Y: ±0.015 mm · Joint 3: ±0.01 mm · Joint 4: ±0.005° · X, Y: ±0.025 mm · Joint 3: ±0.01 mm · Joint 4: ±0.005° Joint speeds (maximum) Joint 1 Joint 2 450 deg/s 720 deg/s Joint 3 1583 deg/s Joint 4 2400 deg/s *1. Payload is considered as any object(s) attached to a robot link or tool flange including items such as endeffectors, tooling, valves, grippers, and objects being handled by the robot. *2. At a duty cycle of 3 seconds pushing and then 2 seconds not pushing. *3. Cycle time is defined as a continuous path with straight-line motion cycle in which the robot tool moves up 25 mm, over 305 mm, down 25 mm, and then back along the same path (not achievable over all paths in the robot working envelope). Values listed are for sustained motion, no joint 4 rotation, with a 2 kg payload. *4. Cycle time values increase by 15% when operating at the maximum ambient temperature of 40° C. Z-axis Quill Bending Moment When the robot is operating at high payloads with high acceleration / deceleration, the z-axis quill is subject to excessive bending moments. Careful considerations must be made under these conditions. Refer to 4-1 Payload and Acceleration Considerations on page 4-2 for more information. 2-2-2 Stopping Distances and Times The following graphs present information required by Clause 7.2 n of ISO 10218-1. This information should be used to calculate the safe distance needed when designing and installing safeguarding devices. 2-10 i4H Robots with EtherCAT User's Manual (I661) 2-2 Performance Specifications 2-2-2 Stopping Distances and Times 2 Specifications WARNING The stopping time and distance, or angle, of a robot joint from initiation of a stop signal is not negligible and must be taken into account when designing and applying safeguarding devices. The graphs show the time elapsed and distances traveled between the initiation of a stop signal and the cessation of all robot motion. For stop category 1, the stopping time and distance values depend on the speed, load, and extension of the robot, stated for 33%, 66% and 100% of the maximum payload (15 kg). Data provided is for the three joints of greatest displacement (J1, J2, and J3). 2 Joint 1 Stopping Time 0.3 Stopping Time (s) 0.2 5 kg 10 kg 0.1 15 kg Stopping Distance (degrees) 0 0 70 20 40 60 80 100 120 Speed (%) Joint 1 Stopping Distance 50 30 10 0 5 kg 10 kg 15 kg 20 40 60 80 100 120 Speed (%) i4H Robots with EtherCAT User's Manual (I661) 2-11 2 Specifications Stopping Time (s) Stopping Distance (degrees) 0.4 0.3 0.2 0.1 0 0 170 150 130 110 90 70 50 30 10 0 0.3 Joint 2 Stopping Time 5 kg 10 kg 15 kg 20 40 60 80 100 120 Speed (%) Joint 2 Stopping Distance 5 kg 10 kg 15 kg 20 40 60 80 100 120 Speed (%) Joint 3 Stopping Time 0.2 5 kg 10 kg 0.1 15 kg 0 0 20 40 60 80 100 120 Speed (%) Stopping Time (s) 2-12 i4H Robots with EtherCAT User's Manual (I661) Stopping Distance (mm) 2-2 Performance Specifications 2 Specifications Joint 3 Stopping Distance 360 320 280 240 200 5 kg 160 10 kg 120 15 kg 80 40 0 2 0 20 40 60 80 100 120 Speed (%) 2-2-2 Stopping Distances and Times i4H Robots with EtherCAT User's Manual (I661) 2-13 2 Specifications 2-3 Electrical Specifications Electrical specifications are provided in the sections below. 2-3-1 Power Supply Specifications Specifications for the 24 VDC and 200 to 240 VAC power supplies are provided below. Power Supply Item Specification 24 VDC Control Supply voltage Power range 24 VDC ±10% Current / power requirements 8 A / 190 W maximum Circuit protection User-supplied 10 A, slow-blow fuse / breaker Wire size 0.75 mm2 to 2.5 mm2 Shielding User-supplied connection from power supply cable shield to robot ground point. 200 to 240 VAC Supply voltage High Power range 200 to 240 VAC Minimum*1: 180 VAC Maximum: 264 VAC Supply frequency 50/60 Hz, single phase Current require- 12 A ments*2 Circuit protection User-supplied 15 A, slow-blow fuse / breaker Shielding User-supplied connection from power supply cable shield to robot ground point. *1. Specifications established at nominal line voltage. Low line voltage can affect robot performance. *2. There is no inrush current beyond the specification provided. Facility Overvoltages Protection You must protect the robot from excessive overvoltages and voltage spikes. If your country requires a CE-certified installation or compliance with IEC 61131-2, the installation must ensure that Category II overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltages Category II, i.e., not higher than the impulse voltage corresponding to the rated voltage for the basic insulation. Your equipment or transient suppressor must be capable of absorbing the energy in the transient. In the industrial environment, nonperiodic overvoltage peaks may appear on mains power supply lines. These can come from power interruptions to high-energy equipment (such as a blown fuse on one branch in a 3-phase system), which will cause high current pulses at relatively low voltage levels. You must take the necessary steps to prevent damage to the robot. 2-3-2 XIO I/O Specifications Specifications for the XIO input and output circuits are provided below. 2-14 i4H Robots with EtherCAT User's Manual (I661) 2-3 Electrical Specifications Type Input circuits Output circuits 2 Specifications Item Specification Type Sinking / Sourcing Operational voltage range 0 to 30 VDC OFF state voltage range 0 to 3 VDC ON state voltage range 10 to 30 VDC Typical threshold voltage 8 VDC Operational current range 0 to 7.5 mA OFF state current range 0 to 0.5 mA ON state current range 2.5 to 6 mA Typical threshold current 2.0 mA Impedance (Vin / Iin) 39 k 2 Current at 24 VDC < 6 mA ON response time (hardware) 5 µs OFF response time (hardware) 5 µs Type Sourcing Output voltage range 24 VDC ±10% Total current output for all XIO circuits 1.0 A maximum at 50° C ambient temperature 1.5 A maximum at 25° C ambient temperature ON state resistance at 0.5A 0.14 maximum at 85° C Output leakage current 5 µA maximum ON response time (hardware) 30 µs OFF response time (hardware) 38 µs Short circuit current limit 0.7 to 2.5 A Output voltage at inductive load (turn OFF) (+V - 52) Vdemag (+V - 41) where Iout = 0.5 A and load 1 mH 2-3-2 XIO I/O Specifications i4H Robots with EtherCAT User's Manual (I661) 2-15 2 Specifications 2-4 Environmental Specifications Environmental specifications are provided below. Item Ambient operating temperature Storage temperature Humidity Altitude Pollution degree Protection class Specification 0 to 40° C -25 to 55° C During operation: 5 to 90% (Non-condensing) During storage and transportation: 75% or less (noncondensing) 2000 m max 2 IP20 / NEMA Type 1 2-16 i4H Robots with EtherCAT User's Manual (I661) 2-5 Other Specifications 2-5-1 Connector and Port Specifications 2 Specifications 2-5 Other Specifications Other specifications for connectors, ports, mounting bolts, and brakes are provided below. 2-5-1 Connector and Port Specifications Robot connector specifications are provided below. Additional Information 2 Refer to Section 3 Installation on page 3-1 for more information about connector wiring and pin diagrams. Connector Pneumatic pass-through ports USER connectors Control Power connector High Power connector XSYSTEM connector XBELTIO connector XIO connector EtherCAT interface ports Tool EtherCAT connector port Specification Push-connect type fittings with a maximum air pressure of 0.55 MPa · Ports 1, 2, 3, 4 fittings: 6 mm 19-pin, M23, male Male-threaded Internal wire size: 0.25 mm2 Internal wire voltage rating: 600 V Connector assembly consists of the following items: · Housing: Harting 09 15 100 0307 · Insert: Harting 09 15 119 3101 · Pins: Harting 09 15 100 6201(1 mm size) and 09 15 100 6211 (1.5 mm size) Molex 2-wire receptacle Part number: 43160-2102 IEC 60320 C15 type Part number: 04118-000 44 pin, D-sub HD, female 26 pin, D-sub HD, male 26 pin, D-sub HD, female RJ-45 4 pin, M12, female D-coded type Female-threaded 2-5-2 Mounting Screws and Torques The following screw type, washers, and torque is required for mounting the robot. WARNING The robot can fall over if it is not properly secured with mounting hardware. i4H Robots with EtherCAT User's Manual (I661) 2-17 2 Specifications Type Socket Head Cap Screw Hex Nuts (through hole mounting only) Flat Washer Quantity 4 4 4 Size · M12 x 1.75 mm · DIN 912 or ISO 4782 · M12 · DIN 125 or ISO 7089 Class 10.9 or 12.9 8.8 Torque 96 to 104 N-m - 2-18 i4H Robots with EtherCAT User's Manual (I661) 3 Installation 3 This section provides information about installing the robot and other necessary equipment. 3-1 Robot Installation Procedure ........................................................................ 3-2 3-2 Mounting the Robot ....................................................................................... 3-3 3-2-1 Robot Mounting Surface.................................................................................. 3-3 3-2-2 Mounting Procedure ........................................................................................ 3-3 3-3 Installing End-of-Arm Tooling ....................................................................... 3-5 3-4 Installing Optional Equipment ...................................................................... 3-6 3-4-1 Mounting External Equipment to the Robot..................................................... 3-6 3-4-2 Tool EtherCAT Connector Wiring .................................................................... 3-6 3-4-3 USER Connector Wiring.................................................................................. 3-7 3-5 Adjustable Hardstop Details ......................................................................... 3-8 3-5-1 Joint 1 Adjustable Hardstops........................................................................... 3-8 3-6 System Cable Installation............................................................................ 3-10 3-6-1 System Cable Overview ................................................................................ 3-10 3-6-2 System Cable Installation Procedure ............................................................ 3-12 3-7 Connecting Digital I/O.................................................................................. 3-13 3-7-1 XIO Connector Signals and Wiring................................................................ 3-13 3-7-2 IO Blox Connections...................................................................................... 3-17 3-8 Installing Safety Equipment ........................................................................ 3-19 3-8-1 Installing the Front Panel............................................................................... 3-19 3-8-2 Safety Circuits ............................................................................................... 3-20 3-9 Setting the EtherCAT Node ID..................................................................... 3-27 3-9-1 EtherCAT Node ID Setting Example ............................................................. 3-27 3-10 Supplying Power and Ground..................................................................... 3-29 3-10-1 Grounding the System................................................................................... 3-29 3-10-2 DC Connections ............................................................................................ 3-30 3-10-3 AC Connections ............................................................................................ 3-31 3-11 Verifying Installation .................................................................................... 3-32 3-11-1 Mechanical Checks ....................................................................................... 3-32 3-11-2 System Cable Checks ................................................................................... 3-32 3-11-3 Safety Equipment Checks ............................................................................. 3-32 3-11-4 Switch Position Checks ................................................................................. 3-34 i4H Robots with EtherCAT User's Manual (I661) 3-1 3 Installation 3-1 Robot Installation Procedure The basic installation steps are provided below. WARNING · Ensure that installation and post-installation checks of the product are performed by personnel in charge who possess a thorough understanding of the machinery to be installed. · The robot must be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create trapping or pinch points. It must be installed in accordance with Standard for Robots and Robotic Devices Safety Requirements for Industrial Robots Part 2: Robot Systems and Integration, ISO 10218-2. 1 Mount the robot. Refer to 3-2 Mounting the Robot on page 3-3 for more information. 2 Install the end-of-arm tooling. Refer to 3-3 Installing End-of-Arm Tooling on page 3-5 for more information. 3 Install any optional equipment. Refer to 3-4 Installing Optional Equipment on page 3-6 for more information. 4 Connect any necessary pneumatic air lines using the pass-through ports. Refer to 2-5-1 Connector and Port Specifications on page 2-17 for more information. 5 Make any necessary adjustments to hardstops. Refer to 3-5 Adjustable Hardstop Details on page 3-8 for more information. 6 Connect all required system cables. Refer to 3-6 System Cable Installation on page 3-10 and 3-7 Connecting Digital I/O on page 3-13 for more information. 7 Connect all required safety equipment. Refer to 3-8 Installing Safety Equipment on page 3-19 for more information. 8 Set the EtherCAT node ID and robot operation mode. Refer to 3-9 Setting the EtherCAT Node ID on page 3-27 for more information. Refer to 4-2 Robot Control Modes on page 4-3 for more information. 9 Make power and ground connections. Refer to 3-10 Supplying Power and Ground on page 3-29 for more information. 10 Verify the robot installation. Refer to 3-11 Verifying Installation on page 3-32 for more information. 3-2 i4H Robots with EtherCAT User's Manual (I661) 3-2 Mounting the Robot 3-2-1 Robot Mounting Surface 3 Installation 3-2 Mounting the Robot Use the information in the following sections to mount the robot. Before beginning the mounting procedure, have the following tools and resources available. · A torque wrench for proper tightening of the mounting screws. · Assistance to maneuver the robot into the mounting position. · Four socket-head cap screws with flat washers and hex nuts (through hole mounting only). Refer to 2-5-2 Mounting Screws and Torques on page 2-17 for more information. · A lifting strap. 3-2-1 Robot Mounting Surface The robot must be mounted on a smooth, level, and flat surface that is rigid enough to prevent vibra- 3 tion and flexing during operation. The mounting surface must be designed to support the weight of the robot with payload and also the reactionary forces that are caused by fast robot motion. Mounting holes can be drilled and tapped or through type. WARNING If a robot is mounted to a surface with inadequate stiffness, damage to the z-axis quill or other mechanical components can result from excessive oscillation during operation. Precautions for Correct Use · It is recommended to use an 18 mm (minimum) thick steel plate with a maximum surface roughness of 25 m that is properly secured to the floor or wall as a robot mounting surface. Mounting surface flatness must not exceed 5 mm. · Keep a minimum of 300 mm clearance behind the robot to avoid unmounting of the robot in case of iCS-ECAT amplifier chassis replacement and to allow for easy switch setting access. Robot Mounting Structure Use the following guidelines when designing a structure to support the robot. · Structures designed for inverted robots require a typical stiffness of 40 Hz minimum. Applications with high payloads or aggressive moves at full link extensions may require higher stiffness. · Structures designed for standard robots require a typical stiffness of 100 Hz minimum. Precautions for Correct Use If the robot mounting structure is not designed with adequate stiffness, robot performance will not meet the specified values. 3-2-2 Mounting Procedure Use the following procedure to mount the robot. i4H Robots with EtherCAT User's Manual (I661) 3-3 3 Installation WARNING Do not remove the shipping brackets or move the robot links until the robot has been secured to its mounting surface. Failure to comply could result in the robot falling and causing either personnel injury or property damage. WARNING · Use a crane and straps to lift the robot by the inner arm and controller handle. Never lift the robot by the quill. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage. · The robot can fall over if it is not properly secured with mounting hardware. Precautions for Correct Use The mounting surface should be clean and prepared according to the information provided in 3-2-1 Robot Mounting Surface on page 3-3 before attempting to mount the robot. Additional Information After mounting the robot, check the mounting screw torque after 72 hours of initial operation and then recheck every 3 months thereafter. 1 Using the dimensions provided in 2-1-3 Mounting Flange Dimensions on page 2-6, prepare four holes in the mounting surface to accommodate the user-supplied machine screws. A slot and hole are provided in the mounting flange for locating purposes if necessary. 2 Maneuver the robot into position on the mounting surface. Place lifting straps under the inner link and around the handle located near the rear of the robot when lifting. 3 Align the holes in the mounting flange with the prepared mounting holes in the mounting sur- face. 4 Insert all four screws with washers to secure the robot to the mounting surface. 5 Torque the mounting screws in a criss-cross sequence using a minimum of three passes until the required torque of 96 to 104 N-m is achieved. 6 After all four screws have been tightened to the specified torque, the mounting procedure is complete. 3-4 i4H Robots with EtherCAT User's Manual (I661) 3-3 Installing End-of-Arm Tooling 3 Installation 3-3 Installing End-of-Arm Tooling You must provide, install, and ground (if necessary) end-of-arm tooling to the tool flange. Use the following details when designing and installing end-of-arm tooling. · Hole diameters and placement on the tool flange comply with ISO-9409-1-50-4-M6 (2004) require- ments for manipulating industrial robots. · End-of-arm tooling is attached to the tool flange using M6 x 1.0 (Class 10.9 or higher) screws with a minimum of 10 mm thread engagement into the tool flange. · Apply Loctite 243 thread lock (or equivalent) to secure the fasteners. · Apply a torque of 7.5 N-m when tightening tooling fasteners. Additional Information 3 Refer to 2-1-4 Tool Flange Dimensions on page 2-7 for more information. If the end-of-arm tooling requires pneumatic or electrical connections, use the connectors on the Secondary Interface Panel. Refer to 1-2-5 Connectors on page 1-9 for more information. Precautions for Safe Use The Joint 3 quill and the tool flange are not grounded to protective earth. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment or tooling to the ground point on the robot base. DANGER Failure to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or fatality of a person touching the end-effector during an electrical fault. i4H Robots with EtherCAT User's Manual (I661) 3-5 3 Installation 3-4 Installing Optional Equipment This section provides information about installing the following optional equipment. 3-4-1 Mounting External Equipment to the Robot The robot body has accommodations to mount external equipment to the underside of the outer link. Use the information below to understand how to mount external equipment to the robot. The following considerations should be made when mounting external equipment to the robot. · Do not mount equipment that will interfere with robot motion or other objects in the work cell. · Do not mount equipment in a way that can induce excessive inertia to the outer link. Precautions for Correct Use Any externally mounted equipment is considered robot payload. Consideration to the payload attached to the Tool Flange should be made when mounting external equipment to the robot. Apply a torque of 2.5 N-m to the user-supplied fasteners when mounting equipment to the 4 mounting holes between joint 2 and joint 4. Apply Loctite thread lock type 222 or equivalent. 80 90 12.5 25 4X M4 X 0.7 8 3-4-2 Tool EtherCAT Connector Wiring Use the information below to make an EtherCAT network connection from the Tool EtherCAT connector to user-supplied devices mounted on the outer link or end-of-arm tooling. Additional Information Refer to 2-5-1 Connector and Port Specifications on page 2-17 for more information about the Tool EtherCAT connector type. PIN 1, Transmit + (TD+) PIN 2, Receive + (RD+) PIN 4, Receive - (RD-) 3-6 PIN 3, Transmit - (TD-) i4H Robots with EtherCAT User's Manual (I661) 3-4 Installing Optional Equipment 3 Installation 3-4-3 USER Connector Wiring Use the information below to make connections to the USER connectors on the Primary Interface Panel and the Secondary Interface Panel. Additional Information Refer to 2-5-1 Connector and Port Specifications on page 2-17 for more information about the USER connector type. 1 12 11 2 18 10 13 17 3 19 9 3 14 16 4 15 8 5 7 6 3-4-3 USER Connector Wiring i4H Robots with EtherCAT User's Manual (I661) 3-7 3 Installation 3-5 Adjustable Hardstop Details The robot is equipped with mechanical hardstop adjustment points for joint 1 as described in the following sections. Adjust this mechanical hardstop to restrict the robot's range of motion in order to prevent collisions within the workspace if necessary. WARNING The robot's physical hardstop devices are not intended to withstand repeated use. If this occurs, the hardstop may become damaged. Implement proper programming and configuration of joint range limits to prevent hardstop impacts. Precautions for Correct Use Always reduce joint motion limits with software configuration settings when hardstops are used to restrict range of motion. Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information. Additional Information · Obstacles may be defined with software configuration to restrict the robot tool-tip from entering specified volumes of the work envelope. Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information. · Refer to 2-1-1 Robot Overall Dimensions on page 2-2 for full range of motion values. 3-5-1 Joint 1 Adjustable Hardstops Joint 1 has adjustable hardstops that can be used to physically limit the range of travel. The full, default range of travel is ±152°. User-supplied socket head cap screws are inserted into slots that limit the travel in the positive or negative directions. The slots are located under a cover for Joint 1 as described in the following procedure. The following Joint 1 motion limits are available. · ±107° · ±62° · ±17° · +28° or -28° The following tools and equipment are required for making adjustments to Joint 1 hardstop(s). · M10 X 1.5 - 14 mm socket head cap screw(s), Class 12.9, alloy steel type. · Torque wrench. · 3 mm hex key. · Loctite thread lock type 243 and 222 or equivalent. Joint 1 Hardstop Adjustment Procedure Use the following procedure to make adjustments to the Joint 1 hardstops. 3-8 i4H Robots with EtherCAT User's Manual (I661) 3-5 Adjustable Hardstop Details 3-5-1 Joint 1 Adjustable Hardstops 3 Installation Precautions for Correct Use Do not remove factory-installed Joint 1 hardstops. When adjusting Joint 1 hardstops, do not let screws or other objects drop into the robot body. 1 Remove the 5 M4 screws that hold the Joint 1 hardstop cover in place. Then, remove the Joint 1 hardstop cover to expose the adjustment slots. Joint 1 Hardstop Cover Cover Screws (x5) Hardstop Slots 3 2 Move the inner arm to the desired position to expose the appropriate slot. Use the following figure to determine the Joint 1 position required to expose a specific hard stop slot. Positions in parenthesis represent the hardstop limit value. Position 1+ Position 2+ Position 1+ 135° (+107°) Position 3+ Position 2+ 90° (+62°) Position 3+ 45° (+17°) Position 4 Position 4 0° (-28° or +28°) Position 1- Position 2- Position 3- Position 1-135° (-107°) Position 2-90° (-62°) Position 3-45° (-17°) 3 Apply Loctite thread lock type 243 to the M10 X 1.5 - 14 mm socket head screws and insert them into the appropriate slot(s). Apply a torque of 34 N-m. 4 Repeat steps 2 and 3 if a second hardstop is required. 5 Replace the Joint 1 hardstop cover. Apply Loctite 222 or equivalent to the fasteners, insert them, and tighten to a torque of 1.1 N-m to complete this procedure. i4H Robots with EtherCAT User's Manual (I661) 3-9 3 Installation 3-6 System Cable Installation This section provides information about installing the robot system cables. WARNING · Never connect or disconnect system cables while power is applied to the robot. Failure to comply may cause unexpected behavior and can result in personnel injury and equipment damage. · Provide appropriately-sized Branch Circuit Protection and Lockout / Tagout Capability in accordance with the National Electrical Code and any local codes. · Ensure that interconnecting cables or pneumatic lines are routed away from the robot workspace. 3-6-1 System Cable Overview Standard and optional cable connections are provided below. Standard Connections The following figure shows standard connections with the XSYSTEM cable. This cable is supplied with the robot. Additional Information Refer to 3-8 Installing Safety Equipment on page 3-19 for more information about XFP, XUSR, and XMCP connections. 3-10 i4H Robots with EtherCAT User's Manual (I661) 3 Installation 3-6 System Cable Installation 3-6-1 System Cable Overview 3 XSYSTEM Cable XUSR Connector XFP Connector Front Panel Extension Cable Ethernet Connector XMCP Connector T20 Pendant Adapter Cable T20 Pendant Jumper Plug Front Panel T20 Pendant Optional Connections The following figure shows optional connections to the robot. Additional Information Refer to 3-7 Connecting Digital I/O on page 3-13 for more information about connecting I/O with IO Blox Units or with the XIO connector. i4H Robots with EtherCAT User's Manual (I661) 3-11 3 Installation XIO Cable XIO Breakout Cable XBELTIO Adapter Cable EXPIO to IO Blox Cable Belt Encoder Y-adapter Cable 3-6-2 System Cable Installation Procedure The following procedure provides details about system cable installation. The robot must be mounted before following the steps below. 1 Connect the XSYSTEM cable to the Primary Interface Panel XSYSTEM connector and route the XFP, XUSR, and XMCP connectors to their appropriate locations. 2 Connect any digital I/O. Refer to 3-7 Connecting Digital I/O on page 3-13 for more information. 3 Connect external equipment such as the Front Panel and Teach Pendant to the XSYSTEM ca- ble XFP and XMCP connectors. Refer to 3-6-1 System Cable Overview on page 3-10 for more information. 4 Connect all user-supplied safety equipment to the XUSR connector on the XSYSTEM cable. Refer to 3-8 Installing Safety Equipment on page 3-19 for more information. 5 If applicable, connect devices to the XBELTIO connector and the USER connectors. Refer to Optional Connections on page 3-11 for more information. 6 Connect the robot to the EtherCAT network. 3-12 i4H Robots with EtherCAT User's Manual (I661) 3 Installation 3-7 Connecting Digital I/O 3-7-1 XIO Connector Signals and Wiring 3-7 Connecting Digital I/O The following sections describe the various methods to connect digital I/O to the robot. 3-7-1 XIO Connector Signals and Wiring The XIO connector on the Primary Interface Panel provides access to 12 built-in digital inputs and 8 built-in digital outputs. The XIO connector pin assignments and V+ signal numbers are provided in the table below. To deter- mine the V+ signal number, use the following formula. n = 100 X Robot Number m = (Robot Number - 1) X 100 The Robot Number is designated with the Robot Device Assignment in Robot Basic Settings using 3 Sysmac Studio. Refer to A-3 I/O Signal Numbering on page A-4 for all V+ signal number designations. Additional Information Refer to 2-3-2 XIO I/O Specifications on page 2-14 for electrical specifications. Refer to 2-5-1 Connector and Port Specifications on page 2-17 for connector specifications. The Designation and Signal Bank information in the table below only apply when using an XIO Termination Block. PIN 9 PIN 18 PIN 26 PIN 1 PIN 10 PIN 19 Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Designation Ground 24 VDC Common 1 Input 1.1 Input 2.1 Input 3.1 Input 4.1 Input 5.1 Input 6.1 Ground 24 VDC Common 2 Input 1.2 Input 2.2 Input 3.2 Input 4.2 Input 5.2 Input 6.2 Signal Bank -- -- 1 -- 901 + n 902 + n 903 + n 904 + n 905 + n 906 + n -- -- 2 -- 907 + n 908 + n 909 + n 910 + n 911 + n 912 + n V+ Signal Number i4H Robots with EtherCAT User's Manual (I661) 3-13 3 Installation Pin Number 19 20 21 22 23 24 25 26 Designation Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Signal Bank -- 1 + m 2 + m 3 + m 4 + m 5 + m 6 + m 7 + m 8 + m V+ Signal Number XIO Internal Circuits Use the following information to understand the XIO internal circuits. XIO Input Signals The twelve inputs are arranged in two banks of six. Each bank is electrically isolated from the other bank. Each input is optically isolated. The six inputs within each bank share a common source / sink line. Input 1.1 Input 1.2 Input 1.3 Input 1.4 Input 1.5 Input 1.6 Common 1 Input 2.1 Input 2.2 Input 2.3 Input 2.4 Input 2.5 Input 2.6 Common 2 Internal Circuits XIO Output Signals The eight outputs share a common, sourcing driver integrated circuit. The driver is designed to supply a load with one side connected to ground. Each channel is capable of switching up to 0.7 A of current. This driver has over-temperature protection, shorted load protection, and is current limiting. The driver draws power from the 24 VDC Control Power supplied to the robot through a self-resetting polyfuse. 3-14 i4H Robots with EtherCAT User's Manual (I661) 3 Installation 3-7 Connecting Digital I/O 3-7-1 XIO Connector Signals and Wiring Precautions for Safe Use Output 8 can be assigned to indicate the robot's High Power state. When High Power is enabled, this output will turn ON. When High Power is not enabled, this output will be OFF. This is not a safety-rated means of indicating a High Power state and should only be used for monitoring the robot status. Use the Sysmac Studio to make this configuration if needed. Precautions for Correct Use Use surge suppression when switching inductive loads such as relays to prevent damage to the output circuits. Additional Information If there is an output short or other over-current condition, the affected output of the driver inte- grated circuit turns OFF until the condition is removed. 3 +24 VDC Internal Circuits Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 XIO Breakout Cable Pinouts Use the following diagrams for XIO Breakout cable pinout information. PIN 1 PIN 10 PIN 9 PIN 18 PIN 19 PIN 26 Pin Number 1 2 3 4 Signal GND 24 VDC Common 1 Input 1.1 White White / Black Red Red / Black i4H Robots with EtherCAT User's Manual (I661) Wire Color 3-15 3 Installation Pin Number 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Shell Signal Input 2.1 Input 3.1 Input 4.1 Input 5.1 Input 6.1 GND 24 VDC Common 2 Input 1.2 Input 2.2 Input 3.2 Input 4.2 Input 5.2 Input 6.2 Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Shield Yellow Yellow / Black Green Green / Black Blue Blue / White Brown Brown / White Orange Orange / Black Gray Gray / Black Violet Violet / White Pink Pink / Black Light blue Light blue / Black Light green Light green / Black White / Red White / Blue Wire Color XIO Termination Block An XIO termination block can be connected directly to the XIO connector to provide simple wiring and access to the built-in I/O. Additional Information Refer to the Adept XIO Termination Block Installation Guide (00340-000) for more information. 3-16 i4H Robots with EtherCAT User's Manual (I661) 3-7 Connecting Digital I/O 3 Installation 3 3-7-2 IO Blox Connections IO Blox units can be connected to the XBELTIO connector using the XBELTIO adapter cable. Up to 4 IO Blox units can be connected as shown below. Additional Information Refer to the IO Box Users Guide (04638-000) for more information. 3-7-2 IO Blox Connections i4H Robots with EtherCAT User's Manual (I661) 3-17 3 Installation XBELTIO Adapter Cable EXPIO to IO Blox Cable 3-18 i4H Robots with EtherCAT User's Manual (I661) 3-8 Installing Safety Equipment 3-8-1 Installing the Front Panel 3 Installation 3-8 Installing Safety Equipment The user-supplied safety equipment connects to the system through the XMCP, XUSR and XFP connectors on the XSYSTEM cable. Refer to the following sections for safety equipment connection details. DANGER · The robot system must be installed with user-supplied interlock barriers. The inter- locked barriers must open the E-Stop circuit in the event of personnel attempting to enter the work cell when High Power is enabled. Failure to install suitable guarding or interlocks could result in injury or death. We strictly prohibit installation, commis- sioning, or operation of any robot without adequate safeguards. These must be compliant with applicable local and national standards. · The placement of safety controls shall avoid requiring a person to enter a hazard- 3 ous area to actuate them. · Controls shall be located outside of the safeguarded space, except for certain con- trols such as emergency stops or a teach pendant, where based on a risk assess- ment they may be located within the safeguarded space. WARNING Before starting the operation of equipment, always confirm that the safety equipment of the robot works properly. If a malfunction of the safety equipment is detected, follow the procedure for abnormal conditions. CAUTION The design and installation of the complete system must comply with the safety standards and regulations in the country of use. The integrators of the robot should understand the safety laws and regulations in their countries and prevent major hazards from occurring in the complete system. Additional Information Refer to the Robot Safety Guide (Cat. No. I590) for more information. 3-8-1 Installing the Front Panel Use the dimensions below to install the Front Panel in a suitable location outside of the robot's workspace where it can be easily accessed for emergency stops. The length of the XSYSTEM cable (1.8 m) and the length of the Front Panel extension cable (3 m) should also be considered when choosing an installation location. If you need to extend the Front Panel beyond the supplied cable distance, contact your local OMRON representative for more information. DANGER Any High Power push-buttons must be installed outside of the robot's workspace. i4H Robots with EtherCAT User's Manual (I661) 3-19 3 Installation 41 mm Ø 4 mm 76 mm 89 mm 56 mm 152 mm 140 mm 125 mm 16 mm 5 mm Front Panel Connections The Front Panel is connected directly to the XFP connector on the XSYSTEM cable with the 3 m extension cable supplied with the Front Panel. · The part number of the extension cable is 10356-10500. · The length of the extension cable is 3 m. Additional Information Refer to XFP Connections on page 3-22 for more information. 3-8-2 Safety Circuits The XSYSTEM cable provides connections for all emergency stop circuits. All emergency stop circuits are dual-channel and voltage-free. These voltage-free contacts are provided by a redundant, cyclically-checked, positive-drive, safety relay circuit for Category 3 PL-d per ISO 13849 operation. The XUSR connector provides access to the following safety circuits. · Dual channel emergency stop inputs. · Dual channel emergency stop status outputs. · Dual channel muted safety gate inputs. · Dual channel Automatic / Manual mode status outputs. The XFP connector provides access to the following safety circuits that are typically used with the Front Panel. · Dual channel emergency stop inputs. · Dual channel Automatic / Manual mode selection inputs. · High power indicator output. · High power enable input. · Control power indicator output. The XMCP connector provides access to the following safety circuits that are use with a connected Teach Pendant. · Dual channel E-stop button inputs. · Dual channel pendant enable switch inputs. Use the diagram below to understand safety circuits. 3-20 i4H Robots with EtherCAT User's Manual (I661) 3-8 Installing Safety Equipment 3-8-2 Safety Circuits 3 Installation XFP-1 XFP-2 XFP-9 XFP-10 XMCP-1 XMCP-2 XMCP-9 XMCP-10 XUSR-1 XUSR-2 XUSR-14 XUSR-15 XUSR-3 XUSR-4 XFP-14 XFP-13 XFP-5 XFP-6 High Power Indicator / Button XSYSTEM-5 XFP-3 XFP-11 AM2 XFP-4 Automatic / Manual Mode Selection XFP-12 AM1 XUSR-16 XUSR-17 Automatic Mode XUSR-17 XUSR-9 XUSR-16 3 XUSR-10 Manual Mode XMCP-3 XMCP-4 AM2 AM1 Automatic Mode AM2 AM1 Status Outputs XUSR-23 XMCP-11 XMCP-12 XUSR-5 XUSR-18 XUSR-6 Muted Safety Gate XUSR-19 XUSR-22 XUSR-8 XUSR-7 Force-Guided ES1 Relay Cycle Check Control Circuit ES2 Emergency Stop ES2 ES1 Status Outputs XUSR-20 XUSR-21 200 to 240 VAC High Power Input (External) Internal High Power SR1 SR2 XUSR Connections Use the information in the following table to understand the signals provided on the XUSR connector. PIN 13 PIN 1 PIN 25 Pins 1, 14 2, 15 Description Emergency stop channel 1 input Emergency stop channel 2 input PIN 14 Additional Information Typically connected to normally closed contacts on usersupplied safety devices such as E-stop buttons, safety switches, or safety relays. i4H Robots with EtherCAT User's Manual (I661) 3-21 3 Installation Pins 3, 16 4, 17 5, 18 6, 19 7, 20 8, 21 9, 22 10, 23 11, 12, 13, 24, 25 Description Line emergency stop inputs Muted safety gate channel 1 input Muted safety gate channel 2 input Emergency stop status channel 1 output Emergency stop status channel 2 output Automatic mode status channel 1 Automatic mode status channel 2 Reserved for future use. Additional Information Normally closed contacts on user-supplied safety devices typically used for other robot or line emergency stop interconnection. This does not affect emergency stop indication signals on pins 7, 20. Causes emergency stop in Automatic mode only. Internal contacts are closed when Front Panel, Teach Pendant, and user-supplied safety devices are not enabled / activated. Internal contacts are closed when the robot is in automatic mode. XUSR Jumper Plug The XUSR jumper plug is provided for safety equipment troubleshooting only. XUSR PLUG 04736-000 WARNING Never run a robot system with all jumpers installed. This would leave the system with no E-Stops. Additional Information The XUSR jumper plug is supplied with the robot. The part number for the XUSR jumper plug is 04736-000. XFP Connections Use the information in the following table to understand the signals provided on the XFP connector. PIN 8 PIN 1 PIN 15 PIN 9 Additional Information Refer to Front Panel Connections on page 3-20 for more information. 3-22 i4H Robots with EtherCAT User's Manual (I661) 3-8 Installing Safety Equipment 3 Installation Pins Description Additional Information 1, 9 2, 10 Front panel E-stop button channel 1 input Front panel E-stop button channel 2 input Typically connected to normally closed contacts on the E-stop button used with the Front Panel. 3, 11 4, 12 Automatic / Manual mode selection channel 1 input Automatic / Manual mode selection channel 2 input Typically connected to the selector switch used with the front panel. An open circuit selects Manual mode. A closed circuit selects Automatic mode. 5, 13 System-supplied 5 VDC output (pin 5) and common (pin 13) for High Power indicator lamp. If lamp is user-supplied, it must draw between 10 mA to 500 mA to satisfy the internal High Power lamp monitoring function.*1 6, 14 High Power ON / OFF Typically connected to a momentary push-button that enables High Power when all safety circuits are satisfied. 7, 15 System-supplied 5 VDC output (pin 7) and common (pin 15) for Control Power indicator. If indicator is user-supplied, the recommended load is between 20 to 500 mA. 3 8 Reserved for future use *1. Lamps that illuminate with a low current (10 mA to 25 mA) may appear dim when the High Power is OFF due to leakage current. If this occurs, add additional resistance to ensure the lamp is OFF when High Power is not enabled. XFP Wiring Diagram Use the following diagram to understand XFP electrical connections. WARNING If you supply your own Front Panel E-Stop, its design must comply with the requirements of IEC 60204-1 and ISO 13849. The E-Stop's push button must comply with ISO 13850. Precautions for Correct Use Do not disable or bypass the High Power button. This will violate IEC 60204-1. 3-8-2 Safety Circuits i4H Robots with EtherCAT User's Manual (I661) 3-23 3 Installation +24 VDC +5 VDC XFP 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 +5 VDC Common PIN 4 PIN 3 PIN 5 +24 VDC PIN 1 Common Common Control Power Indicator PIN 12 PIN 11 PIN 13 PIN 14 Automatic / Manual High Power Mode Switch Button / Indicator PIN 10 PIN 9 E-stop Button XFP Jumper Plug The XFP jumper plug is provided for safety equipment troubleshooting. XFP PLUG 10053-000 WARNING Never run a robot system with all jumpers installed. This would leave the system with no E-Stops. Additional Information · The XFP jumper plug is supplied with the robot. · The part number for the XFP jumper plug is 10053-000. XMCP Connections Use the information in the following table to understand the signals provided on the XMCP connector. PIN 8 PIN 1 PIN 15 PIN 9 3-24 i4H Robots with EtherCAT User's Manual (I661) 3-8 Installing Safety Equipment 3-8-2 Safety Circuits 3 Installation Additional Information Refer to the T20 Pendant User's Manual (Cat. No. I601) for additional information. Precautions for Correct Use If Teach Pendant cabling is installed, the jumper plug or the Teach Pendant must be connected to satisfy safety circuits and allow High Power to be enabled. Pins 1, 9 2, 10 3, 11 4, 12 6 7 8 13 Shield 5, 14, 15 Description Pendant E-stop button channel 1 Pendant E-stop button channel 2 Pendant enable switch channel 1 Pendant enable switch channel 2 24 VDC pendant supply Serial communications TXD Serial communications RXD Serial communications GND Ground shield Reserved for future use. Additional Information Connected to the pendant's integrated E-stop button. Connected to the pendant's integrated enable switch. 3 Pendant serial communications transmit signal. Pendant serial communications receive signal. Pendant serial communications ground signal. XMCP Jumper Plug The XMCP jumper plug is used when there is no T20 pendant adapter cable connected. XMCP PLUG 10052-000 WARNING Never run a robot system with all jumpers installed. This would leave the system with no E-Stops. Additional Information · The XMCP jumper plug is supplied with the robot. · The part number for the XMCP jumper plug is 10052-000. i4H Robots with EtherCAT User's Manual (I661) 3-25 3 Installation Teach Pendant Jumper Plug The Teach Pendant jumper plug is provided to allow the system to operate when Teach Pendant cabling is installed, but the Teach Pendant is not connected. This plugs into the Teach Pendant adapter cable when the pendant is not in use. Additional Information · The jumper plug is supplied with the Teach Pendant kit. · The part number for the Teach Pendant jumper plug is 10048-000. 3-26 i4H Robots with EtherCAT User's Manual (I661) 3-9 Setting the EtherCAT Node ID 3 Installation 3-9 Setting the EtherCAT Node ID The EtherCAT node ID / address can be set with two methods as described below. · Use Hardware Switches on the Robot. Use the hardware switches on the robot interface panel to set an explicit EtherCAT node ID for the robot. Refer to 3-9-1 EtherCAT Node ID Setting Example on page 3-27 for more information. Switch positions are only evaluated during the power-up procedure after 24 VDC Control Power is applied. Changing switch positions while the robot Control Power is ON will have no effect until the power is cycled. Use Sysmac Studio to verify the EtherCAT node ID setting after adjusting the switches. · Use Sysmac Studio When using Sysmac Studio to set the EtherCAT node ID, ensure the switches are set to the default 0 positions. If the switches are set to a non-zero value, the switch positions will dictate the EtherCAT 3 node ID and software adjustment of this value is not possible. Switches should be in the following positions when using Sysmac Studioto set the EtherCAT node ID. 3-9-1 EtherCAT Node ID Setting Example When the EtherCAT node ID is set with Sysmac Studio, it is retained in non-volatile memory and will persist after subsequent power cycles. Additional Information Refer to the Sysmac Studio Version 1 Operation Manual (Cat. No. W504) for more information about setting the EtherCAT node ID with software. 3-9-1 EtherCAT Node ID Setting Example In the following example, an EtherCAT node ID of 196 is used to demonstrate how to make the switch settings. 1 Begin by converting the desired node ID into a hexadecimal format. In this example, 196 is converted to 0x0C4. 2 Set the x256 dip switch to the OFF position. 3 Set the x16 rotary switch to position C. 4 Set the x1 rotary switch to position 4. i4H Robots with EtherCAT User's Manual (I661) 3-27 3 Installation 5 Confirm that the switches are in the following positions. 6 Apply or cycle Control Power to implement the new node ID setting. 7 Confirm the correct EtherCAT node ID of 196 with Sysmac Studio.. 3-28 i4H Robots with EtherCAT User's Manual (I661) 3-10 Supplying Power and Ground 3 Installation 3-10 Supplying Power and Ground The robot requires separate 24 VDC and 200-240 VAC power supplies. The DC supply provides Control Power and the AC power supply provides power to the internal servo amplifiers for High Power. The end-user shall install a branch rated overcurrent protection. There must be a branch rated overcurrent protection on both the 200-240 VAC circuit, as well as the 24 VDC circuit. A lockout tagout main disconnect device must be installed on the AC supply to the 24 VDC and also on the 200-240 VAC power supply. These devices are user-supplied. Disconnect devices shall be accessible and conveniently located to facilitate application of lockout devices during service and maintenance. Use the information below to make all power supply connections to the robot. Additional Information 3 Refer to 2-3-1 Power Supply Specifications on page 2-14 for information about power supply requirements and other wiring details. 3-10-1 Grounding the System The system should be grounded properly to avoid transient voltages or other electrical noise. There are three ground points on the system as described below. · High Power ground · Chassis ground · Housing ground Precautions for Safe Use The Joint 3 quill and the tool flange are not grounded to protective earth. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment or tooling to the ground point on the robot base. High Power Ground 3-10-1 Grounding the System Chassis Ground Housing Ground i4H Robots with EtherCAT User's Manual (I661) 3-29 3 Installation 3-10-2 DC Connections The 24 VDC Control Power connector is located on the Primary Interface Panel Use the illustration below to understand the polarity of the mating connector. Additional Information A connector and pins are included with the robot. The part number for this assembly is 22822-200. +24 VDC 0 VDC 3-30 i4H Robots with EtherCAT User's Manual (I661) 3-10 Supplying Power and Ground 3 Installation 3-10-3 AC Connections The 200-240 VAC High Power connector is located on the Primary Interface Panel. Use the illustrations below to understand the AC connections for single and three-phase power sources. Additional Information A connector and pins are included with the robot. The part number for this assembly is 22822-100. 12 A Fuse / Breaker Slow-blow Type Line 1 200-240 VAC Neutral 3 Earth Ground Primary Interface Panel 1 , 200-240 VAC 12 A Fuse / Breaker Slow-blow Type 3 200-240 VAC Line 1 200-240 VAC Line 2 Line 3 (unused) Earth Ground Primary Interface Panel 1 , 200-240 VAC 3-10-3 AC Connections i4H Robots with EtherCAT User's Manual (I661) 3-31 3 Installation 3-11 Verifying Installation If any modifications have been made to the robot during installation or other actions, make the following checks before operation. 3-11-1 Mechanical Checks Make the following mechanical checks after any hardware adjustments have been made to the system. · Check that the robot mounting surface is secure and adequate. · Check all mounting bolts and other fasteners for proper torque. · Check the tool flange and end-of-arm tooling for correct installation and grounding (when necessa- ry). · Check any equipment that is mounted to the robot to make sure it is securely fastened. 3-11-2 System Cable Checks Make the following system cable checks after any adjustments have been made to cable connections. · Check all cables and connectors to ensure that they are securely fastened and free of damage. · Check the system ground and power supply connections to make sure that they are connected properly. · Check that all cables are adequately supported and not strained near the connectors. 3-11-3 Safety Equipment Checks Make the following checks to all user-supplied safety equipment to ensure emergency stops are properly installed and other safety systems are functioning correctly. When checking safety equipment, the following prerequisites are necessary. · Sysmac Studio must be installed and available. · The Front Panel operating mode switch must be in the Automatic position. · All emergency stop devices must be able to be activated and deactivated easily. Use the following utilities in Sysmac Studio to confirm safety operations controlled by robot software. Safety Setting Function Configure Teach Restrict Verify Teach Restrict Auto Verify Teach Restrict Manual Description The objective of the Teach Restrict feature is to comply with safety regulations which require that the speed be limited while the robot is in Manual mode. This is hardware-based safety functionality to prevent rapid robot motion in Manual mode even in the unexpected event of software error attempting to move a robot faster than allowed. While jogging the robot in Manual mode, if any joint exceeds its configured speed limit, the system will disable High Power. Configuration will set predetermined speed limits for each robot motor. Verification will verify that Teach Restrict operations are functioning properly in Automatic and Manual modes. 3-32 i4H Robots with EtherCAT User's Manual (I661) 3 Installation 3-11 Verifying Installation 3-11-3 Safety Equipment Checks Safety Setting Function Configure E-stop Hardware Delay Verify E-stop Hardware Delay Description The objective of the ESTOP hardware delay feature is to comply with safety regulations which require the robot to have the capability of disabling High Power without software intervention in an emergency stop situation. Configuration will set the delay for the emergency stop timer circuit. Verification will verify that High Power is disabled without software intervention in an emergency stop situation. Additional Information Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information about using the Safety Setting functions. Emergency Stop Check Procedure 3 Use the following procedure to check for correct emergency stop operation. 1 If a pendant is present in the system, connect it to the XSYSTEM cable. 2 Prepare all emergency stop devices for enabling the robot High Power. 3 Enable the robot High Power with one of the methods described in 4-3-1 Enabling Robot High Power on page 4-6. 4 Confirm that robot High Power is enabled using the High Power indicator. If robot High Power is not enabled, refer to Section 5 Troubleshooting on page 5-1 for more information. 5 If XUSR emergency stop status outputs are being monitored by other equipment, confirm that the signal state transition is detected properly. 6 Activate each and every emergency stop device connected to the system to check that High Power is disable for all safety equipment. This includes pendant safety devices, Front Panel safety devices, and any other safety equipment wired to the XUSR connector. After one safety device check is made, deactivate it, enable High Power again, and make a check for the next safety device. Repeat 2 to 5 until all safety device functionality is confirmed to be working properly to complete this procedure. High Power Indicator Check The robot monitors current used by the High Power indicator. This is to ensure that a High Power indicator device is connected and functioning properly to satisfy safety requirements. If the robot does not detect a current between 10 mA to 500 mA when High Power is requested, an error condition (-924) *Front panel HIGH POWER lamp failure* will be present and High Power will not be enabled. The High Power indicator needs to be periodically checked for correct functionality. The following considerations should be made before beginning the High Power indicator check procedure. i4H Robots with EtherCAT User's Manual (I661) 3-33 3 Installation · Control power and High Power supplies need to be available. · All connected safety devices must be capable of providing signals for a safe state. · The robot High Power needs to be disabled and robot motions will not execute during this proce- dure. · High Power safety timeout must be enabled to allow the indicator to flash after a High Power re- quest is made. The recommended setting is 10 seconds. Refer to Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information. High Power Indicator Check Procedure Use the following procedure to verify that the High Power indicator is working correctly. 1 Apply Control Power to the robot and disable High Power. 2 Make a High Power request using one of the methods described in High Power Request Meth- ods on page 4-7. 3 Check that the High Power indicator flashes. After the High Power request is made and the in- dicator is checked, the procedure is complete. 3-11-4 Switch Position Checks Check the following switch positions on the Primary Interface Panel to make sure they are set correctly. The following settings are required for normal operation. · Mode switches Dip switch 1: NX Dip switch 2: OP · EtherCAT node ID switches Dip switch and rotary switches: set to 0 if node ID is set with Sysmac Studio. Set to desired node ID if setting an explicit node ID. 3-34 i4H Robots with EtherCAT User's Manual (I661) 4 Operation This section provides information necessary to operate the robot. 4 4-1 Payload and Acceleration Considerations .................................................. 4-2 4-2 Robot Control Modes..................................................................................... 4-3 4-2-1 Manual Mode................................................................................................... 4-3 4-2-2 Automatic Mode .............................................................................................. 4-3 4-2-3 Operation Mode............................................................................................... 4-4 4-2-4 Host Mode ....................................................................................................... 4-4 4-2-5 Service Mode .................................................................................................. 4-5 4-3 Enabling and Disabling the Robot................................................................ 4-6 4-3-1 Enabling Robot High Power ............................................................................ 4-6 4-3-2 Disabling High Power ...................................................................................... 4-7 4-4 LED Light Ring ............................................................................................... 4-8 4-5 LCD Display .................................................................................................... 4-9 4-5-1 LCD Display Status Messages........................................................................ 4-9 4-6 Brake Operation ........................................................................................... 4-10 4-6-1 Built-in Brake Release Button ....................................................................... 4-10 4-6-2 Remote Brake Release ..................................................................................4-11 4-7 Manually Jogging the Robot ....................................................................... 4-12 i4H Robots with EtherCAT User's Manual (I661) 4-1 4 Operation 4-1 Payload and Acceleration Considerations Careful considerations must be made when using high payloads, high accelerations, or a combination of both. Use the following diagrams to understand the limitations to acceleration and payload. Precautions for Correct Use Operating the robot outside of the payload and speed constraints described in this document can damage the z-axis quill of the robot. Acceleration (%) Acceleration (m/s²) Payload Z-Location vs. Acceleration at 100% Speed (Linear Moves Only) 1100 130 1000 120 900 110 100 800 90 700 1 kg 80 2 kg 600 70 3 kg 500 60 4 kg 5 kg 400 50 10 kg 300 40 15 kg 30 200 20 100 10 0 0 0 100 200 300 400 500 Payload Z-Location (mm) = Joint 3 Position + Payload Center of Gravity 4-2 i4H Robots with EtherCAT User's Manual (I661) 4-2 Robot Control Modes 4 Operation 4-2 Robot Control Modes The robot can operate in Automatic or Manual control modes. These modes are described in the following sections. 4-2-1 Manual Mode Manual mode is typically used during functions of commissioning, position teaching, and other setup operations. In this mode, the robot will respond to the control signals issued by the connected pendant. When the robot is placed in Manual mode, robot motion speed is limited to 250 mm/sec and servo torque is limited so an operator can safely work inside the cell. Programs can execute from the pendant in STEP mode. Precautions for Safe Use 4 · After the robot is placed in Manual mode using the Front Panel key switch, the key should be removed for safety purposes. · During manual operation, ensure all persons are a safe distance away from the robot work- space. Additional Information Refer to the T20 Pendant User's Manual (Cat. No. I601) for more information. To place the robot in Manual mode, use the Front Panel key switch and rotate it to the left position as indicated below. Changing the robot control mode will automatically disable High Power. 4-2-1 Manual Mode 4-2-2 Automatic Mode Automatic mode is used when the robot is operating under normal conditions. When the robot is placed in Automatic mode, program execution will control the robot up to the maximum speed. i4H Robots with EtherCAT User's Manual (I661) 4-3 4 Operation Precautions for Safe Use Prior to placing the robot in Automatic Mode, all safeguards must be returned to their safe state. To place the robot in Automatic mode, use the Front Panel key switch and rotate it to the right position as indicated below. Changing the robot control mode will automatically disable High Power. WARNING In Automatic mode, the robot can move unexpectedly. Ensure all personnel remain clear of the cell when Automatic mode is enabled. 4-2-3 Operation Mode Operation mode should be used when the robot is operating under normal conditions and is being controlled by the NJ-series Robot Integrated CPU Unit with EtherCAT communications. Additional Information The position of the operation mode dip switch is checked during power-up only. Changing this switch position while 24 VDC Control Power is supplied will not change the mode of the robot until power is cycled. It is recommended to remove all robot power before changing the position of this switch. To place the robot in operation mode, set dip switch 2 on the Primary Interface Panel to the OP position as shown in the figure below and then apply Control Power to the robot. 4-2-4 Host Mode Dip switch 1 on the Primary Interface Panel is used to control the host mode of the robot. 4-4 i4H Robots with EtherCAT User's Manual (I661) 4-2 Robot Control Modes 4 Operation Dip switch 1 on the Primary Interface Panel should remain in the NX position during normal operation as shown in the figure below. The switch position 3P is reserved for future use. 4-2-5 Service Mode Service mode is used for special conditions when the robot must be accessed with methods other than EtherCAT communications. Dip switch 2 on the Primary Interface Panel should remain in the OFF / OP position during normal op- eration. If any of the following conditions are present on your robot, contact your local OMRON representative for support using service mode. 4 · The license mode of the robot needs to be changed. · EtherCAT communications cannot be achieved. · The robot has an unrecoverable fault or error. · Factory recalibration is required. Additional Information The position of the operation mode dip switch is checked during power-up only. Changing this switch position while 24 VDC Control Power is supplied will not change the mode of the robot until power is cycled. It is recommended to remove all robot power before changing the position of this switch. 4-2-5 Service Mode i4H Robots with EtherCAT User's Manual (I661) 4-5 4 Operation 4-3 Enabling and Disabling the Robot Enabling the robot energizes all robot servo motors. This is also referred to as enabling High Power. When the robot is enabled, it is capable of moving. Program execution and I/O control functions are still operational when High Power is disabled. However, ATTACH or other motion commands may return errors or delay program execution if high power is disabled. Refer to the eV+3 User's Manual (Cat. No. I651) and the eV+3 Keyword Reference Manual (Cat. No. I652) for more information. Disabling the robot de-energizes all robot servo motors. Additional Information When High Power is enabled, the brake is automatically released. When High Power is disabled, the brake is automatically activated to prevent downward motion of the quill due to gravity. Precautions for Safe Use High power cannot be enabled unless all safety circuits are satisfied. 4-3-1 Enabling Robot High Power Enabling the robot High Power can be achieved with different methods under certain conditions as described in the following sections. High Power Safety Timeout If the safety timeout function is enabled in the robot configuration, the High Power indicator on the Front Panel will flash for a specified amount of time after a High Power request is made. If the High Power button is not pressed within the specified amount of time, a safety timeout occurs and High Power is not applied. The safety timeout function is enabled by default and has a duration set for 10 seconds. The safety timeout function configuration settings are accessed with Sysmac Studio. Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information. Precautions for Correct Use If a Front Panel is not present, the High Power indicator and High Power button signals can be accessed with the XFP system cable connector. Refer to Front Panel Connections on page 3-20 for more information. High Power and Faults If a fault is present, the robot will not enter the High Power state. The AUTO.POWER.OFF system switch controls if the robot prevents or disables High Power for specific errors. Refer to the eV+3 Keyword Reference Manual (Cat. No. I652) for more information. 4-6 i4H Robots with EtherCAT User's Manual (I661) 4-3 Enabling and Disabling the Robot 4 Operation High Power Request Methods There are several methods to request robot High Power as described below. Request Power with the Front Panel When a Front Panel is present in the system, the High Power button can be used to request High Power to the robot. Additional Information Refer to Front Panel Connections on page 3-20 for more information about connecting external devices to the High Power enable signal on the XFP connector. Request High Power with a Connected PC High power can be requested with Sysmac Studio. Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) more information. 4 Request High Power with a User Program High power can be requested with a user program through the use of the POWER system switch keyword. Refer to the eV+3 Keyword Reference Manual for more information. Request High Power with the Pendant If a pendant is connected to the robot, it can be used to request High Power. Refer to the T20 Pendant User's Manual (Cat. No. I601) for more information. 4-3-2 Disabling High Power The conditions described below can disable or prevent the robot High Power state. · Robot faults. · E-stop open circuit detection. · User programming with the POWER system switch keyword. · External signals connected to the XUSR connector on the XSYSTEM cable. 4-3-2 Disabling High Power i4H Robots with EtherCAT User's Manual (I661) 4-7 4 Operation 4-4 LED Light Ring The LED light ring indicator around Joint 1 of the robot provides a visual status of the robot. The LED indications and associated robot states are described below. Precautions for Safe Use The LED ring does not reflect the robot's High Power status. To see the robot's High Power status, use the Front Panel indicator or a user-supplied indicator connected to the XFP connector. LED Indication OFF Solid White Solid Blue Slow Flashing Blue (0.25 Hz) Fast Flashing Green (1 Hz) Slow Flashing Green (0.25 Hz) Fast Flashing Red (1 Hz) Solid Red Robot State Control Power is not present. The robot is initializing. The robot is booting. The robot is in an idle state with no errors present. The robot is in a normal operating state while in Automatic mode. The robot is in a normal operating state while in Manual mode. The robot is in an error state from an emergency stop or other condition. The robot has a system error. 4-8 i4H Robots with EtherCAT User's Manual (I661) 4 Operation 4-5 LCD Display The LCD display on the robot base provides messages for robot status and any error codes that may be present. 4-5-1 LCD Display Status Messages The following messages can be shown on the LCD display when there are no errors present. When an error is present, the LED light ring will flash red at 1 Hz and an error code will be shown on the LCD display. Refer to 5-3 Error Messages on page 5-4 for more information about error codes. Message Description OMRON logo The robot is booting after Control Power is applied. OK The robot is in an idle state with no errors present. ON The robot is in a normal operating state while in Automatic mode. MA The robot is in a normal operating state while in Manual mode. 4 4-5 LCD Display 4-5-1 LCD Display Status Messages i4H Robots with EtherCAT User's Manual (I661) 4-9 4 Operation 4-6 Brake Operation The robot has a mechanical brake on joints 3 and 4. Releasing the brake is typically done when you need to manually position joint 3 or 4. The brake is controlled with the methods described below. The mechanical brake is capable of preventing the z-axis quill from lowering more than 5 mm when up to 340 N of downward force is applied. WARNING Releasing a brake may cause the quill, tool flange, end-effector, and payload to drop. To prevent possible injury to personnel or damage to the equipment, make sure that the equipment is supported when releasing the brake and verify that the end-effector and payload are clear of all obstructions. Precautions for Safe Use · The braking mechanism operates passively. If 24 VDC Control Power is removed from the system, the brake mechanism will automatically activate. 24 VDC Control Power must be supplied to release the brake. To prevent possible damage to the equipment, remove any payload from the end-of-arm tooling, make sure that Joint 3 is supported while releasing the brake, and verify that the end-of-arm tooling or other installed equipment is clear of all obstructions. · In case of entrapment of a person by the robot or any other emergency or abnormal situation, you can manually move the inner and outer links to a safe position while High Power is disabled. A brake device prevents Joints 3 and 4 from moving when High Power is disabled and can only be released while 24 VDC Control Power is present. Precautions for Correct Use · Attempting to release the brake while High Power is ON will automatically disable High Power. If the robot is moving, this will cause it to stop abruptly. · Robot joints 1 and 2 have no brake mechanism and can be manually moved when power is not present. · Avoid rotating the quill / Joint 4 when the brake is released. This could result in an out-ofrange condition and may prevent program execution. 4-6-1 Built-in Brake Release Button The brake release button is located on the front of the base of the robot, near the LCD display. Pressing this button while the 24 VDC control power is ON and High Power is disabled will release the brake. The brake will remain released while the button is pressed. Releasing the button will re-enable the brake. 4-10 i4H Robots with EtherCAT User's Manual (I661) 4 Operation 4-6 Brake Operation 4-6-2 Remote Brake Release 4 4-6-2 Remote Brake Release The brake can be released with a signal connected to the XIO connector. This is typically used for remote control of the brake. Use Sysmac Studio to configure the robot by selecting Enable Brake Release Input. This setting will change the XIO input 6.2 (pin 18) for use as a brake release signal from another device such as a remote pushbutton or an output from another control device. Additional Information Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information about the Enable Brake Release Input robot configuration item. Precautions for Safe Use To comply with ISO 10218-1 when using a remote brake release button, ensure the brake release button displays a warning label to indicate that the z-axis of the robot may fall due to gravity if the brake is released. i4H Robots with EtherCAT User's Manual (I661) 4-11 4 Operation 4-7 Manually Jogging the Robot Manually jogging the robot is typically performed during setup or when teaching locations. Precautions for Safe Use During manual operation, ensure all persons are a safe distance away from the robot workspace. The following considerations should be made when jogging the robot. · The jog speed and accelerations of the robot are reduced from normal operating speeds and accel- erations. · The jog speed of the robot can be adjusted. · Robot motion can be incremented by specified amounts when extra precision is needed. · Jogging can be executed in world, tool, or joint modes. · The robot can be manually jogged with software or a pendant. Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) or the T20 Pendant User's Manual (Cat. No. I601) for more information. · The robot can be jogged with the pendant while in Automatic mode or in Manual mode. · The robot can be jogged with the software while in Automatic mode. If the pendant is connected, it must be set to COMP to allow the software to jog the robot. 4-12 i4H Robots with EtherCAT User's Manual (I661) 5 Troubleshooting This section provides robot troubleshooting information. 5-1 Fault Detection ............................................................................................... 5-2 5-2 Emergency Stop Troubleshooting................................................................ 5-3 5 5-3 Error Messages .............................................................................................. 5-4 i4H Robots with EtherCAT User's Manual (I661) 5-1 5 Troubleshooting 5-1 Fault Detection Robot faults can be detected with the following methods. · Create a V+ program to change the state of an output signal when a fault is present. Refer to the eV +3 Keyword Reference Manual (Cat. No. I652) for more information. · Use the LED light ring and LCD display to visually see when a fault is present. 5-2 i4H Robots with EtherCAT User's Manual (I661) 5 Troubleshooting 5-2 Emergency Stop Troubleshooting If the emergency stop circuit is not operating as expected, the following supplied jumper plugs can be used to troubleshoot the problem. These jumpers can be placed on the XSYSTEM cable to bypass and isolate safety devices. Refer to 3-6-1 System Cable Overview on page 3-10 for jumper installation locations. · XFP jumper plug (part number 10052-000) · XUSR jumper plug (part number 04736-000) · XMCP jumper plug (10052-000) WARNING Never run a robot system with all jumpers installed. This would leave the system with no E-Stops. 5 5-2 Emergency Stop Troubleshooting i4H Robots with EtherCAT User's Manual (I661) 5-3 5 Troubleshooting 5-3 Error Messages The following table lists robot error messages. Additional Information Other system messages may be present. Use the Sysmac Studio to check for these messages. If errors persist, contact your local OMRON representative. Error Message 24 A# AC B# BA D# E# ES FM h# H# hV I# M# NV P# Explanation 24 VDC power fault. The 24 VDC input voltage is out of range. Amplifier fault where # represents the associated joint number. AC power fault. IO Blox communication error where # represents the associated IO Blox unit. The encoder backup battery voltage is low. Duty cycle exceeded where # represents the associated joint number. Encoder fault where # represents the associated joint number. Emergency stop detected by the robot. Firmware mismatch. Amplifier high temperature where # represents the associated joint number. Encoder high temperature where # represents the associated joint number. High DC bus voltage fault. The high DC bus voltage is out of range. Initialization state where # represents the step number. Motor stalled where # represents the associated joint number. Non-volatile memory fault. Power system fault where # represents the code number. Corrective Action Check connections and voltage level from the user-supplied 24 VDC power supply. Check user motor power connections for shorts or opens. Turn High Power back on and restart the program. Check connections and voltage level from the user-supplied AC power supply. Check IO Blox connections for shorts or opens. Check IOBlox address switches for proper configuration. Cycle power to the control system. Replace the backup encoder batteries. Reduce the speed or acceleration for the motion that was in progress when the error occurred. Use Sysmac Studio to get the failure message for more information. Check safety devices connected to the robot for an emergency stop condition. Contact your local OMRON representative. Try slowing the motion or insert pauses. Check for excessive ambient temperature, inadequate ventilation, and proper function of any cooling fans. Reduce robot speed, acceleration or deceleration, or introduce delays in the application cycle to reduce heat accumulation. This can be cause when AC power is abruptly removed. Check AC connections. If this code persists longer than 30 seconds, an initialization failure has occurred. Contact your local OMRON representative for support. Check for obstacles and free movement of all joints. Contact your local OMRON representative for support. Contact your local OMRON representative for support. 5-4 i4H Robots with EtherCAT User's Manual (I661) 5 Troubleshooting Error Message PR RC SW S# T# TR V# Explanation Processor overloaded. A servo task has overrun its allotted execution window. RSC fault. There is a failure to communicate with the Robot Signature Card. Watchdog timeout. Safety system fault where # represents the code number. Safety system fault where # represents the code 10 + #. The safety system is not commissioned. Hard envelope error where # represents the associated joint number. The indicated motor was not tracking the commanded position with sufficient accuracy as set by Sysmac Studio. Corrective Action Contact your local OMRON representative for support. Contact your local OMRON representative for support. Contact your local OMRON representative for support. Contact your local OMRON representative for support. Contact your local OMRON representative for support. Commission and verify the Teach Restrict. Retry the motion at a slower speed. Ensure nothing is obstructing the robot motion. 5 5-3 Error Messages i4H Robots with EtherCAT User's Manual (I661) 5-5 5 Troubleshooting 5-6 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance This section provides information on the maintenance of the i4H robot. 6-1 Field-replaceable Items ................................................................................. 6-2 6-2 Periodic Maintenance .................................................................................... 6-3 6-2-1 Periodic Maintenance Overview...................................................................... 6-3 6-2-2 Checking Safety Functions.............................................................................. 6-3 6-2-3 6-2-4 Checking Fastener Torques ............................................................................ 6-4 Checking Safety and Warning Labels ............................................................. 6-5 6 6-2-5 Checking for Oil Leaks .................................................................................... 6-5 6-2-6 Lubricating Joint 3 ........................................................................................... 6-5 6-2-7 Replacing Encoder Batteries........................................................................... 6-6 6-2-8 Harmonic Drive Oil Change............................................................................. 6-8 6-2-9 Cleaning the Robot.......................................................................................... 6-8 6-3 Non-periodic Maintenance ............................................................................ 6-9 6-3-1 Replacing the Tool Flange............................................................................... 6-9 6-3-2 Replacing the iCS-ECAT Amplifier Chassis .................................................. 6-10 6-3-3 Replacing the Outer Link Cover .................................................................... 6-14 i4H Robots with EtherCAT User's Manual (I661) 6-1 6 Maintenance 6-1 Field-replaceable Items The following items are field replaceable. Contact your local OMRON representative for parts not listed below. Precautions for Correct Use Only replace items on the robot system with the parts supplied by OMRON. Item Encoder Backup Batteries Pack Tool Flange Front Panel Outer Link Cover iCS-ECAT Controller Chassis Assembly Part Number 19238-000F 19106-000F 19106-100F 92546-10358 19211-002F 19227-002F 29900-000F 29910-000F Description Encoder backup battery pack assembly with connector. Standard Tool Flange (ISO mount). eCobra Tool Flange (eCobra mount). Front Panel kit including the Front Panel and a 3 m cable. Cover, Outer Link, i4-650H Cover, Outer Link, i4-750H / 850H Standard robot configuration. Inverted robot configuration. 6-2 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance 6-2 Periodic Maintenance 6-2-1 Periodic Maintenance Overview 6-2 Periodic Maintenance This section lists when to perform periodic maintenance on your robots and the steps for checking each item to inspect. WARNING · You must perform the Lockout and tagout procedure prior to servicing the robot. · The procedures and replacement of the parts mentioned in this manual must be performed only by the skilled or instructed persons. · The access covers on the robot are not interlocked. You should turn OFF and dis- connect the power before the covers of the robot are removed. 6-2-1 Periodic Maintenance Overview The following table gives a summary of the periodic maintenance procedures and guidelines on frequency. The frequency of these procedures will depend on the particular system, its operating environment, and the amount of usage. Use the times in the table above as guidelines and modify the schedule as needed. Item Period Reference Check fastener torques 3 months 6-2-3 Checking Fastener Torques on page 6-4 6 Check safety labels 1 week 6-2-4 Checking Safety and Warning Labels on page 6-5 Check all installed safety equipment 6 months 3-11-3 Safety Equipment Checks on page 3-32 Check High Power indicator opera- 1 week tion High Power Indicator Check on page 3-33 Check for signs of oil around of har- 3 months monic drive area 6-2-5 Checking for Oil Leaks on page 6-5 Lubricate Joint 3 (Z-axis) ball screw 150 km of linear travel, or every 3 months (whichever comes first)*1 6-2-6 Lubricating Joint 3 on page 6-5 Replace encoder backup batteries 2 years or as needed (whichever comes first) 6-2-7 Replacing Encoder Batteries on page 6-6 Clean the exterior of the robot as needed 6-2-9 Cleaning the Robot on page 6-8 Harmonic Drive Oil Change (Joint 1 12 months and Joint 2 Harmonic Drives) 6-2-8 Harmonic Drive Oil Change on page 6-8 *1. 150 km of linear travel is approximately 2 weeks if a robot is operating 24 hours per day for 7 days per week. 6-2-2 Checking Safety Functions All safety devices in the system should be checked regularly for proper functionality. Operating any of the following safety devices should disable robot high power. · E-stop button(s) on the Front Panel or connected to the XSYSTEM cable. · E-stop button and enabling switch on the pendant (if connected). i4H Robots with EtherCAT User's Manual (I661) 6-3 6 Maintenance · Auto/manual switch on the Front Panel. · All other safety devices connected to the XSYSTEM cable. Precautions for Safe Use The high power indicator must be operational to satisfy safety requirements. Additional Information Refer to 3-11-3 Safety Equipment Checks on page 3-32 for more information. High Power Indicator Check The robot monitors current used by the High Power indicator. This is to ensure that a High Power indicator device is connected and functioning properly to satisfy safety requirements. If the robot does not detect a current between 10 mA to 500 mA when High Power is requested, an error condition (-924) *Front panel HIGH POWER lamp failure* will be present and High Power will not be enabled. The High Power indicator needs to be periodically checked for correct functionality. The following considerations should be made before beginning the High Power indicator check procedure. · Control power and High Power supplies need to be available. · All connected safety devices must be capable of providing signals for a safe state. · The robot High Power needs to be disabled and robot motions will not execute during this proce- dure. · High Power safety timeout must be enabled to allow the indicator to flash after a High Power re- quest is made. The recommended setting is 10 seconds. Refer to Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more information. High Power Indicator Check Procedure Use the following procedure to verify that the High Power indicator is working correctly. 1 Apply Control Power to the robot and disable High Power. 2 Make a High Power request using one of the methods described in High Power Request Meth- ods on page 4-7. 3 Check that the High Power indicator flashes. After the High Power request is made and the in- dicator is checked, the procedure is complete. 6-2-3 Checking Fastener Torques The following fasteners must be periodically checked for proper torque. · Mounting screws: 96 to 104 N-m · External equipment mounting fasteners (if present): 2.5 N-m · Cable D-sub connectors: finger tight · Tool flange setscrew: 1.1 N-m 6-4 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance · Tool flange socket-head screws: 2.5 N-m · Tool flange end-of-arm tooling mounting fasteners: 7.5 N-m · Camera bracket mounting screws (if present): 2.5 N-m 6-2-4 Checking Safety and Warning Labels This section lists the various safety and warning labels and their placement on the robot. Use this information to perform periodic checks to ensure the labels are not damaged and are legible. 6-2 Periodic Maintenance 6-2-4 Checking Safety and Warning Labels Risk of electric shock. Multiple power sources may be present, lockout and tagout all power. Residual voltage may be present, wait 2 minutes before servicing. Use a crane and straps to lift the robot by inner arm and controller handle. Never lift the robot by the quill. Install in a controlled environment relatively free of contaminants. Additional Information 6 The label indicates the operation of the joint 3 and joint 4 brake. 6-2-5 Checking for Oil Leaks The robot uses oil in the harmonic drive components for lubrication. Periodically inspect the robot for any signs of oil in areas immediately outside of the harmonic drive. Check these locations: · The area around Joint 1. · The area around Joint 2. · Inside the base of the robot. Refer to iCS-ECAT Replacement Procedure on page 6-11 for informa- tion about about accessing the inside of the base of the robot. 6-2-6 Lubricating Joint 3 The joint 3 quill needs to be lubricated on a periodic basis of 3 months or 150 km of linear travel, whichever comes first. 150 km of linear travel is approximately 2 weeks if a robot is operating 24 hours per day for 7 days per week. Precautions for Correct Use Only use the recommended grease on the joint 3 quill (part number 90401-04029). Refer to the provided Safety Data Sheet for proper handling. i4H Robots with EtherCAT User's Manual (I661) 6-5 6 Maintenance Joint 3 Lubrication Procedure Use the following procedure to lubricate joint 3. Precautions for Safe Use The braking mechanism operates passively. If 24 VDC Control Power is removed from the system, the brake mechanism will automatically activate. 24 VDC Control Power must be supplied to release the brake. To prevent possible damage to the equipment, remove any payload from the endof-arm tooling, make sure that Joint 3 is supported while releasing the brake, and verify that the end-of-arm tooling or other installed equipment is clear of all obstructions. Precautions for Correct Use Avoid rotating the quill / Joint 4 when the brake is released. This could result in an out-of-range condition and may prevent program execution. Additional Information Ensure there are no z-axis motion restrictions. The full operating stroke is required during this lubrication procedure. 1 Press the brake release button while moving the z-axis to the top of its stroke to expose the upper section of the quill. 2 Remove any existing grease or debris from the exposed quill with a clean, lint-free cloth. 3 Apply a small bead of grease to all grooves on the quill. 4 Press the brake release button while moving the z-axis to the bottom of its stroke to expose the lower section of the quill. 5 Remove any existing grease or debris from the newly exposed section of the quill with a clean, lint-free cloth. 6 Move the z-axis up and down to distribute the new grease. This can be accomplished manually with the brake release button or by jogging the z-axis. After this step is finished, the joint 3 lubrication procedure is complete. 6-2-7 Replacing Encoder Batteries Backup encoder batteries maintain joint position data stored by internal encoders. This data is protected by 3 lithium backup batteries located behind the LCD display assembly. Encoder backup batteries need to be replaced on a periodic basis of 2 years or when a low battery error message is present. Before beginning the replacement procedure, have the following items available. · Cross-head screwdriver, point size #1. · Cutter tool. · Cable tie / plastic strap · Loctite thread lock type 243 or equivalent. 6-6 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance · Replacement battery pack (part number 19238-000F). Encoder Battery Replacement Procedure Use the following procedure to replace encoder backup battery pack. Voltage must be maintained during the encoder backup battery replacement procedure to preserve joint position data. There are two connectors near the battery pack. Ensure that at least one battery pack is connected at all times during this procedure. Use the following diagram to identify items referenced during the replacement procedure. 6-2 Periodic Maintenance 6-2-7 Replacing Encoder Batteries LCD Display Battery Pack J3 Connector 6 J4 Connector Plastic Strap Precautions for Safe Use · Batteries may leak, rupture, heat, or ignite. Never short-circuit, charge, disassemble, heat, or incinerate a battery or subject it to strong shock. · Dispose of any battery that has been dropped or otherwise subjected to excessive shock. Batteries that have been subjected to shock may leak if they are used. · Customers can contribute to resource conservation and protecting the environment by the proper disposal of WEEE (Waste Electronics and Electrical Equipment). All electrical and electronic products should be disposed of separately from the municipal waste system via designated collection facilities. For information about disposal of your old equipment, contact your local OMRON representative. Precautions for Correct Use Only replace items on the robot system with the parts supplied by OMRON. 1 Remove the four screws that fasten the LCD display assembly to the robot. 2 Tilt the LCD display assembly forward and carefully lift and move it away from the robot. Take care not to strain or damage the cables. i4H Robots with EtherCAT User's Manual (I661) 6-7 6 Maintenance 3 Plug in the new battery pack to one of the available J3 or J4 connectors. Do not disconnect the existing battery pack until the new battery pack is plugged in. 4 Cut the plastic strap securing the old batteries to the bracket. 5 Disconnect the old battery pack from the connector. Ensure the new battery pack is plugged in simultaneously before disconnecting the old battery pack. 6 Place the new batteries on the bracket and secure with a plastic strap / cable tie. Make sure that the excess cable is properly secured under the cable tie. 7 Re-install the LCD display assembly and secure it with the four screws that were removed in step 1 to complete this procedure. Apply Loctite thread lock type 243 or equivalent to the screws before inserting. 6-2-8 Harmonic Drive Oil Change The harmonic drive oil in Joint 1 and Joint 2 should be changed every 12 months. This will extend the life of the harmonic drives and ensure continued performance. An oil change kit is available. The part number for the oil change kit is 12370-000F. Additional Information Follow the procedure included with the oil change kit when changing the harmonic drive oil. 6-2-9 Cleaning the Robot Clean the exterior of the robot as needed. Inspect the external surface of the robot frequently when used in a dirty environment. Remove any dirt and debris from the exterior of the robot. Debris can accumulate around robot joints. Take extra effort to clean around these areas. WARNING Do not use organic solvents to clean any part of the robot unless directed in the cleaning instructions. Organic solvents might damage electronics resulting in an unsafe operating state that could cause injury or damage to equipment. 6-8 i4H Robots with EtherCAT User's Manual (I661) 6-3 Non-periodic Maintenance 6 Maintenance 6-3 Non-periodic Maintenance This section provides information and instructions for performing maintenance that does not occur at regular intervals. WARNING · Never connect or disconnect system cables while power is applied to the robot. Failure to comply may cause unexpected behavior and can result in personnel injury and equipment damage. · The procedures and replacement of the parts mentioned in this manual must be performed only by the skilled or instructed persons. · The access covers on the robot are not interlocked. You should turn OFF and disconnect the power before the covers of the robot are removed. 6-3-1 Replacing the Tool Flange Replace the tool flange if it gets damaged. Before beginning the procedure, have the following tools available. · 2.5 mm hex bit · 3 mm hex bit · Torque wrench · Loctite thread lock type 243 or equivalent 6 · Loctite thread lock type 222MS or equivalent DANGER Failure to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or fatality of a person touching the end-effector during an electrical fault. WARNING If air pressure is present, disconnect it from the robot when servicing end-of-arm tooling or other pneumatic components to prevent unsecured pneumatic air lines from accidentally injuring personnel. Precautions for Safe Use The Joint 3 quill and the tool flange are not grounded to protective earth. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment or tooling to the ground point on the robot base. Precautions for Correct Use When removing and replacing the tool flange, you must reinstall it in the same position to avoid losing the calibration for the robot. 6-3-1 Replacing the Tool Flange i4H Robots with EtherCAT User's Manual (I661) 6-9 6 Maintenance Tool Flange Replacement Procedure Use the following procedure to replace the tool flange on the z-axis quill if necessary. Quill Slots Setscrew Socket-head Screws (x4) 1 Take note of the old tool flange position and orientation on the quill. 2 Loosen the setscrew and socket-head screws while holding the old tool flange in place. This prevents it from falling off the z-axis quill. 3 Slide the tool flange off the z-axis quill. 4 Align the setscrew with the proper groove in the z-axis quill. 5 When the orientation is correct, slide the new tool flange up on the z-axis quill until it stops. 6 Apply thread lock (Loctite 243 or equivalent) to the setscrew and tighten to a torque of 1.1 N-m. Precautions for Correct Use Do not over-tighten the tool flange setscrew. This will cause off-center alignment of the tool flange on the quill. 7 Apply thread lock (Loctite 222MS or equivalent) to the socket-head screws and then use a tor- que wrench to tighten one of the socket-head screws to 1 N-m. Then, apply the same torque to the other socket-head screws. Finally, tighten each socket-head screw to the full 2.5 N-m torque. 8 When all socket-head screws are tight and the new tool flange is verified to be in the correct orientation, the replacement procedure is complete. 6-3-2 Replacing the iCS-ECAT Amplifier Chassis The iCS-ECAT amplifier chassis can be replaced in the event of repair or upgrade. 6-10 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance Precautions for Correct Use Follow appropriate ESD procedures when removing or replacing the iCS-ECAT amplifier chassis. Before beginning this procedure, have the following items available. · Replacement iCS-ECAT amplifier chassis. · 8 mm socket. · Torque wrench. iCS-ECAT Replacement Procedure Use the following procedure to replace the iCS-ECAT amplifier chassis. Additional Information If you are installing a new iCS-ECAT into robot, you will need to run Teach Restrict and Estop Safety commissioning prior to operating the robot. Refer to 3-11-3 Safety Equipment Checks on page 3-32 for more information. 1 Disconnect all external cables connected to the Primary Interface Panel. 2 Remove the six M5 X 16 screws securing the iCS-ECATto the robot base. 6 6-3 Non-periodic Maintenance 6-3-2 Replacing the iCS-ECAT Amplifier Chassis i4H Robots with EtherCAT User's Manual (I661) 6-11 6 Maintenance M5 X 16 Screws (6) 3 Carefully pull the iCS-ECAT away from the robot base a small amount to expose internal har- ness connections. The assembly slides with guides in tracks. Pulling the iCS-ECAT too far from the robot base can damage the internal harness. Take note of the internal harness and cable routing. Similar routing must be used when reassembling the components. 4 Disconnect the following items from the iCS-ECAT: · Ground connection · Encoder and I/O connections · Motor power connection · End-of-arm PCA connection 6-12 i4H Robots with EtherCAT User's Manual (I661) 6-3 Non-periodic Maintenance Ground Connection Encoder and I/O Connections 6 Maintenance End-of-Arm PCA Connection Motor Power Connection 5 After all internal connections have been removed, slide the iCS-ECAT out of the robot base completely. 6 6 Remove the Micro SD card from the iCS-ECAT. Press the Micro SD card in and then release to eject it from the slot. Micro SD Card 6-3-2 Replacing the iCS-ECAT Amplifier Chassis i4H Robots with EtherCAT User's Manual (I661) 6-13 6 Maintenance 7 If the iCS-ECAT is being replaced with an identical unit, insert the removed Micro SD card into the new iCS-ECAT Micro SD card slot to transfer licensing and firmware. If the iCS-ECAT is not being replaced with an identical unit, this step can be skipped. 8 To install the replacement iCS-ECAT, insert the first set of guides into the track in the base of the robot and then slide the chassis forward into the robot base until the second set of guides is reached. 9 Connect all items that were disconnected in step 5 above, while considering the cable routing that was observed in step 4. 10 After all internal connections are made, carefully push the chassis into the base of the robot while ensuring no cables are pinched and no connectors are strained. Do not force the chassis into the base of the robot. Doing so may damage the unit. It may be necessary to pull the chassis out enough to correct the cable routing and retry. 11 After the iCS-ECAT is in the original position, apply Loctite thread lock type 222 or equivalent to the six M5 X 16 screws and insert them . Apply a torque of 2.5 N-m to tighten them. 12 Make all necessary external cable connections to complete this procedure. 6-3-3 Replacing the Outer Link Cover The outer link cover can be replaced if it becomes damaged. The replacement outer link cover part numbers are provided below. · i4-650H: 19211-002F · i4-750H / i4-850H: 19227-002F Before beginning this procedure, have the following items available. · 3 mm hex bit · Loctite thread lock types 222 and 243 or equivalent · Torque wrench Outer Link Cover Replacement Procedure Use the following procedure to replace the outer link cover. Precautions for Correct Use Never release the z-axis brake while the quill clamp collar is loose or removed. This can allow the quill to fall out of the robot. 1 Disconnect all cables as well as any pneumatic tubing connected to the Secondary Interface Panel. 2 Remove the quill clamp collar from the top of the quill by loosening the socket-head capscrew and then slide the collar off of the quill. 6-14 i4H Robots with EtherCAT User's Manual (I661) 6 Maintenance 3 Remove the six M5 x 12 screws that fasten the cover to the Secondary Interface Panel. M5 x 12 Screws (6) 4 Carefully lift the cover off of the outer link. 5 Place the new cover on the outer link and align the lower edge and mounting screw holes. 6 Replace the six M5 x 12 screws that fasten the cover to the Secondary Interface Panel. Apply Loctite thread lock type 222 or equivalent and torque screws to 0.8 N-m. 6 7 Slide the quill clamp collar into position apply Loctite 243 or equivalent to the socket-head cap- screw. Apply 2.8 N-m of torque to the socket-head capscrew to secure the clamp collar. 8 Connect all previously disconnected cables as well as any pneumatic tubing connected to the Secondary Interface Panel to complete this procedure. 6-3 Non-periodic Maintenance 6-3-3 Replacing the Outer Link Cover i4H Robots with EtherCAT User's Manual (I661) 6-15 6 Maintenance 6-16 i4H Robots with EtherCAT User's Manual (I661) A Appendix A-1 Repacking the Robot for Transport ............................................................. A-2 A-2 Transportation and Storage Considerations .............................................. A-3 A-3 I/O Signal Numbering.................................................................................... A-4 A-3-1 Input Signal Numbering................................................................................... A-4 A-3-2 Output Signal Numbering ................................................................................ A-5 A-4 Cable Pinouts ................................................................................................ A-7 A-4-1 XSYSTEM Cable Pinouts................................................................................ A-7 A-4-2 XBELTIO Adapter Cable Pinouts .................................................................... A-8 A-4-3 Belt Encoder Y-adapter Cable Pinouts ............................................................ A-9 A-5 Parts List .......................................................................................................A-11 A i4H Robots with EtherCAT User's Manual (I661) A-1 Appendix A-1 Repacking the Robot for Transport The robot must be carefully packed if it needs to be transported. Reuse all original packing containers and materials and follow all safety guidelines detailed in the installation section of this manual. Reverse the installation instructions and unpacking instructions to repack the robot for transport. A-2 i4H Robots with EtherCAT User's Manual (I661) Appendix A-2 Transportation and Storage Considerations This section provides details about transporting and storing your robot. Precautions for Correct Use · This equipment must be shipped and stored in a temperature-controlled environment, within the range 25 to +55° C. The recommended humidity range must be 5 to 90%, non-condensing. It should be shipped and stored in the supplied packaging, which is designed to prevent damage from normal shock and vibration. · Do not expose the shipping container to excessive shock and vibration. Do not lay the crate on its side or any other non-upright position. This could damage the robot. Use a forklift or pallet jack to transport the packaged equipment in an upright position. Always keep the ISO double-arrows on the sides of the crate oriented up. A A-2 Transportation and Storage Considerations i4H Robots with EtherCAT User's Manual (I661) A-3 Appendix A-3 I/O Signal Numbering Digital I/O for the eV+ programming language uses numeric signal numbers in the ranges provided below based on the I/O configuration of the system. A-3-1 Input Signal Numbering Use the table below to understand the digital input signal numbers. Robot 1 2 3 4 5 6 7 Input Type XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 Switch Position -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON -OFF, OFF ON, OFF OFF, ON ON, ON V+ Signal Numbers 1001 to 1012 1065 to 1072 1073 to 1080 1081 to 1088 1089 to 1096 1101 to 1112 1165 to 1172 1173 to 1180 1181 to 1188 1189 to 1196 1201 to 1212 1265 to 1272 1273 to 1280 1281 to 1288 1289 to 1296 1301 to 1312 1365 to 1372 1373 to 1380 1381 to 1388 1389 to 1396 1401 to 1412 1465 to 1472 1473 to 1480 1481 to 1488 1489 to 1496 1501 to 1512 1565 to 1572 1573 to 1580 1581 to 1588 1589 to 1596 1601 to 1612 1665 to 1672 1673 to 1680 1681 to 1688 1689 to 1696 A-4 i4H Robots with EtherCAT User's Manual (I661) Appendix A-3 I/O Signal Numbering Robot 8 Input Type XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 Switch Position -OFF, OFF ON, OFF OFF, ON ON, ON V+ Signal Numbers 1701 to 1712 1765 to 1772 1773 to 1780 1781 to 1788 1789 to 1796 A-3-2 Output Signal Numbering Use the table below to understand the digital output signal numbers. Robot 1 2 3 4 5 6 7 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 Output Type Switch Position V+ Signal Numbers -- 1 to 8 OFF, OFF 65 to 72 ON, OFF 73 to 80 OFF, ON 81 to 88 ON, ON 89 to 96 -- 101 to 108 OFF, OFF 165 to 172 ON, OFF 173 to 180 OFF, ON 181 to 188 ON, ON 189 to 196 -- 201 to 208 OFF, OFF 265 to 272 ON, OFF 273 to 280 OFF, ON ON, ON 281 to 288 289 to 296 A -- 301 to 308 OFF, OFF 365 to 372 ON, OFF 373 to 380 OFF, ON 381 to 388 ON, ON 389 to 396 -- 401 to 408 OFF, OFF 465 to 472 ON, OFF 473 to 480 OFF, ON 481 to 488 ON, ON 489 to 496 -- 501 to 508 OFF, OFF 565 to 572 ON, OFF 573 to 580 OFF, ON 581 to 588 ON, ON 589 to 596 -- 601 to 608 OFF, OFF 665 to 672 ON, OFF 673 to 680 OFF, ON 681 to 688 ON, ON 689 to 696 i4H Robots with EtherCAT User's Manual (I661) A-5 A-3-2 Output Signal Numbering Appendix Robot 8 XIO IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 Output Type Switch Position -OFF, OFF ON, OFF OFF, ON ON, ON V+ Signal Numbers 701 to 708 765 to 772 773 to 780 781 to 788 789 to 796 A-6 i4H Robots with EtherCAT User's Manual (I661) A-4 Cable Pinouts Cable pinout information is provided below. A-4-1 XSYSTEM Cable Pinouts Use the following diagrams for XSYSTEM cable pinout information. Appendix XFP 13322-000 XSYSTEM 13322-000 XUSR 13322-000 XMCP 13322-000 A A-4 Cable Pinouts A-4-1 XSYSTEM Cable Pinouts i4H Robots with EtherCAT User's Manual (I661) A-7 Appendix XSYSTEM PIN 5 PIN 14 PIN 30 PIN 10 PIN 26 PIN 12 PIN 28 PIN 13 PIN 43 PIN 1 PIN 31 PIN 29 PIN 44 PIN 25 PIN 40 PIN 27 PIN 42 PIN 11 PIN 41 PIN 9 PIN 39 PIN 24 SHELL PIN 44 PIN 15 PIN 37 PIN 23 PIN 8 PIN 38 PIN 7 PIN 6 PIN 20 SHELL PIN 31 PIN 32 PIN 3 PIN 18 PIN 34 PIN 4 PIN 19 PIN 33 SHELL PIN 11 PIN 12 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 3 PIN 14 PIN 4 PIN 15 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 16 PIN 17 PIN 1 PIN 2 SHELL XUSR PIN 1 PIN 14 PIN 25 PIN 13 PIN 10 PIN 3 PIN 4 PIN 9 PIN 6 PIN 13 PIN 11 PIN 12 PIN 7 PIN 8 PIN 1 PIN 2 SHELL XMCP PIN 1 PIN 9 PIN 15 PIN 8 PIN 10 PIN 9 PIN 1 PIN 6 PIN 2 PIN 5 PIN 7 PIN 14 PIN 11 PIN 12 PIN 13 PIN 15 PIN 3 PIN 4 SHELL XFP PIN 1 PIN 9 PIN 15 PIN 8 A-4-2 XBELTIO Adapter Cable Pinouts Use the following diagrams for XBELTIO adapter cable pinout information. A-8 i4H Robots with EtherCAT User's Manual (I661) Appendix BELT ENCODER FORCE/ EXPIO XBELT IO 13463-000 RS232 A-4 Cable Pinouts A-4-3 Belt Encoder Y-adapter Cable Pinouts BELT ENCODER PIN 8 PIN 15 PIN 15 PIN 7 PIN 14 PIN 6 PIN 13 PIN 1 PIN 5 PIN 11 PIN 3 PIN 9 PIN 10 PIN 2 PIN 9 PIN 1 PIN 4 PIN 12 SHIELD FORCE EXPIO PIN 1 PIN 6 PIN 5 PIN 5 PIN 4 PIN 6 PIN 1 PIN 9 PIN 3 PIN 2 SHIELD RS-232 PIN 1 PIN 3 PIN 2 PIN 5 PIN 5 SHIELD PIN 6 PIN 9 XBELTIO PIN 2 (ENC1_A+) PIN 3 (ENC1_A-) PIN 11 (ENC1_B+) PIN 12 (ENC1_B-) PIN 19 (ENC1_Z+) PIN 9 PIN 20 (ENC1_Z-) PIN 4 (ENC2_A+) PIN 18 PIN 5 (ENC2_A-) PIN 13 (ENC2_B+) PIN 26 PIN 14 (ENC2_B-) PIN 21 (ENC2_Z+) PIN 22 (ENC2_Z-) PIN 1 (5V) PIN 10 (GND) SHIELD XBELTIO PIN 7 (CLK +) PIN 8 (CLK -) PIN 6 (5V) PIN 9 PIN 9 (EXPIO 5V) PIN 18 PIN 15 (GND) PIN 16 (DATA +) PIN 26 PIN 17 (DATA -) SHIELD PIN 1 PIN 10 PIN 19 PIN 1 PIN 10 PIN 19 XBELTIO PIN 25 (TXD) PIN 26 (RXD) PIN 18 (GND) SHIELD PIN 9 PIN 18 PIN 26 PIN 1 PIN 10 PIN 19 A-4-3 Belt Encoder Y-adapter Cable Pinouts Use the following diagrams for Belt Encoder Y-adapter cable pinout information. i4H Robots with EtherCAT User's Manual (I661) A A-9 Appendix Encoder 1 (M12, Female, 8 PIN) 1 2 Encoder 2 (M12, Female, 8 PIN) Encoder 1 PIN 1 PIN 7 PIN 6 PIN 8 PIN 5 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 3 PIN 6 PIN 4 PIN 8 PIN 2 PIN 7 SHIELD PIN 1 PIN 7 PIN 6 Encoder 2 PIN 1 PIN 8 PIN 2 PIN 3 PIN 4 PIN 5 PIN 3 PIN 6 PIN 8 PIN 4 PIN 5 PIN 2 PIN 7 SHIELD BELT ENC. PIN 15 (ENC1_A+) PIN 7 (ENC1_A-) PIN 14 (ENC1_B+) PIN 6 (ENC1_B-) PIN 13 (ENC1_I+) PIN 5 (ENC1_I-) PIN 4 (5V) PIN 12 (GND) SHIELD PIN 1 PIN 8 PIN 11 (ENC2_A+) PIN 3 (ENC2_A-) PIN 10 (ENC2_B+) PIN 2 (ENC2_B-) PIN 9 (ENC2_I+) PIN 1 (ENC2_I-) PIN 4 (5V) PIN 12 (GND) SHIELD PIN 9 PIN 15 BELT ENC. 09443-000 A-10 i4H Robots with EtherCAT User's Manual (I661) Appendix A-5 Parts List Standard robot parts and accessories are provided in the following table. Item Part Number Details Included Optional Cables XSYSTEM cable 13322-100 X XBELTIO Cable 13463-000 X XIO Breakout 04465-000 X Cable IO Blox Exten- 04677-030 Extends the X sion Cable (to connection be- robot) tween the IO Blox and the ro- bot up to 3 m. IO Blox Exten- 04679-030 Extends the X sion Cable ( be- connection be- tween units) tween IO Blox units up to 3 m. Encoder Exten- 09446-050 Replaces or ex- X sion Cable tends encoder cable up to 5 m. Belt Encoder Y- 09443-000 X adapter Cable Connectors / High Power 04118-000 Includes con- X Jumpers Connector nector and pins. Control Power 43160-2102 Includes con- X Connector nector and pins. A XFP Jumper 10053-000 X Plug XUSR Jumper 04736-000 X Plug XMCP Jumper 10052-000 X Plug T20 Pendant 10048-000 X Jumper Plug A-5 Parts List i4H Robots with EtherCAT User's Manual (I661) A-11 Appendix Other Items Item Encoder Backup Battery Pack Camera Mounting Bracket Camera Mounting Adapter Front Panel Kit Part Number 19238-000F 18908-000 22295-000 92546-10358 Tool Flange Outer Link Cover (i4-650H) Outer Link Cover (i4-750H, i4-850H) iCSECAT(standard robot type) iCS-ECAT(inverted robot type) XIO Termination Block and Cable T20 Pendant Kit 19106-000F 19211-002F 19227-002F 29900-000F 29910-000F 90356-40100 10046-010 T20 Pendant Wall Bracket IPC Application Controller 10079-000 AC1-152000 eCobra Mount Adapter eCobra Tool Flange IO Blox Kit (robot connection) 21636-000 19106-100F 90356-30200 IO Blox Kit (IO 90356-30100 Blox connection) Joint 3 Quill Grease 90401-04029 Details Kit includes front panel and 3 m cable. Kit includes the pendant, 3 m adapter cable, and a jumper plug. Includes ACE software pre-installed. Includes 300 mm cable to connect directly to the robot. Includes 200 mm cable to connect to another IO Blox unit. Showa Shell LG 2 type. Included X X X X X X X Optional X X X X X X X X X X X A-12 i4H Robots with EtherCAT User's Manual (I661) Appendix Other Items Item Harmonic Drive Oil Change Kit Part Number 12370-000F Encoder Kit 09742-001 NJ501-R Series Machine Automation Controller NJ501-R[ ][ ][ ] Details Kit includes funnel, separator bottle, vacuum pump, reducer, tubing, and instructions. Includes endoder, mounting bracket, and 5 m cable. Contact your local Omron representative for complete part number. Included Optional X X A A-5 Parts List i4H Robots with EtherCAT User's Manual (I661) A-13 Appendix A-14 i4H Robots with EtherCAT User's Manual (I661) I Index I i4H Robots with EtherCAT User's Manual (I661) I-1 Index Index A F Altitude.............................................................................2-16 B Base.................................................................................. 1-4 Brake Force............................................................................ 4-10 Release Button..................................................... 1-6, 4-10 Remote Release...........................................................4-11 C Cable Clearances.............................................................. 2-6 Cables Belt Encoder Y-adapter....................................... 1-19, 3-11 EXPIO to IO Blox..........................................................3-11 XBELTIO Adapter.........................................................3-11 XIO Breakout................................................................3-11 XIO............................................................................... 3-11 XSYSTEM...........................................................1-10, 3-10 Connectors Control Power....................................................... 1-9, 2-17 High Power........................................................... 1-9, 2-17 TIO............................................................................... 2-17 Tool EtherCAT.............................................................. 1-11 USER....................................................................1-9, 2-17 XBELTIO............................................................. 1-10, 2-17 XFP.............................................................................. 3-10 XIO......................................................................1-10, 2-17 XMCP...........................................................................3-10 XSYSTEM...........................................................1-10, 2-17 XUSR........................................................................... 3-10 Control Power LED Indicator............................................. 1-7 Controller Label............................................................... 1-12 Cycle Time.......................................................................2-10 D Dimensions Camera Mounting Bracket............................................. 2-8 eCobra Mount Adapter...................................................2-7 Front Panel.................................................................... 2-7 Mounting Flange............................................................ 2-6 Robot............................................................................. 2-2 Tool Flange.................................................................... 2-7 E Emergency Stop................................................................ 1-7 Encoder Backup Batteries..........................................6-2, 6-6 End-of-Arm Tooling............................................................3-5 Error Messages................................................................. 5-4 EtherCAT Interface Port...................................................2-17 External Equipment Mounting........................................... 3-6 Faults................................................................................. 5-2 Front Panel.................................................................1-7, 6-2 G Grounding........................................................................ 3-29 H Hardstops.......................................................................... 3-8 Joint 1............................................................................ 3-8 High Power Disabling........................................................................ 4-7 Enabling......................................................................... 4-6 Request Methods...........................................................4-7 Safety Timeout............................................................... 4-6 Humidity...........................................................................2-16 I I/O Signal Numbers...........................................................A-4 Inner Link...........................................................................1-4 IO Blox.............................................................................3-17 IPC Application Controller............................................... 1-17 J Jogging............................................................................ 4-12 Joint 1................................................................................ 1-4 Joint 2................................................................................ 1-4 Joint 3................................................................................ 1-4 Joint 4................................................................................ 1-4 Joint Ranges....................................................................2-10 Joint Speeds....................................................................2-10 Jumper Plugs Teach Pendant............................................................. 3-26 XFP.............................................................................. 3-24 XUSR........................................................................... 3-22 XMCP...........................................................................3-25 L LCD Display............................................................... 1-6, 4-9 LED Light Ring Indicator............................................ 1-6, 4-8 M Mode Selection Switch...................................................... 1-7 Model Numbers Controller Model Number.............................................1-15 Robot Model Numbers................................................. 1-15 Modes Automatic....................................................................... 4-3 Manual........................................................................... 4-3 I-2 i4H Robots with EtherCAT User's Manual (I661) Moment of Inertia.............................................................2-10 Mounting Procedure...................................................................... 3-4 Surface...........................................................................3-3 O Operating Temperature....................................................2-16 Outer Link.......................................................................... 1-4 P Payload............................................................................2-10 Pneumatic Pass-through Ports............................... 1-11, 2-17 Protection Class.............................................................. 2-16 Pollution Degree.............................................................. 2-16 Power Supply.................................................................. 2-14 Primary Interface Panel..................................................... 1-5 Q Quill................................................................................... 1-4 R Repeatability.................................................................... 2-10 Robot Label..................................................................... 1-12 S Safety Circuits................................................................. 3-20 Secondary Interface Panel................................................ 1-6 Storage Temperature.......................................................2-16 T T20 Pendant.................................................................... 1-16 Tool Flange.................................................................1-4, 6-2 W Warning Labels..................................................................6-5 Wiring Belt Encoder Y-adapter Cable....................................... A-9 XBELTIO Adapter Cable................................................A-8 XFP Connector............................................................ 3-22 XIO Connector............................................................. 3-14 XMCP Connector......................................................... 3-24 XUSR Connector......................................................... 3-21 XSYSTEM Cable........................................................... A-7 X XIO Termination Block..................................................... 1-17 Z Z-axis................................................................................. 1-4 i4H Robots with EtherCAT User's Manual (I661) Index I I-3 Index I-4 i4H Robots with EtherCAT User's Manual (I661) OMRON Corporation Industrial Automation Company Kyoto, JAPAN Contact: www.ia.omron.com Regional Headquarters OMRON EUROPE B.V. Wegalaan 67-69, 2132 JD Hoofddorp The Netherlands Tel: (31)2356-81-300/Fax: (31)2356-81-388 OMRON ASIA PACIFIC PTE. LTD. No. 438A Alexandra Road # 05-05/08 (Lobby 2), Alexandra Technopark, Singapore 119967 Tel: (65) 6835-3011/Fax: (65) 6835-2711 OMRON ELECTRONICS LLC 2895 Greenspoint Parkway, Suite 200 Hoffman Estates, IL 60169 U.S.A. Tel: (1) 847-843-7900/Fax: (1) 847-843-7787 OMRON ROBOTICS AND SAFETY TECHNOLOGIES, INC. 4225 Hacienda Drive, Pleasanton, CA 94588 U.S.A. OMRON (CHINA) CO., LTD. Room 2211, Bank of China Tower, 200 Yin Cheng Zhong Road, PuDong New Area, Shanghai, 200120, China Tel: (86) 21-5037-2222/Fax: (86) 21-5037-2200 Authorized Distributor: © OMRON Corporation 2021 All Rights Reserved. In the interest of product improvement, specifications are subject to change without notice. Cat. No. I661-E-02 0121 22794-000 BAntenna House PDF Output Library 6.5.1167 (Windows (x64))