Omron IX4 User manual

iX4 650 H/HS and 800 H/HS Robot

with EtherCAT

User's Manual

I656-E-01

The information contained herein is the property of OMRON, and shall not be reproduced in whole or in

part without prior written approval of OMRON. The information herein is subject to change without

notice and should not be construed as a commitment by OMRON. The documentation is periodically

reviewed and revised.

OMRON assumes no responsibility for any errors or omissions in the documentation.

Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan and

other countries for OMRON factory automation products.

EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH,

Germany.

ODVA, CIP, DeviceNet, and EtherNet/IP are trademarks of ODVA.

Other company names and product names in this document are the trademarks or registered trademarks

of their respective companies.

Created in the United States of America.

Table of Contents

Chapter 1: Introduction 9

1.1 Related Manuals 9

1.2 Intended Audience 10

1.3 Robot Overview 10

Major Differences Between iX4-650H/800H and iX4-650HS/800HS Robots 11

Robot Amplifier and Controller 12

Robot Base 15

Outer Arms and Ball Joints 15

Inner Arms 16

Platforms 16

Robot Motions and Obstacles 18

1.4 Robot Options 18

I/O Options 18

T20 Pendant 19

IPC Application Controller 20

Front Panel 20

Optional Cables 21

Cable Inlet Box 24

Ball Stud Locks 25

Chapter 2: Safety 27

2.1 Dangers, Warnings, and Cautions 27

Alert Levels 27

Alert Icons 27

Falling Hazards 27

Special Information 28

2.2 What to Do in an Emergency or Abnormal Situation 28

Stopping the Robot 28

Entrapment and Brake Release Button 28

Releasing an E-Stop 28

2.3 Safety Precautions 29

User's Responsibilities 29

General Hazards 29

Qualification of Personnel 30

2.4 Robot Behavior 30

Hardstops 30

Limiting Devices 31

Singularities 31

2.5 Intended and Non-intended Use 31

22793-000 Rev. A iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

Table of Contents

Intended Use of the Robots 31

Non-Intended Use 31

2.6 Additional Safety Information 32

Manufacturer’s Declaration of Incorporation 32

Robot Safety Guide (Cat. No. I590) 32

Emergency Stop Circuit and Buttons 32

2.7 How CanIGet Help? 32

T20 Manual Control Pendant (Option) 33

Disposal 33

Chapter 3: Robot Installation 35

3.1 Robot Installation Overview 35

Basic Installation Steps 35

3.2 Mounting Frame 35

Frame Orientation 37

Frame Construction 37

Frame Mounting Tabs 37

Robot-to-Frame Considerations 38

Mounting Surfaces 38

Gussets 39

3.3 Mounting the Robot Base 39

Robot Orientation 39

Mounting Procedure 39

3.4 Installing the Platform 42

Align the Platform with the Robot Base 42

Attach the Outer Arms 43

Outer Arm Attachment Procedure 46

3.5 Installing the FrontPanel 47

Mounting the Front Panel 47

Connecting the Front Panel 48

3.6 Installing User-Supplied Safety Equipment 49

Contacts on XUSR Connector 50

Contacts on XFP Connector 51

Remote Pendant Signals on the XMCPConnector 51

E-Stop Circuits on XUSR and XFP Connectors 52

Emergency Stop Circuits 54

Remote Manual Mode 56

User Manual/Auto Indication 56

Remote High Power ON / OFF Control 57

Using a User-Supplied Control Panel 58

Remote Pendant Usage 58

3.7 Setting the EtherCATNodeID 58

Setting the EtherCATNode ID UsingHardware Switches 59

3.8 Installing or Removing Ball Stud Locks 61

4 iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

22793-000 Rev. A

Table of Contents

Installing Ball StudLocks 61

Removing Ball StudLocks 62

Chapter 4: System Cable Installation 63

4.1 Basic System Cable Layout 63

List of Cables and Parts 65

Cable Installation Steps 66

XBELT IO Belt Encoder Y Adapter Cable 67

4.2 Connecting Digital I/O to the System 70

Digital I/O Signal Configuration 70

XIO Connector Signals 77

4.3 Connecting the 24 VDC Cable to the Robot 79

24 VDC Power Supply Connector 79

Making the 24 VDC Power Supply Cable 79

Connecting the 24 VDC Cable 80

4.4 Connecting 200 to 240 VAC Power Cable 82

AC Power Diagrams 83

AC Power Supply Connector 84

Making the 200 to 240 VAC Power Supply Cable 85

AC Power Supply Cable Connection Procedure 86

4.5 Grounding the Robot System 86

Grounding the iX4-650H/800H Robot Base 87

Grounding the iX4-650HS/800HS Robot Base 88

Grounding Robot-Mounted Equipment 88

4.6 Installing a Cable Inlet Box for iX4-650H/800H Robots 88

4.7 Installing a Cable Inlet Box for iX4-650HS/800HS Robots 91

Assembling the Cable Inlet Box 91

Connecting the Cables 96

Installing the Cable Inlet Box 96

4.8 Attaching the Cable Tray 98

Chapter 5: System Operation 103

5.1 Verifying Installation 103

Mechanical Checks 103

System Cable Checks 103

Safety Equipment Checks 104

Switch Position Checks 105

5.2 Robot Status LED and Display Panel 105

General Robot States 105

5.3 EtherCAT Communications Description 106

5.4 Brakes 107

Brake Release Button 107

Remote Brake Release Feature 108

22793-000 Rev. A iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

Table of Contents

5.5 Robot Control Modes 109

Manual Mode 109

Automatic Mode 109

Operation Mode 109

Service Mode 110

5.6 Manually Jogging the Robot 110

5.7 Enabling Robot High Power 110

High Power Safety Timeout 111

High Power and Faults 111

High Power Request Methods 111

5.8 Disabling Robot High Power 113

Chapter 6: Maintenance 115

6.1 Periodic Maintenance Schedule 115

6.2 Non-periodic Maintenance Schedule 117

6.3 Cleaning iX4-650H/800H Robots 118

Caustic Compatibility 118

Wash Down 119

Water Shedding 119

Design Factors 119

6.4 Cleaning iX4-650HS/800HS Robots 120

Chemical Compatibility 121

Wash Down 121

Water Shedding 122

Design Factors 122

6.5 Checking Safety Systems 123

High Power Indicator Check 123

6.6 Checking Labels 124

Warning Labels 124

6.7 Checking for Gear Drive Leaks 125

6.8 Checking Fan Operation 126

6.9 Replacing the Encoder Battery Pack 126

Encoder Battery Pack Replacement Interval 127

Encoder Battery Pack Replacement Procedure 127

6.10 Replacing a Platform 130

Configuration 131

6.11 Replacing Outer Arm Spring Assemblies 131

6.12 Replacing a Ball Joint Socket Insert 133

6.13 Replacing the iCS-ECAT Unit for an iX4-650H/800H Robot 135

Removing the iCS-ECAT Chassis 135

Installing a New iCS-ECAT Chassis 137

6 iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

22793-000 Rev. A

Table of Contents

6.14 Replacing the iCS-ECAT Unit for an iX4-650HS/800HS Robot 138

Removing the iCS-ECAT Chassis from an iX4-650HS/800HS Robot 138

Installing a new iCS-ECAT Chassis 141

6.15 Remove and Replace a MicroSD Card 142

Removing a MicroSD Card from an iCS-ECAT 142

Replacing a MicroSD Card in an iCS-ECAT 143

Chapter 7: Technical Specifications 145

7.1 Robot Physical Dimension Drawings 145

7.2 Arm Travel Volumes 149

7.3 Tool Flanges 152

7.4 General Robot Specifications 154

7.5 Performance Specifications 156

Payload Specifications 156

Payload Center ofGravity Specifications 158

Stopping Time and Distance 158

7.6 Electrical Specifications 166

External Connection Specifications 166

Facility Overvoltages Protection 169

7.7 EtherCAT Communications Specifications 169

7.8 Mounting Frame Specifications 170

7.9 Environmental and Facility Specifications 176

Environmental Requirements 176

Design Considerations 177

7.10 Weights 178

7.11 Power Connector Specifications 178

Chapter 8: Status Codes 179

8.1 Status Display Panel 179

8.2 Status Codes Table 179

Appendix 187

9.1 Unpacking and Inspecting the Equipment 187

Before Unpacking 187

After Unpacking 187

Unpacking Procedure 187

9.2 Repacking for Relocation 189

9.3 Transportation and Storage 189

22793-000 Rev. A iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

Chapter 1: Introduction

This manual contains information that is necessary to install and use an iX4 robot. Please read

this manual and make sure you understand the functionality, installation, and performance of

the robot before attempting to use it.

1.1 Related Manuals

Use the following related manuals for reference.

Table 1-1. Related Manuals

Manual Description

Robot Safety Guide (Cat. No.

I590)

Contains safety information for OMRON industrial robots.

Sysmac Studio Robot Integ-

rated System Building Func-

tion with Robot Integrated

CPU Unit Operation Manual

(Cat. No. W595)

Describes the operating procedures of the Sysmac Studio.

Sysmac Studio Robot Integ-

rated System Building Func-

tion with IPC Application

Controller Operation Manual

(Cat. No. W621)

Describes the operating procedures of the IPC

ApplicationController.

eV+3 User'sManual (Cat.

No. I651)

Provides a description of the V+ programming language

and functionality.

eV+3 User'sManual (Cat.

No. I651)

Provides reference to V+ Keyword use and functionality.

eV+3 Keyword

ReferenceManual (Cat. No.

I652)

Provides information that is necessary to use the robot con-

trol function of the NJ-series CPU Unit.

IPC Application Controller

User’s Manual (Cat. No.

I632)

Provides information that is necessary to use the robot con-

trol function of the IPC Application Controller.

NJ-series Robot Integrated

CPU Unit User's Manual

(Cat. No. O037)

Describes the use of the NJ-series Robot Integrated CPU Unit.

T20 Pendant User's Manual

(Cat. No. I601)

Describes the use of the optional T20 manual control

pendant.

22793-000 Rev. A iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

10 iX4 650 H/HS and 800 H/HS Robot with EtherCAT

User’s Manual (Cat. No. I656)

22793-000 Rev. A

1.2 Intended Audience

Manual Description

IO Blox User’s Guide (04638-

000)

Describes the IO Blox product, its connections, and input/out-

put signals.

1.2 Intended Audience

This manual is intended for the following personnel, who must also have knowledge of fact-

ory automation (FA) systems and robotic control methods.

lPersonnel in charge of introducing FA systems.

lPersonnel in charge of designing FA systems.

lPersonnel in charge of installing and maintaining FA systems.

lPersonnel in charge of managing FA systems and facilities.

1.3 Robot Overview

The iX4 is a four-arm parallel robot. Servo motors in the robot base control movement of the

robot platform through mechanical links and arms. A tool flange is provided on the bottom of

the platform for mounting end-of-arm tooling.

Servo and other control functions are provided with an integrated controller(iCS-ECAT) that is

mounted in the top of the robot base.

Built-in EtherCAT communications allow this robot to operate together with EtherCAT slaves,

other Sysmac products, and the Sysmac Studio Automation Software to achieve optimum func-

tionality and ease of operation.

NA-series

T20Teach pendant

(with built-in EtherCAT

communications)

Slave

Terminal

Vision sensor

OMRON

robot

Robot Integrated CPU Unit

NJ501-R

I/O control

external devices

1S-series Servo Drives

G5-series Servo Drives

Server Relational database

USB

Camera

FH-series Vision

Systems

Robots controllable by NJ Robotics function

EtherCAT

Application Controller

Sysmac Studio

EtherNet/IP

Front Panel

Safety

devices Encoder,

digital I/O

Figure 1-1. EtherCATSystem Topology

This manual suits for next models

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