Omron Viper 650 User manual

Viper 650 and 850

Robot with EtherCAT

User's Manual

I654-E-01

2 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

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 doc-

umentation 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 Auto-

mation 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 7

Related Manuals 7

1.1 Intended Audience 8

1.2 Robot Overview 8

Robot Amplifier and Controller 8

IP54/65 and Cleanroom Versions 12

Robot Features 12

Robot Links and Joints 13

Robot Connections 13

eCS-ECAT Interface Panel 16

1.3 Robot Options 18

IO Blox 18

T20 Pendant 19

IPC Application Controller 20

Front Panel 20

Optional Cables 22

Chapter 2: Safety 27

2.1 Dangers, Warnings, and Cautions 27

Alert Levels 27

Alert Icons 27

Special Information 28

2.2 Safety Precautions 28

2.3 What To Do In An Emergency 29

Stopping the Robot 29

Fire Response 29

Entrapment and Brake Release Box 29

2.4 Robot Behavior 29

Hardstops 29

Limiting Devices 29

Singularities 30

2.5 Intended Use of the Robot 30

2.6 Additional Safety Information 31

Manufacturer’s Declarations 31

Robot Safety Guide 31

T20 Pendant (Option) 31

2.7 Disposal 31

2.8 How Can I Get Help? 31

Chapter 3: Robot Installation 33

3.1 Robot Installation Overview 33

Basic Installation Steps 33

3.2 Mounting a Viper Robot 33

21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 3

Mounting Surface 33

Mounting Surface Preparation 34

Mounting Procedure for Upright Viper 35

Mounting Procedure for Ceiling Mount 36

Robot Mounting Torque 37

3.3 Mounting the eCS-ECAT 37

3.4 Installing the Front Panel 37

Connecting the Front Panel 38

Front Panel Schematic 38

3.5 Air Lines and Signal Wiring 39

3.6 Installing User-Supplied Safety Equipment 41

Contacts on XUSR Connector 41

Contacts on XFP Connector 43

Remote Pendant Signals on the XMCPConnector 43

E-Stop Circuits on XUSR and XFP Connectors 45

Emergency Stop Circuits 46

Remote Manual Mode 48

User Manual/Auto Indication 48

Remote High Power ON / OFF Control 48

Using a User-Supplied Control Panel 50

Remote Pendant Usage 50

3.7 Setting the EtherCATNodeID 50

Setting the EtherCATNode ID UsingHardware Switches 51

3.8 Installing Joint Labels 52

Chapter 4: System Cable Installation 55

4.1 Basic System Cable Layout 55

List of Cables and Parts 56

Cable Installation Steps 58

XBELT IO Belt Encoder Y Adapter Cable 59

4.2 Connecting Digital I/O to the System 62

Optional I/O Products 62

Digital I/O Signal Configuration 62

XIO Connector Signals 70

4.3 Connecting Cable from the eCS-ECAT to the Robot 72

4.4 Connecting the 24 VDC Cable to the eCS-ECAT 73

24 VDC Power Supply Connector 73

Making the 24 VDC Power Supply Cable 74

Connecting the 24 VDC Cable 74

4.5 Connecting 200-240 VAC Power Cable 76

AC Power Diagrams 76

AC Power Supply Connector 77

Making the 200-240 VAC Power Supply Cable 78

Connecting the AC Power Supply Cable 79

4.6 Grounding the Robot System 79

Grounding the Robot Base 79

Ground Point on eCS-ECAT 80

Grounding Robot-Mounted Equipment 80

4 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 5

Chapter 5: Optional Equipment Installation 83

5.1 Installing End-Effectors 83

5.2 Mounting Locations for External Equipment 83

Chapter 6: System Operation 85

6.1 Verifying Installation 85

Mechanical Checks 85

System Cable Checks 85

User-Supplied Safety Equipment Checks 86

Switch Position Checks 87

6.2 Status LED and Display Panel 87

General Robot States 87

6.3 EtherCAT Communications Description 88

SystemBehavior with EtherCATCommunication Errors 89

6.4 Brakes 89

Brake Release Connector 89

Installing and Using the Brake Release Box 90

6.5 Robot Control Modes 91

Manual Mode 91

Automatic Mode 92

Operation Mode 92

Service Mode 92

6.6 Manually Jogging the Robot 93

6.7 Enabling Robot High Power 93

High Power Safety Timeout 93

High Power and Faults 94

High Power Request Methods 94

6.8 Disabling Robot High Power 95

Chapter 7: Maintenance 97

7.1 Periodic Maintenance 97

Periodic Maintenance Schedule 97

Checking Safety Systems 97

Checking Robot Mounting Bolts and CoverPlates 98

Checking Safety and Warning Labels 98

Replacing the Encoder Batteries 99

7.2 Non-Periodic Maintenance 102

Field-Replaceable Parts 103

Replacing the eCS-ECAT Amplifier Chassis 103

Remove and Replace a MicroSD Card 104

Chapter 8: Technical Specifications 107

8.1 Robot Physical Dimension Drawings 107

8.2 General Robot Specifications 112

8.3 Performance Specifications 113

General Performance Information 113

Stopping Distances and Times 114

8.4 Electrical Specifications 121

Solenoid Valve Specifications 121

External Connection Specifications 121

8.5 Environment and Facility Specifications 123

8.6 Other Specifications 124

ConnectorSpecifications 124

Power Consumption Specifications 126

8.7 Tool Flange Dimensions 126

8.8 Front Panel Dimensions 127

8.9 EtherCAT Communications Specifications 128

Chapter 9: IP54/65 Option Considerations 129

9.1 IP54/65 Option Classification 129

9.2 Differences from Standard Robot Model 129

Robot Connector Panel 129

Cable Clearance 130

Replacing Encoder Backup Battery 130

Chapter 10: Cleanroom Option Considerations 131

10.1 Differences from Standard Robot Model 131

10.2 Cleanroom Robot Connections 131

Cleanroom CN22 Cable 132

Air Lines and Signal Wiring 133

10.3 Cleanroom Cover at J6 Flange 135

10.4 Cleanroom Technical Specifications 136

10.5 Cable Clearance 137

10.6 Replacing Encoder Backup Battery 137

Chapter 11: Status Codes 139

11.1 eCS-ECAT Display Panel 139

11.2 Status Codes Table 139

Appendix 145

A.1 Unpacking and Inspecting the Equipment 145

Before Unpacking 145

After Unpacking 145

Inspecting the Equipment 145

A.2 Repacking for Relocation 145

A.3 Transportation and Storage of Robot 145

Transportation and Storage Environment 145

Precautions when Transporting Robot 146

Transport Procedure 147

6 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

Chapter 1: Introduction

This manual contains information that is necessary to install and use Viper 650 and 850

Robot with EtherCAT. Read this manual and make sure you understand the functionality,

installation, and performance of the robot before attempting to use it.

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 Integrated System

Building Function with Robot Integrated

CPU Unit Operation Manual (Cat. No.

W595)

Describes the operating procedures of the Sys-

mac Studio.

Sysmac Studio Robot Integrated System

Building Function with IPC Application Con-

troller 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 eV+ pro-

gramming language and functionality.

eV+3 Keyword ReferenceManual (Cat. No.

I652)

Provides reference to eV+ Keyword use and

functionality.

AutomationControl Environment

(ACE)Version 4 User'sManual (Cat. No.

I633)

Describes the installation and use of the ACE

software.

NJ-series Robot Integrated CPU Unit User's

Manual (Cat. No. O037)

Provides information that is necessary to use

the robot control 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 control function of the IPC Applic-

ation Controller.

T20 Pendant User's Manual (Cat. No. I601) Describes the use of the optional T20 manual

control pendant.

IO Blox User’s Guide (04638-000) Describes the IO Blox product, its connections,

and input/output signals.

21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 7

8 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

1.1 Intended Audience

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

mon programming practices and robotic control methods.

lPersonnel in charge of introducing factory automation systems.

lPersonnel in charge of designing factory automation systems.

lPersonnel in charge of installing and maintaining factory automation systems.

lPersonnel in charge of managing factory automation systems and facilities.

1.2 Robot Overview

The Viper 650 and Viper 850 robots are high-performance, six-axis articulated robots designed

specifically for assembly applications. The speed and precision of the Viper robots also make

them ideal for material handling, packaging, machine tending, and many other operations

requiring fast and precise automation.

EtherCAT communications allow the robots to operate together with EtherCATnodes, other

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

tionality and ease of operation.

NA-series

Teaching pendant

T20

(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. System Topology

These robots are offered with two different arm reaches to provide different working envelopes.

The Viper 650 has a 650 mm radial reach and the Viper 850 has an 850 mm radial reach,

measured from Joint 1 to Joint 5. Refer to Robot Physical Dimension Drawings on page 107

NOTE: The descriptions and instructions in this manual apply to all Viper 650

and 850 Robot with EtherCAT. If there are differences based on type or options,

this manual will provide details in the associated sections.

Robot Amplifier and Controller

The robot's amplifier and controller are contained in the External Control System, or eCS-

ECAT.

Chapter 1: Introduction

The eCS-ECAT is a distributed servo controller and amplifier. It is designed with a dedicated

digital signal processor to communicate, coordinate, and execute servo commands. The eV+

operating system runs on both the eCS-ECAT and the NJ-series Robot Integrated CPU Unit.

The eCS-ECAT contains power amplifiers, safety circuitry, and I/O as well as full trajectory, kin-

ematic, and servo robot control hardware. The robot motors are powered by the eCS-ECAT

amplifiers.

This robot is intended to operate within an EtherCAT network. It receives commands and con-

trol signals from the NJ-series Robot Integrated CPU Unit over an EtherCAT network.

Figure 1-2. Viper 650 Robot

External Control System (eCS-ECAT)

This section is about the eCS-ECAT, which is a distributed servo controller and amplifier used

with Viper robots. The eCS-ECAT has a dedicated microprocessor to communicate, coordinate,

and execute servo commands. The eCS-ECAT unit receives eV+ commands from the NJ-series

Robot Integrated CPU Unit and processes these commands to execute robots motions and other

functions.

The eCS-ECAT contains the interface panel, which provides connections for power supply, peri-

pheral devices such as the front panel, pendant, and user-supplied safety equipment, and

EtherCATnetwork cables. The interface panel also has switches for setting an explicit

EtherCATNode address and operating mode as well as LEDs to indicate operating status.

Additional Information: Refer to eCS-ECAT Interface Panel on page 16 for more

information.

21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 9

10 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

Figure 1-3. eCS-ECAT

eCS-ECAT Features

The eCS-ECAT unit has the following general features.

lEtherCAT communications, for distributed control by an NJ-series Robot Integrated CPU

Unit.

lIntegrated digital I/O.

lDual 1 GHz Cortex A9 ARM Processors, 1 GB SDRAM.

l8 GB MicroSD card.

lLow EMI for use with noise sensitive equipment.

l8 kHz servo rate to deliver low positional errors and high-performance path following.

lDigital feed-forward control to maximize efficiency, torque, and positioning.

lInternal temperature sensors for hardware protection and troubleshooting.

lPower controller that uses single-phase AC power, 200-240 Volts.

l2-digit alpha-numeric status panel to show operating status and fault codes.

lExpansion Input/Output (EXPIO) port

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