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Maintenance

This section provides information for maintaining the robot.

6-1 Periodic Maintenance .................................................................................... 6-2

6-1-1

Periodic Maintenance Overview...................................................................... 6-2

6-1-2

Checking Safety Functions.............................................................................. 6-2

6-1-3

Checking Fastener Torques ............................................................................ 6-3

6-1-4

Checking Safety and Warning Labels ............................................................. 6-4

6-1-5

Checking for Oil Leaks .................................................................................... 6-4

6-1-6

Lubricating Joint 3 ........................................................................................... 6-5

6-1-7

Replacing Encoder Backup Batteries.............................................................. 6-6

6-1-8

Cleaning the Robot.......................................................................................... 6-7

6-1-9

Bellows Inspection........................................................................................... 6-8

6-2 Non-periodic Maintenance ............................................................................ 6-9

6-2-1

Replacing the Tool Flange............................................................................... 6-9

6-1

i4L Robots with EtherCAT User's Manual (I659)

Summary of Contents for i4-350L

Page 1: ...i4L Robots with EtherCAT User s Manual i4 350L i4 450L i4 550L I659 E 01...

Page 2: ...prove 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 assume...

Page 3: ...knowledge of factory automa tion 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...

Page 4: ...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 Produ...

Page 5: ...se 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 un...

Page 6: ...Manual Information 4 i4L Robots with EtherCAT User s Manual I659...

Page 7: ...ons in this Manual Sections in this Manual 5 i4L Robots with EtherCAT User s Manual I659 Maintenance Operation Troubleshooting Installation Specifications Overview 1 2 3 4 5 6 1 2 3 4 6 5 1 A A Append...

Page 8: ...rect Use 21 Regulations and Standards 23 Conformance to EU Directives 23 Conformance to KC Certification 23 Software Licenses and Copyrights 24 Related Manuals 25 Glossary 26 Section 1 Overview 1 1 In...

Page 9: ...Supply Specifications 2 13 2 3 2 XIO and TIO Connector I O Specifications 2 13 2 3 3 Belt Encoder Specifications 2 14 2 4 Environmental Specifications 2 15 2 5 Other Specifications 2 16 2 5 1 EtherCA...

Page 10: ...7 3 11 4 Switch Position Checks 3 49 Section 4 Operation 4 1 Configuration Procedure Overview 4 2 4 2 Payload and Acceleration Considerations 4 4 4 3 Robot Control Modes 4 5 4 3 1 Manual Mode 4 5 4 3...

Page 11: ...Replacing the Tool Flange 6 9 Appendices A 1 Unpacking and Inspecting the Robot A 2 A 1 1 Before Unpacking the Robot A 2 A 1 2 Unpacking the Robot A 2 A 2 Repacking the Robot for Transport A 4 A 3 Tra...

Page 12: ...t provided that in no event shall Omron be re sponsible for warranty repair indemnity or any other claims or expenses regarding the Products unless Omron s analysis confirms that the Products were pro...

Page 13: ...nies 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 operatin...

Page 14: ...y Omron Companies has been checked and is believed to be accurate how ever no responsibility is assumed for clerical typographical or proofreading errors or omissions Terms and Conditions Agreement 12...

Page 15: ...e Symbols The circle and slash symbol indicates operations that you must not do The specific opera tion is shown in the circle and explained in text This example indicates prohibiting disassembly The...

Page 16: ...botic 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 main...

Page 17: ...ailure 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 b...

Page 18: ...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 contam...

Page 19: ...in hazardous environments explosive gas and oil mist The robot shall be operated within its specified temperature range to ensure proper oper ation The robot s physical hardstop devices are not intend...

Page 20: ...stand ards and regulations in the country of use The integrators of the robot should under stand the safety laws and regulations in their countries and prevent major hazards from occurring in the com...

Page 21: ...ke 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 The High Power indicator must be operationa...

Page 22: ...ent noise at the end use application You can burn yourself Do not touch the robot after it has been running at high ambient tempera tures or at fast cycle times over 60 cycles per minute The robot sur...

Page 23: ...duce 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 ac cessed with the XFP system cable connector Attempting to rele...

Page 24: ...the z axis retracted position and 27 mm 180 mm quill length 53 mm 350 mm quill length in the z axis extended position Always adjust joint mo tion limits with software settings in the robot configurat...

Page 25: ...Robots for industrial environments Safety requirements Part 1 Robot EN 60204 1 Safety of Machinery Electrical equipment of machines Part 1 General Requirements EN 61000 6 4 EMC Part 6 4 Emissions Sta...

Page 26: ...oduct incorporates certain third party software The license and copyright information associat ed with this software is available at http www fa omron co jp nj_info_e Regulations and Standards 24 i4L...

Page 27: ...W595 Describes the operating procedures of the Sysmac Studio for Robot Integrated CPU Unit Sysmac Studio Version 1 Operation Manual Cat No W504 Describes the operating procedures of the Sysmac Studio...

Page 28: ...pply that energizes all internal servo motors to allow robot mo tion Joint Mechanical robot component that connects its moving parts LED Indicator Multi colored light on top of the outer link that pro...

Page 29: ...i4 350L 1 13 1 4 2 i4 450L 1 13 1 4 3 i4 550L 1 13 1 4 4 i4 550L 350 mm Z 1 14 1 4 5 Mounting and Cabling Options 1 14 1 5 Model Numbers 1 15 1 5 1 Robot Model Numbers 1 15 1 5 2 Controller Model Numb...

Page 30: ...o perform automated motion control typically used with material handling opera tions The i4L robot is capable of high speed high precision motion for payloads up to 5 kg Its compact de sign and flexib...

Page 31: ...y Interface Panel provides a central location for all cable connections and a Secondary Interface Panel on the outer link provides connections for end of arm tooling and other hardware Built in optica...

Page 32: ...dio EtherNet IP Front Panel Safety devices Encoder digital I O 1 2 2 Basic Robot Components The robot consists of the following components that are referred to throughout this manual Use the informati...

Page 33: ...anels and their functions Primary Interface Panel Secondary Interface Panel Primary Interface Panel The Primary Interface Panel is located on the base of the robot and provides access to the follow in...

Page 34: ...el 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 th...

Page 35: ...he XFP connector on the XSYSTEM cable Refer to 3 8 1 Installing the Front Panel on page 3 34 for more information Design of the factory supplied Front Panel E Stop is in accordance with the requiremen...

Page 36: ...er face Panel are one to one For example pins 1 through pins 15 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 ondar...

Page 37: ...ore High Power can be enabled Additional Information Refer to the following sections for more information 2 3 1 Power Supply Specifications on page 2 13 3 10 3 48 VDC Connections on page 3 45 XSYSTEM...

Page 38: ...or more information 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 throug...

Page 39: ...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...

Page 40: ...neral electrical power supply information is displayed 5 MAC Address Reserved for future use 6 Production information The following information is provided SN indicates the serial number Lot No indica...

Page 41: ...as a reach of 350 mm and a z axis stroke of 180 mm 180 mm 350 mm 1 4 2 i4 450L The i4 450L configuration has a reach of 450 mm and a z axis stroke of 180 mm 180 mm 450 mm 1 4 3 i4 550L The i4 550L con...

Page 42: ...flange and a wall mount flange integrated into the base This allows the robot to be table mounted or wall mounted without the need for additional brackets or adapters The rear bottom Primary Interface...

Page 43: ...002 350 mm 180 mm Rear RS4 2064002 450 mm RS4 2065002 550 mm RS4 2065004 550 mm 350 mm RS4 2063102 350 mm 180 mm Bottom RS4 2064102 450 mm RS4 2065102 550 mm RS4 2065104 550 mm 350 mm 1 5 2 Controller...

Page 44: ...638 000 1 6 2 T20 Pendant The T20 pendant is an optional handheld device that allows you to manually jog the robot teach loca tions and view V programs without a PC The part number for the pendant kit...

Page 45: ...d on the data that you set up in the Sysmac Studio It is executed on the IPC Application Controller Additional Information Refer to the following areas for more information Sysmac Studio Robot Integra...

Page 46: ...number for the XIO Termination Block is 90356 40100 2 m cable included Additional Information Refer to the following areas for more information XIO Cable on page 1 20 Adept XIO Termination Block Inst...

Page 47: ...Information Refer to A 5 2 XBELTIO Adapter Cable Pinouts on page A 10 for more information Belt Encoder Y adapter Cable The optional belt encoder Y adapter cable connects to the XBELTIO adapter cable...

Page 48: ...2 m Additional Information Refer to the following areas for more information 1 6 4 XIO Termination Block on page 1 17 EXPIO to IO Blox Cable The optional EXPIO to IO Blox cable connects to the XBELTI...

Page 49: ...ill 0 25 inch holes in the locations shown below and then insert the cable tie mounts Refer to 3 4 4 Pneumatic Valve Kit Installation Procedure on page 3 15 for more information about outer link cover...

Page 50: ...th software settings in the robot configuration area when bellows are installed to restrict range of motion Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated C...

Page 51: ...Control Power Kit The Control Power Kit provides 24 VDC power to the robot This kit consists of a power supply and the required DC connector and cable The connector is pre installed on the cable The C...

Page 52: ...913 000 The power supply part number is S8VK G48048 The redundancy unit part number is S8VK R20 The length of the cable from the power supply to the robot is 5 m Additional Information Refer to the fo...

Page 53: ...48 VDC Power Supplies Redundancy Unit 1 Overview 1 25 i4L Robots with EtherCAT User s Manual I659 1 6 Optional Hardware 1 1 6 9 Power Supply Kits...

Page 54: ...1 Overview 1 26 i4L Robots with EtherCAT User s Manual I659...

Page 55: ...1 6 Robot Work Envelope Dimensions 2 6 2 1 7 Robot Weights 2 8 2 2 Performance Specifications 2 9 2 2 1 General Performance Information 2 9 2 2 2 Stopping Distances and Times 2 9 2 3 Electrical Speci...

Page 56: ...l Dimensions Use the diagrams below to understand the robot s overall physical dimensions i4 350L Dimensions Overall dimensions for the i4 350L are provided below 30 mm 160 mm 350 mm 61 mm 590 mm 656...

Page 57: ...80 mm 242 5 mm 62 5 mm 180 mm 240 mm i4 550L Dimensions Overall dimensions for the i4 550L are provided below 160 mm 550 mm 61 mm 600 mm 642 mm 62 5 mm 360 180 mm 242 5 mm 180 mm 240 mm 2 Specificatio...

Page 58: ...y to all robot models 2 1 2 Mounting Flange Dimensions The robot s mounting flange dimensions are provided below 4X 9 5 mm THRU 215 mm 180 mm 6mm 6 mm 85 mm 0 31 5 mm 28 5 mm 6 mm 0 020 mm 0 6 mm SLOT...

Page 59: ...6 2004 requirements for manipulating industrial robots b 0 02 B 1 mm x 45 31 5 mm 0 025 0 H7 63 mm 0 0 046 H8 r n 0 02 A B 6 mm 0 015 0 THRU j n 0 040 A B 4 X 5 5 mm THRU M6 x 1 0 6H THRU j n 0 2 A B...

Page 60: ...mm 31 5 mm 6 0 mm 36 5 mm 3 2 mm 34 0 mm 16 0 mm 20 0 mm 5 2 mm 2 1 6 Robot Work Envelope Dimensions Use the diagrams below to understand the robot s working envelope dimensions i4 350L Work Envelope...

Page 61: ...Work Envelope Work envelope dimensions are provided below 20 mm 191 mm R 275 mm R 550 mm R 150 mm 136 148 245 mm 79 mm R 275 mm 180 mm 242 5 mm i4 550L 350 mm Z Work Envelope Work envelope dimensions...

Page 62: ...eights for the different robot models are provided in the following table Additional Information Weights provided do not include optional accessories Robot Model Weight i4 350L 15 1 kg i4 450L 15 9 kg...

Page 63: ...ined 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 wor...

Page 64: ...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 5 kg Data provided is for the three...

Page 65: ...0 20 40 60 80 100 120 Joint 2 Stopping Distance all payloads Speed Stopping Distance degrees 0 0 1 0 2 0 3 0 20 40 60 80 100 120 Joint 3 Stopping Time all payloads Stopping Time s Speed 2 Specificatio...

Page 66: ...0 20 40 60 80 100 120 140 0 20 40 60 80 100 120 Joint 3 Stopping Distance all payloads Speed Stopping Distance mm 2 Specifications 2 12 i4L Robots with EtherCAT User s Manual I659...

Page 67: ...Current power requirements 5 A 120 W maximum Circuit protection User supplied 5 A in line fuse Wire size 0 75 mm2 to 2 5 mm2 Shielding User supplied connection from power supply cable shield to robot...

Page 68: ...tempera ture Total current output for all TIO cir cuits 1 0 A maximum at 50 C ambient tempera ture 1 5 A maximum at 25 C ambient tempera ture ON state resistance at 0 5A 0 14 maximum at 85 C Output le...

Page 69: ...relatively free of contaminants Item Specification Ambient operating temperature 1 5 to 40 C Storage temperature 25 to 55 C Humidity 5 to 90 non condensing Altitude 2000 m maximum Pollution degree 2...

Page 70: ...le 2 5 2 Connector and Port Specifications Robot connector specifications are provided below Additional Information Refer to Section 3 Installation on page 3 1 for more information about connector wir...

Page 71: ...Screw 4 M8 x 1 25 mm DIN 912 or ISO 4782 10 9 or 12 9 30 32 N m Flat Washer 4 M8 DIN 125 or ISO 7089 8 8 WARNING The robot s center of mass can cause the robot to fall over if the robot is not properl...

Page 72: ...2 Specifications 2 18 i4L Robots with EtherCAT User s Manual I659...

Page 73: ...ps 3 20 3 5 1 Joint 1 Adjustable Hardstops 3 21 3 5 2 Joint 2 Adjustable Hardstops 3 21 3 5 3 Joint 3 Adjustable Hardstop 3 21 3 6 System Cable Installation 3 23 3 6 1 System Cable Overview 3 23 3 6 2...

Page 74: ...3 11 1 Mechanical Checks 3 47 3 11 2 System Cable Checks 3 47 3 11 3 Safety Equipment Checks 3 47 3 11 4 Switch Position Checks 3 49 3 Installation 3 2 i4L Robots with EtherCAT User s Manual I659...

Page 75: ...l any equipment such as cameras solenoid valves a Front Panel or bellows Refer to 3 4 Installing Optional Equipment on page 3 8 for more information 4 Connect any necessary pneumatic air lines using t...

Page 76: ...Refer to 3 11 Verifying Installation on page 3 47 for more information 3 Installation 3 4 i4L Robots with EtherCAT User s Manual I659...

Page 77: ...o use a properly secured 18 mm minimum thick steel plate with a maxi mum surface roughness of 25 m as a robot mounting surface Keep a minimum of 300 mm clearance from the Primary Interface Panel to al...

Page 78: ...r supplied machine bolts specified above A slot and hole are provided in the mounting flange for dowel pins 2 Maneuver the robot into position on the mounting surface 3 Align the holes in the mounting...

Page 79: ...res pneumatic or electrical connections use the pass through connec tions from the Primary Interface Panel to the Secondary Interface Panel Refer to 1 2 4 Connectors and Ports on page 1 8 for more inf...

Page 80: ...s can interfere with internal components Precautions for Correct Use Any externally mounted equipment is considered robot payload Consideration to the payload attached to the Tool Flange should be mad...

Page 81: ...n page 1 21 for more information Torque wrench 2 5 mm 3 mm 4 mm hex bits T8 torx bit Make the following considerations before installing the bellows If cables or tubing are routed through the center o...

Page 82: ...he quill and then wrap it around the exterior of the robot housing Orientation of the bellows must be correct Ensure the taller bellows collar is mated with the robot housing Take care to ensure the b...

Page 83: ...pter is completely seated on top of the quill 6 Apply thread lock to the upper bearing adapter clamp screw 51000 67016 insert and tighten using a 3 mm hex bit to a torque of 1 3 N m 7 Lift the bellows...

Page 84: ...ting cables or lines through the center of the quill is not required insert the plug 22921 000 into the upper bearing adapter to complete the installation of the upper bellows 11 Begin the lower bello...

Page 85: ...ows are completely seated and positioned between the clamp and the robot hous ing Tighten to a torque of 2 4 N m 14Slide the tool flange bearing adapter 1 up the quill and then move the tool flange in...

Page 86: ...ter on the tool flange Ensure the bearing adapter is completely mated to the tool flange 18Rotate the tool flange bearing adapter to ensure that the setscrews will make contact with a flush surface of...

Page 87: ...obot configuration area when bellows are installed to restrict range of motion Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operating Manual Cat...

Page 88: ...o remove and replace the upper bellows assembly The pneumatic valve kit includes the following main components TIO Connector Wire Harness Wire Harness Retainers Stand off Studs 4 Socket Head Cap Screw...

Page 89: ...que of 2 9 N m 6 Screw the stand off studs 22873 000 into the inner bracket Apply thread lock to the stand off studs and tighten using a 6 mm socket to a torque of 2 9 N m 7 Place the pneumatic valve...

Page 90: ...ng a slotted screwdriver 10Secure the wire harness to the robot by inserting two cable ties 27300 00024 through the wire harness retaining clips and then around the wire harness Trim excess cable tie...

Page 91: ...3 4 6 High Power Kit Connections Use the following diagram to connect the High Power Kit to the robot AC Supply Robot Main Disconnect Device 23910 000 23910 000 23910 000 1 1 2 2 1 2 2 1 1 2 3 1 Blac...

Page 92: ...ays reduce joint motion limits with software settings in the robot configuration area when hardstops are used to restrict range of motion Refer to the Sysmac Studio Robot Integrated System Building Fu...

Page 93: ...17 N m when tightening the hardstop screws 3 5 2 Joint 2 Adjustable Hardstops Use the following information when making joint 2 hardstop adjustments Four M8 X 10 socket head cap screws class 12 9 are...

Page 94: ...ead screw and slide the clamp to the appropriate location to limit the down stroke of the z axis quill When the clamp is in the desired location apply thread lock and tighten the socket head screw to...

Page 95: ...al Electrical Code and any local codes Ensure that interconnecting cables or pneumatic lines are routed away from the ro bot workspace 3 6 1 System Cable Overview Standard and optional cable connectio...

Page 96: ...FP Connector XMCP Connector Optional Connections The following figure shows optional connections to the robot Additional Information Refer to 3 7 Connecting Digital I O on page 3 26 for more informati...

Page 97: ...XIO and TIO connectors Refer to 3 7 Connecting Digital I O on page 3 26 for more information 3 Connect external equipment such as the Front Panel and Teach Pendant to the XSYSTEM ca ble XFP and XMCP c...

Page 98: ...on page A 6 Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operating Manual Cat No W595 Additional Information Refer to the following sections for more informat...

Page 99: ...l Circuits Input 1 1 Input 1 2 Input 1 3 Input 1 4 Input 1 5 Input 1 6 Common 1 Common 2 Input 2 1 Input 2 2 Input 2 3 Input 2 4 Input 2 5 Input 2 6 XIO Output Signals The eight outputs share a common...

Page 100: ...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...

Page 101: ...k 21 Output 3 Light blue 22 Output 4 Light blue Black 23 Output 5 Light green 24 Output 6 Light green Black 25 Output 7 White Red 26 Output 8 White Blue Shell Shield XIO Termination Block An XIO termi...

Page 102: ...al number assignments Additional Information Refer to the following areas for more information 2 3 2 XIO and TIO Connector I O Specifications on page 2 13 2 5 2 Connector and Port Specifications on pa...

Page 103: ...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 cur rent This driver ha...

Page 104: ...3 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 V signal number assignments vary bas...

Page 105: ...XBELTIO Adapter Cable EXPIO to IO Blox Cable 3 Installation 3 33 i4L Robots with EtherCAT User s Manual I659 3 7 Connecting Digital I O 3 3 7 3 IO Blox Connections...

Page 106: ...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 c...

Page 107: ...SO 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 inpu...

Page 108: ...Safety Gate 48 VDC High Power Input External Internal High Power Emergency Stop Status Outputs Automatic Mode Status Outputs Automatic Manual Mode Selection High Power Indicator Button XUSR Connection...

Page 109: ...l 1 Internal contacts are closed when the robot is in automat ic mode 10 23 Automatic mode status channel 2 11 12 13 24 25 Reserved for future use XUSR Jumper Plug The XUSR jumper plug is provided for...

Page 110: ...ed to a momentary push but ton that enables High Power when all safety circuits are satisfied 7 15 System supplied 5 VDC output pin 7 and com mon pin 15 for Control Power indicator If indicator is use...

Page 111: ...ubleshooting 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...

Page 112: ...al 8 Serial communications RXD Pendant serial communications receive signal 13 Serial communications GND Pendant serial communications ground signal Shield Ground shield 5 14 15 Reserved for future us...

Page 113: ...per plug is supplied with the Teach Pendant kit The part number for the Teach Pendant jumper plug is 10048 000 3 Installation 3 41 i4L Robots with EtherCAT User s Manual I659 3 8 Installing Safety Equ...

Page 114: ...set to a non zero value the switch positions will dictate the EtherCAT node ID and software adjustment of this value is not possible Switches should be in the following positions when using Sysmac Stu...

Page 115: ...y or cycle Control Power to implement the new node ID setting 7 Confirm the correct EtherCAT node ID of 196 with Sysmac Studio 3 Installation 3 43 i4L Robots with EtherCAT User s Manual I659 3 9 Setti...

Page 116: ...Supply Specifications on page 2 13 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 voltag...

Page 117: ...h the robot and require assembly with user supplied wires The connector part number is 02708 000 The pin part number is 02709 000 24 VDC 0 VDC Refer to 3 4 5 Control Power Kit Connections on page 3 19...

Page 118: ...nd require assembly with user supplied wires The connector part number is 22009 000L The pin part number is 02709 000 48 VDC 0 VDC GND Refer to 3 4 6 High Power Kit Connections on page 3 19 for more i...

Page 119: ...rly 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...

Page 120: ...ed in 4 4 1 Robot High Power Operations on page 4 8 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 p...

Page 121: ...ce Panel to make sure they are set correct ly The following settings are required for normal operation Mode switches Dip switch 1 B Dip switch 2 OP EtherCAT node ID switches Dip switch and rotary swit...

Page 122: ...3 Installation 3 50 i4L Robots with EtherCAT User s Manual I659...

Page 123: ...6 4 3 4 Host Mode 4 7 4 4 Enabling and Disabling the Robot 4 8 4 4 1 Robot High Power Operations 4 8 4 5 LED Indicator 4 10 4 6 Brake Operation 4 11 4 6 1 Built in Brake Release Button 4 11 4 6 2 Remo...

Page 124: ...h the sequence control program and the V program Refer to NJ series Robot Integrated CPU Unit User s Manual Cat No O037 for more infor mation 7 Perform teaching in the simulation operation Refer to th...

Page 125: ...for the error periodic inspections and maintenance Refer to the following manuals for more information NJ series Robot Integrated CPU Unit User s Manual Cat No O037 NJ NX series Troubleshooting Manual...

Page 126: ...ng linear moves Some linear moves are not achievable over all paths in the working envelope Precautions for Correct Use Operating the robot outside of the payload and speed constraints described in th...

Page 127: ...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 e...

Page 128: ...uld be used when the robot is operating under normal conditions and is being controlled by the with EtherCAT communications Additional Information The position of the operation mode dip switch is chec...

Page 129: ...on 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...

Page 130: ...s Robot High Power operations are described below 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...

Page 131: ...c Studio Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit Operating Manual Cat No W595 more information User Program High Power can be controlled wit...

Page 132: ...r LED Indication Robot State OFF Control Power is not present Solid White The robot is initializing Solid Blue The robot is booting Slow Flashing Blue 0 25 Hz The robot is in an idle state with no err...

Page 133: ...alled equipment is clear of all ob structions 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 posi...

Page 134: ...setting does not affect the normal functionality of the brake release button Additional Information Refer to the Sysmac Studio Robot Integrated System Building Function with Robot Integrated CPU Unit...

Page 135: ...y 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 Int...

Page 136: ...quill is retracted in the up position The 6 mm through hole on the tool flange is at the position shown below 6 THRU 4 8 2 Ready Position Use the READY keyword to place the robot in the ready positio...

Page 137: ...cations Moves to precision points are not affected by arm configurations because these points are unique joint positions Refer to the V Keyword Reference Manual Cat No I672 for more information Left A...

Page 138: ...4 Operation 4 16 i4L Robots with EtherCAT User s Manual I659...

Page 139: ...ubleshooting This section provides robot troubleshooting information 5 1 Fault Detection 5 2 5 2 Emergency Stop Troubleshooting 5 3 5 3 Error Messages 5 4 5 1 i4L Robots with EtherCAT User s Manual I6...

Page 140: ...put signal when a fault is present Refer to the V User s Manual Cat No I671 for more information Use the LED indicator to visually see when a fault is present Refer to 4 5 LED Indicator on page 4 10 f...

Page 141: ...ass and isolate safety devices Refer to 3 6 1 System Cable Overview on page 3 23 for jumper installation locations XFP jumper plug part number 10052 000 XUSR jumper plug part number 04736 000 XMCP jum...

Page 142: ...mmissioned and verified Commission and verify the E Stop Delay or Teach Restrict 651 RSC communications failure There is a failure to communicate with the Robot Signature Card Contact your local OMRON...

Page 143: ...are safety system de tected an encoder OVERSPEED and turned power off This circuit is active in Manual mode only on select robots which have the CAT 3 teach mode option Intentionally triggered during...

Page 144: ...commanded position with sufficient accuracy as set by the configuration Turn on high power and try to per form the motion at a slower speed Make sure that noth ing is obstructing the robot s mo tion I...

Page 145: ...ns 6 2 6 1 3 Checking Fastener Torques 6 3 6 1 4 Checking Safety and Warning Labels 6 4 6 1 5 Checking for Oil Leaks 6 4 6 1 6 Lubricating Joint 3 6 5 6 1 7 Replacing Encoder Backup Batteries 6 6 6 1...

Page 146: ...tion Check safety labels 1 week Refer to 6 1 4 Checking Safety and Warning Labels on page 6 4 for more information Check the High Power indicator op eration 1 week Refer to High Power Indicator Check...

Page 147: ...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 Studi...

Page 148: ...ore servicing WARNING Install in a controlled environment relatively free of contaminants CAUTION The robot can be lifted by hand Only use the base and inner link when lifting the robot Never lift the...

Page 149: ...ons for Safe Use The braking mechanism operates passively If 24 VDC Control Power is removed from the sys tem the brake mechanism will automatically activate 24 VDC Control Power must be supplied to r...

Page 150: ...e brake release button or by jogging the z axis After this step is finished the joint 3 lu brication procedure is complete 6 1 7 Replacing Encoder Backup Batteries Backup batteries maintain joint posi...

Page 151: ...er Encoder Battery Compartment Cover Fastener Screw 2 Remove and replace the batteries while observing orientation for correct polarity indicated in the battery compartment upwards is positive If 24 V...

Page 152: ...bellows each week for cracks wear or damage and replace if necessary Refer to the 3 4 3 Bellows Kit Installation Procedure on page 3 9 for replacement and installation steps 6 Maintenance 6 8 i4L Robo...

Page 153: ...e 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 d...

Page 154: ...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 Th...

Page 155: ...4 A 3 Transportation and Storage Considerations A 5 A 4 I O Signal Numbering A 6 A 4 1 Input Signal Numbering A 6 A 4 2 Output Signal Numbering A 7 A 5 Cable Pinouts A 9 A 5 1 XSYSTEM Cable Pinouts A...

Page 156: ...ional Information Retain all containers and packaging materials These items may be necessary if there is any apparent damage or relocation becomes necessary at a later date Prepare the mounting surfac...

Page 157: ...ured with the mounting bolts Do not reuse the screws to mount the robot They are not sufficient grade 7 Lift the robot and relocate it to the mounting surface 8 Fasten the robot to the mounting surfac...

Page 158: ...euse 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...

Page 159: ...ended humidity range is 5 to 90 non condensing It should be shipped and stored in the supplied packaging which is designed to prevent dam age from normal shock and vibration Do not expose the shipping...

Page 160: ...1173 to 1180 IO Blox 3 OFF ON 1181 to 1188 IO Blox 4 ON ON 1189 to 1196 3 XIO 1201 to 1212 TIO 1217 to 1221 IO Blox 1 OFF OFF 1265 to 1272 IO Blox 2 ON OFF 1273 to 1280 IO Blox 3 OFF ON 1281 to 1288...

Page 161: ...V Signal Numbers 1 XIO 1 to 8 TIO 17 to 20 IO Blox 1 OFF OFF 65 to 72 IO Blox 2 ON OFF 73 to 80 IO Blox 3 OFF ON 81 to 88 IO Blox 4 ON ON 89 to 96 2 XIO 101 to 108 TIO 117 to 120 IO Blox 1 OFF OFF 165...

Page 162: ...F 565 to 572 IO Blox 2 ON OFF 573 to 580 IO Blox 3 OFF ON 581 to 588 IO Blox 4 ON ON 589 to 596 7 XIO 601 to 608 TIO 617 to 620 IO Blox 1 OFF OFF 665 to 672 IO Blox 2 ON OFF 673 to 680 IO Blox 3 OFF O...

Page 163: ...A 5 1 XSYSTEM Cable Pinouts Use the following diagrams for XSYSTEM cable pinout information XUSR 13322 000 XFP 13322 000 XMCP 13322 000 XSYSTEM 13322 000 Appendices A 9 i4L Robots with EtherCAT User s...

Page 164: ...PIN 23 PIN 13 PIN 8 PIN 11 PIN 38 PIN 12 PIN 7 PIN 7 PIN 6 PIN 8 PIN 20 PIN 1 PIN 2 SHELL SHELL PIN 10 PIN 9 PIN 31 PIN 1 PIN 6 PIN 32 PIN 2 PIN 3 PIN 5 PIN 18 PIN 7 PIN 34 PIN 14 PIN 4 PIN 11 PIN 19...

Page 165: ...IN 1 PIN 3 PIN 2 PIN 7 CLK PIN 8 CLK PIN 9 EXPIO 5V PIN 15 GND PIN 16 DATA PIN 17 DATA PIN 1 PIN 5 PIN 6 PIN 1 PIN 10 PIN 19 PIN 9 PIN 18 PIN 26 PIN 9 SHIELD SHIELD FORCE EXPIO PIN 6 5V PIN 3 PIN 2 PI...

Page 166: ..._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 PIN 1 PIN 3 PIN 4 PIN 5 PIN 6 PIN 8 PIN 2 PIN 7 PIN 1 PIN 8 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 1 PIN 8 PIN...

Page 167: ...n sion Cable be tween units 04679 030 Extends the connection be tween IO Blox units up to 3 m X Encoder Exten sion Cable 09446 050 Replaces or ex tends encoder cable up to 5 m X Belt Encoder Y adapter...

Page 168: ...robot X IO Blox Kit IO Blox connection 90356 30100 Includes 200 mm cable to connect to an other IO Blox unit X Joint 3 Quill Grease 20950 000 THK AFF type X Encoder Kit 09742 001 Includes encod er mo...

Page 169: ...I Index I 1 i4L Robots with EtherCAT User s Manual I659 I...

Page 170: ...ll 2 2 i4 350L Work Envelope 2 6 i4 450L Overall 2 3 i4 450L Work Envelope 2 7 i4 550L 350 mm Z Overall 2 4 i4 550L 350 mm Z Work Envelope 2 7 i4 550L Overall 2 3 i4 550L Work Envelope 2 7 Mounting Fl...

Page 171: ...n Degree 2 15 Power Supply 1 23 2 13 Primary Interface Panel 1 5 Primary Interface_Panel 1 5 Protection Class 2 15 R Ready Position 4 14 Repeatability 2 9 Right Arm 4 15 Robot Label 1 11 S Safety Circ...

Page 172: ...Index I 4 i4L Robots with EtherCAT User s Manual I659...

Page 173: ......

Page 174: ...egional Headquarters OMRON EUROPE B V Wegalaan 67 69 2132 JD Hoofddorp The Netherlands Tel 31 2356 81 300 Fax 31 2356 81 388 Contact www ia omron com Kyoto JAPAN OMRON ASIA PACIFIC PTE LTD No 438A Ale...

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