Omron i4H User Manual
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Omron i4H User Manual

Robots with ethercat
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i4H
Robots with EtherCAT
User's Manual
i4-650H
i4-750H
i4-850H
I661-E-01

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Summary of Contents for Omron i4H

  • Page 1 Robots with EtherCAT User's Manual i4-650H i4-750H i4-850H I661-E-01...
  • Page 2 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 publica- tion.

  • Page 3: Intended Audience

    • 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 Models...
  • Page 4 Introduction i4H Robots with EtherCAT User's Manual (I661)

  • Page 5: Sections In This Manual

    Sections in this Manual Sections in this Manual Overview Specifications Installation Operation Troubleshooting Maintenance Appendices i4H Robots with EtherCAT User's Manual (I661)

  • Page 6: Table Of Contents

    Information Labels....................... 1-11 1-3-1 Robot Label ..........................1-11 1-3-2 Controller Label ......................... 1-11 Robot Configurations ......................1-13 1-4-1 i4-650H............................1-13 1-4-2 i4-750H............................1-13 1-4-3 i4-850H............................1-13 Model Numbers ........................1-14 1-5-1 Robot Model Numbers ......................1-14 1-5-2 Controller Model Numbers ......................1-14 i4H Robots with EtherCAT User's Manual (I661)
  • Page 7 System Cable Overview ......................3-10 3-6-2 System Cable Installation Procedure ..................3-12 Connecting Digital I/O ......................3-13 3-7-1 XIO Connector Signals and Wiring ...................3-13 3-7-2 IO Blox Connections .........................3-17 Installing Safety Equipment....................3-19 3-8-1 Installing the Front Panel ......................3-19 i4H Robots with EtherCAT User's Manual (I661)
  • Page 8 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 i4H Robots with EtherCAT User's Manual (I661)
  • Page 9 Input Signal Numbering......................A-4 A-3-2 Output Signal Numbering ......................A-5 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 Index i4H Robots with EtherCAT User's Manual (I661)

  • Page 10: Manual Information

    Level 2 heading Manual name Level 3 heading Page tab with the number of the main section Step in a procedure Page number Special Information Special information in this manual is classified as follows: i4H Robots with EtherCAT User's Manual (I661)
  • Page 11 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)

  • Page 12: Terms And Conditions Agreement

    Omron’s exclusive warranty is that the Products will be free from defects in materials and workman- ship 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.

  • Page 13: Application Considerations

    • 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 sys- tem (e.g. Windows, Linux), or any consequence thereof.
  • Page 14 Terms and Conditions Agreement Errors and Omissions Information presented by 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 15: Safety Precautions

    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.

  • Page 16: Dangers

    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 re- sponsibilities in regard to the robot.

  • Page 17: Warnings

    Ensure compliance with all local and national safety and electrical codes for the installa- tion and operation of the robot system. i4H Robots with EtherCAT User's Manual (I661)
  • Page 18 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. i4H Robots with EtherCAT User's Manual (I661)
  • Page 19 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 per- formed only by the skilled or instructed persons. i4H Robots with EtherCAT User's Manual (I661)

  • Page 20: Cautions

    The integrators of the robot should under- stand the safety laws and regulations in their countries and prevent major hazards from occurring in the complete system. i4H Robots with EtherCAT User's Manual (I661)

  • Page 21: Precautions For Safe Use

    For information about disposal of your old equipment, contact your local Omron representative. • 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.
  • Page 22 • 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 re- moved for safety purposes. i4H Robots with EtherCAT User's Manual (I661)

  • Page 23: Precautions For Correct Use

    • 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 pro- vided Safety Data Sheet for proper handling.
  • Page 24 • 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 25: Regulations And Standards

    Regulations and Standards Regulations and Standards The OMRON i4H robot series are compliant to the following standard: Regulations and Standards Regulation/Standard Description 2006/42/EC Machinery Directive. 2014/30/EU EMC Directive. EN ISO 12100 Safety of Machines - General Principles for Design - Risk Assessment and Reduction.

  • Page 26: Related Manuals

    T20 Pendant User's Manual (Cat. No. I601) Describes the setup, operation, and user maintenance for the Teaching Pendant T20. Robot Safety Guide (Cat. No. I590) Describes how to use the OMRON robot safely. i4H Robots with EtherCAT User's Manual (I661)

  • Page 27: Terminology And Abbreviations

    Work Envelope Working area that is accessible by the robot considering any end-of-arm tooling and part shapes that are attached. Workspace Total area that the robot occupies considering all capable range of motion. i4H Robots with EtherCAT User's Manual (I661)
  • Page 28 Terminology and Abbreviations i4H Robots with EtherCAT User's Manual (I661)

  • Page 29: Overview

    XIO Termination Block................... 1-16 1-6-5 Optional Cables..................... 1-17 1-6-6 Wall Mount Bracket ..................1-19 1-6-7 eCobra Mount Adapter .................. 1-19 1-6-8 Camera Mounting Bracket and Adapter ............1-20 1-6-9 eCobra Tool Flange ..................1-20 i4H Robots with EtherCAT User's Manual (I661)

  • Page 30: Intended Use

    It is designed to perform automated motion control typically used with material handling opera- tions. 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.

  • Page 31: Robot Features

    1 Overview 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.

  • Page 32: Basic Robot Components

    Use the following diagrams to understand the robot's 4 axes of motion. Joint 2 Joint 1 Joint 3 (Z-axis) Joint 4 Interface Panels Use the information below to identify the robot's interface panels and their functions. i4H Robots with EtherCAT User's Manual (I661)
  • Page 33 Connector Node Switches EtherCAT Chassis XSYSTEM Ports Ground Connector  Secondary Interface Panel The Secondary Interface Panel is located on top of the outer link and provides access to the follow- ing items. i4H Robots with EtherCAT User's Manual (I661)

  • Page 34: Other Components

    • 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. i4H Robots with EtherCAT User's Manual (I661)
  • Page 35 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 36: Connectors

    The Control Power connector is used to supply 24 VDC to the robot logic circuits. When power is sup- plied to this connector, the robot will boot up and control functions such as programming and configu- ration are possible. A mating connector is supplied with the robot. i4H Robots with EtherCAT User's Manual (I661)
  • Page 37 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 i4H Robots with EtherCAT User's Manual (I661)
  • Page 38 This connector provides EtherCAT communications to user-supplied devices that can be mounted to the outer link or end-of-arm tooling. Additional Information Refer to 3-4-2 Tool EtherCAT Connector Wiring on page 3-6 for more information. 1-10 i4H Robots with EtherCAT User's Manual (I661)

  • Page 39: Information Labels

    Z for December. FF is reserved for internal use. • Product origin information is displayed. Refer to 1-5 Model Numbers on page 1-14 for model information. 1-3-2 Controller Label The controller label is described below. 1-11 i4H Robots with EtherCAT User's Manual (I661)
  • Page 40 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. Refer to 1-5 Model Numbers on page 1-14 for model information. 1-12 i4H Robots with EtherCAT User's Manual (I661)

  • Page 41: Robot Configurations

    1 Overview 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...

  • Page 42: Model Numbers

    410 mm RS4-2068702 210 mm Inverted RS4-2068704 410 mm 1-5-2 Controller Model Numbers The table below provides all robot controller model numbers and descriptions. Model Number Description iCS-ECAT Controller with EtherCAT communications support. 1-14 i4H Robots with EtherCAT User's Manual (I661)

  • Page 43: Optional Hardware

    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. 1-15 i4H Robots with EtherCAT User's Manual (I661)

  • Page 44: Ipc Application Controller

    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 pur- poses. 1-16 i4H Robots with EtherCAT User's Manual (I661)

  • Page 45: Optional Cables

    • 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. XIO Breakout XIO Cable Cable EXPIO to IO Blox Cable XBELTIO Adapter Cable Belt Encoder Y-adapter Cable 1-17 i4H Robots with EtherCAT User's Manual (I661)
  • Page 46 • 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. 1-18 i4H Robots with EtherCAT User's Manual (I661)

  • Page 47: Wall Mount Bracket

    • 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. 1-19 i4H Robots with EtherCAT User's Manual (I661)

  • Page 48: Camera Mounting Bracket And Adapter

    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.

  • Page 49: Specifications

    Power Supply Specifications ................. 2-14 2-3-2 XIO I/O Specifications ................... 2-14 Environmental Specifications ..............2-16 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)

  • Page 50: Physical Specifications

    Standard Dimensions Overall dimensions for the i4-650H Standard are provided below. ±152° ±140° ±360° 418.5 i4-650H Long Quill Dimensions Overall dimensions for the i4-650H Long Quill are provided below. ±152° ±140° 1080 ±360° 418.5 i4H Robots with EtherCAT User's Manual (I661)
  • Page 51 ±140° ±360° i4-750H Standard Dimensions Overall dimensions for the i4-750H Standard are provided below. 1056 ±152° ±140° ±360° 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)
  • Page 52 Inverted Long Quill Dimensions Overall dimensions for the i4-750H Inverted Long Quill are provided below. 1056 173.5 ±152° ±140° ±360° i4-850H Standard Dimensions Overall dimensions for the i4-850H Standard are provided below. i4H Robots with EtherCAT User's Manual (I661)
  • Page 53 418.5 i4-850H Inverted Dimensions Overall dimensions for the i4-850H Inverted are provided below. 1156 ±152° ±140° ±360° 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)

  • Page 54: Cable Clearances

    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 +0.02 Ø 8 332 375 +0.02 Ø 8 i4H Robots with EtherCAT User's Manual (I661)

  • Page 55: Tool Flange Dimensions

    4 X M6 X 1.0 THRU 45° +0.013 THRU 2-1-5 Front Panel Dimensions The Front Panel dimensions are provided below. Ø 4 2-1-6 eCobra Mount Adapter Dimensions The eCobra mount adapter dimensions are provided below. i4H Robots with EtherCAT User's Manual (I661)

  • Page 56: Wall Mount Bracket Dimensions

    -0.015 THRU 4X Ø 13.5 THRU ALL 9 STOCK 582.7 0.75 42° 0.75 442 ±2.0 12.0 STOCK 468 ±2.0 2-1-8 Camera Mounting Bracket and Adapter Dimensions The camera mounting bracket dimensions are provided below. i4H Robots with EtherCAT User's Manual (I661)

  • Page 57: Robot Weights

    Inverted Long Quill i4-750H Standard 50.9 kg i4-750H Inverted i4-750H Long Quill 51.3 kg i4-750H Inverted Long Quill i4-850H Standard 51.6 kg i4-850H Inverted i4-850H Long Quill 52.0 kg i4-850H Inverted Long Quill i4H Robots with EtherCAT User's Manual (I661)

  • Page 58: Performance Specifications

    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 de- vices. 2-10 i4H Robots with EtherCAT User's Manual (I661)
  • Page 59 (J1, J2, and J3). Joint 1 Stopping Time 5 kg 10 kg 15 kg Speed (%) Joint 1 Stopping Distance 5 kg 10 kg 15 kg Speed (%) 2-11 i4H Robots with EtherCAT User's Manual (I661)
  • Page 60 Joint 2 Stopping Time 5 kg 10 kg 15 kg Speed (%) Joint 2 Stopping Distance 5 kg 10 kg 15 kg Joint 3 Stopping Time 5 kg 10 kg 15 kg Speed (%) 2-12 i4H Robots with EtherCAT User's Manual (I661)
  • Page 61 2 Specifications Joint 3 Stopping Distance 5 kg 10 kg 15 kg 2-13 i4H Robots with EtherCAT User's Manual (I661)

  • Page 62: Electrical Specifications

    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)
  • Page 63 Short circuit current limit 0.7 to 2.5 A Output voltage at inductive load (+V - 52) ≤ V ≤ (+V - 41) where I demag (turn OFF) 0.5 A and load ≥ 1 mH 2-15 i4H Robots with EtherCAT User's Manual (I661)

  • Page 64: Environmental Specifications

    -25 to 55° C Humidity During operation: 5 to 90% (Non-condensing) During storage and transportation: 75% or less (non- condensing) Altitude 2000 m max Pollution degree Protection class IP20 / NEMA Type 1 2-16 i4H Robots with EtherCAT User's Manual (I661)

  • Page 65: Other Specifications

    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. 2-17 i4H Robots with EtherCAT User's Manual (I661)
  • Page 66 10.9 or 12.9 96 to 104 N-m M12 x 1.75 mm • Screw DIN 912 or ISO 4782 Hex Nuts (through hole mounting only) • Flat Washer –- • DIN 125 or ISO 7089 2-18 i4H Robots with EtherCAT User's Manual (I661)

  • Page 67: Installation

    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)

  • Page 68: Robot Installation Procedure

    Make power and ground connections. Refer to 3-10 Supplying Power and Ground on page 3-29 for more information. Verify the robot installation. Refer to 3-11 Verifying Installation on page 3-32 for more information. i4H Robots with EtherCAT User's Manual (I661)

  • Page 69: Mounting The Robot

    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)
  • Page 70 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. After all four screws have been tightened to the specified torque, the mounting procedure is complete. i4H Robots with EtherCAT User's Manual (I661)

  • Page 71: Installing End-Of-Arm Tooling

    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)

  • Page 72: Installing Optional Equipment

    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-) PIN 3, Transmit - (TD-) i4H Robots with EtherCAT User's Manual (I661)

  • Page 73: 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 74: Adjustable Hardstop Details

    • 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. i4H Robots with EtherCAT User's Manual (I661)
  • Page 75 Repeat steps 2 and 3 if a second hardstop is required. 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)

  • Page 76: System Cable Installation

    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)
  • Page 77 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. 3-11 i4H Robots with EtherCAT User's Manual (I661)

  • Page 78: System Cable Installation Procedure

    Refer to 3-8 Installing Safety Equipment on page 3-19 for more information. If applicable, connect devices to the XBELTIO connector and the USER connectors. Refer to Optional Connections on page 3-11 for more information. Connect the robot to the EtherCAT network. 3-12 i4H Robots with EtherCAT User's Manual (I661)

  • Page 79: Connecting Digital I/O

    Common 2 Input 1.2 907 + n Input 2.2 908 + n Input 3.2 909 + n Input 4.2 910 + n Input 5.2 911 + n Input 6.2 912 + n 3-13 i4H Robots with EtherCAT User's Manual (I661)
  • Page 80 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-reset- ting polyfuse. 3-14 i4H Robots with EtherCAT User's Manual (I661)
  • Page 81 Use the following diagrams for XIO Breakout cable pinout information. PIN 1 PIN 9 PIN 10 PIN 18 PIN 19 PIN 26 Pin Number Signal Wire Color White 24 VDC White / Black Common 1 Input 1.1 Red / Black 3-15 i4H Robots with EtherCAT User's Manual (I661)
  • Page 82 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)

  • Page 83: 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. 3-17 i4H Robots with EtherCAT User's Manual (I661)
  • Page 84 3 Installation XBELTIO Adapter Cable EXPIO to IO Blox Cable 3-18 i4H Robots with EtherCAT User's Manual (I661)

  • Page 85: Installing Safety Equipment

    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 Pan- el 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.

  • Page 86: Safety Circuits

    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)
  • Page 87 Emergency stop channel 1 input Typically connected to normally closed contacts on user- supplied safety devices such as E-stop buttons, safety 2, 15 Emergency stop channel 2 input switches, or safety relays. 3-21 i4H Robots with EtherCAT User's Manual (I661)
  • Page 88 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)
  • Page 89 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. 3-23 i4H Robots with EtherCAT User's Manual (I661)
  • Page 90 • 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)
  • Page 91 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. 3-25 i4H Robots with EtherCAT User's Manual (I661)
  • Page 92 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)

  • Page 93: Setting The Ethercat Node Id

    Begin by converting the desired node ID into a hexadecimal format. In this example, 196 is converted to 0x0C4. Set the x256 dip switch to the OFF position. Set the x16 rotary switch to position C. Set the x1 rotary switch to position 4. 3-27 i4H Robots with EtherCAT User's Manual (I661)
  • Page 94 Confirm that the switches are in the following positions. Apply or cycle Control Power to implement the new node ID setting. Confirm the correct EtherCAT node ID of 196 with Sysmac Studio.. 3-28 i4H Robots with EtherCAT User's Manual (I661)

  • Page 95: 3-10 Supplying Power And Ground

    High Power Ground Chassis Ground Housing Ground 3-29 i4H Robots with EtherCAT User's Manual (I661)

  • Page 96: Dc Connections

    Use the illustration below to understand the polarity of the mating connector. Additional Information A 5 m cable assembly is included with the robot. The part number for this cable assembly is 04120-000. +24 VDC 0 VDC 3-30 i4H Robots with EtherCAT User's Manual (I661)

  • Page 97: Ac Connections

    1 Φ, 200-240 VAC 12 A Fuse / Breaker Slow-blow Type Line 1 200-240 VAC 3 Φ Line 2 200-240 VAC Line 3 (unused) Earth Ground Primary Interface Panel 1 Φ, 200-240 VAC 3-31 i4H Robots with EtherCAT User's Manual (I661)

  • Page 98: 3-11 Verifying Installation

    High Pow- 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)
  • Page 99 (-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 proce- dure. 3-33 i4H Robots with EtherCAT User's Manual (I661)

  • Page 100: Switch Position Checks

    • 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)
  • Page 101 LED Light Ring ....................4-8 LCD Display ....................4-9 4-5-1 LCD Display Status Messages................ 4-9 Brake Operation ................... 4-10 4-6-1 Built-in Brake Release Button ............... 4-10 4-6-2 Remote Brake Release ..................4-11 Manually Jogging the Robot ............... 4-12 i4H Robots with EtherCAT User's Manual (I661)

  • Page 102: Payload And Acceleration Considerations

    Payload Z-Location vs. Acceleration at 100% Speed (Linear Moves Only) 1100 1000 1 kg 2 kg 3 kg 4 kg 5 kg 10 kg 15 kg Payload Z-Location (mm) = Joint 3 Position + Payload Center of Gravity i4H Robots with EtherCAT User's Manual (I661)

  • Page 103: Robot Control Modes

    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 maxi- mum speed. i4H Robots with EtherCAT User's Manual (I661)

  • Page 104: Operation Mode

    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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 105: Service Mode

    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.

  • Page 106: Enabling And Disabling The Robot

    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 spe- cific errors. Refer to the eV+3 Keyword Reference Manual (Cat. No. I652) for more information. i4H Robots with EtherCAT User's Manual (I661)

  • Page 107: 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 108: Led Light Ring

    The robot is in a normal operating state while in Manual mode. Flashing Red (1 Hz) The robot is in an error state from an emergency stop or other condition. Solid Red The robot has a system error. i4H Robots with EtherCAT User's Manual (I661)

  • Page 109: Lcd Display

    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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 110: Brake Operation

    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)

  • Page 111: Remote Brake Release

    To comply with ISO 10218-1 when using a remote brake release button, ensure the brake re- lease button displays a warning label to indicate that the z-axis of the robot may fall due to grav- ity if the brake is released. 4-11 i4H Robots with EtherCAT User's Manual (I661)

  • Page 112: Manually Jogging The Robot

    • 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)

  • Page 113: Troubleshooting

    Troubleshooting This section provides robot troubleshooting information. Fault Detection ....................5-2 Emergency Stop Troubleshooting..............5-3 Error Messages ....................5-4 i4H Robots with EtherCAT User's Manual (I661)

  • Page 114: Fault Detection

    • 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 115: Emergency Stop Troubleshooting

    • 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 116: Error Messages

    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 Explanation Corrective Action 24 VDC power fault.
  • Page 117 Retry the motion at a slower speed. sents the associated joint number. Ensure nothing is obstructing the robot motion. The indicated motor was not tracking the commanded position with sufficient accuracy as set by Sysmac Studio. i4H Robots with EtherCAT User's Manual (I661)
  • Page 118 5 Troubleshooting i4H Robots with EtherCAT User's Manual (I661)
  • Page 119 Maintenance This section provides information on the maintenance of the i4H robot. Field-replaceable Items ................. 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 ..................

  • Page 120: Field-Replaceable Items

    6 Maintenance 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 Part Number...

  • Page 121: Periodic Maintenance

    • 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)

  • Page 122: 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 i4H Robots with EtherCAT User's Manual (I661)

  • Page 123: Checking Safety And Warning Labels

    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)

  • Page 124: Replacing Encoder Batteries

    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. i4H Robots with EtherCAT User's Manual (I661)
  • Page 125 RON representative. Precautions for Correct Use Only replace items on the robot system with the parts supplied by OMRON. Remove the four screws that fasten the LCD display assembly to the robot. 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.

  • Page 126: Harmonic Drive Oil Change

    Do not use organic solvents to clean any part of the robot unless directed in the clean- ing instructions. Organic solvents might damage electronics resulting in an unsafe op- erating state that could cause injury or damage to equipment. i4H Robots with EtherCAT User's Manual (I661)

  • Page 127: Non-Periodic Maintenance

    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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 128: Replacing The Ics-Ecat Amplifier Chassis

    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)
  • Page 129 • If a robot is mounted using the wall mount bracket, it must be un-mounted before beginning this procedure. Disconnect all external cables connected to the Primary Interface Panel. Remove the six M5 X 16 screws securing the iCS-ECATto the robot base. 6-11 i4H Robots with EtherCAT User's Manual (I661)
  • Page 130 Take note of the internal harness and cable routing. Similar routing must be used when reas- sembling the components. 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)
  • Page 131 After all internal connections have been removed, slide the iCS-ECAT out of the robot base completely. 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 6-13 i4H Robots with EtherCAT User's Manual (I661)

  • Page 132: Replacing The Outer Link Cover

    Disconnect all cables as well as any pneumatic tubing connected to the Secondary Interface Panel. 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)
  • Page 133 Apply 2.8 N-m of torque to the socket-head capscrew to secure the clamp collar. Connect all previously disconnected cables as well as any pneumatic tubing connected to the Secondary Interface Panel to complete this procedure. 6-15 i4H Robots with EtherCAT User's Manual (I661)
  • Page 134 6 Maintenance 6-16 i4H Robots with EtherCAT User's Manual (I661)
  • Page 135 Input Signal Numbering................... A-4 A-3-2 Output Signal Numbering ................A-5 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 i4H Robots with EtherCAT User's Manual (I661)

  • Page 136: 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 137: Transportation And Storage Considerations

    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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 138: A-3 I/O Signal Numbering

    1601 to 1612 IO Blox 1 OFF, OFF 1665 to 1672 IO Blox 2 ON, OFF 1673 to 1680 IO Blox 3 OFF, ON 1681 to 1688 IO Blox 4 ON, ON 1689 to 1696 i4H Robots with EtherCAT User's Manual (I661)

  • Page 139: A-3-2 Output Signal Numbering

    601 to 608 IO Blox 1 OFF, OFF 665 to 672 IO Blox 2 ON, OFF 673 to 680 IO Blox 3 OFF, ON 681 to 688 IO Blox 4 ON, ON 689 to 696 i4H Robots with EtherCAT User's Manual (I661)
  • Page 140 701 to 708 IO Blox 1 OFF, OFF 765 to 772 IO Blox 2 ON, OFF 773 to 780 IO Blox 3 OFF, ON 781 to 788 IO Blox 4 ON, ON 789 to 796 i4H Robots with EtherCAT User's Manual (I661)

  • Page 141: A-4 Cable Pinouts

    Appendix 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. i4H Robots with EtherCAT User's Manual (I661)

  • Page 142: Xbeltio Adapter Cable Pinouts

    PIN 12 PIN 33 PIN 13 PIN 15 PIN 8 PIN 15 PIN 3 PIN 4 SHELL SHELL A-4-2 XBELTIO Adapter Cable Pinouts Use the following diagrams for XBELTIO adapter cable pinout information. i4H Robots with EtherCAT User's Manual (I661)

  • Page 143: A-4-3 Belt Encoder Y-Adapter Cable Pinouts

    PIN 5 SHIELD SHIELD PIN 10 PIN 18 PIN 6 PIN 26 PIN 19 PIN 9 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)
  • Page 144 PIN 7 PIN 3 PIN 6 PIN 9 (ENC2_I+) PIN 8 PIN 1 (ENC2_I-) PIN 6 PIN 4 PIN 2 PIN 4 (5V) PIN 5 PIN 7 PIN 12 (GND) SHIELD SHIELD A-10 i4H Robots with EtherCAT User's Manual (I661)
  • Page 145 Index i4H Robots with EtherCAT User's Manual (I661)
  • Page 146 Encoder Backup Batteries..........6-2, 6-6 End-of-Arm Tooling............3-5 Error Messages..............5-4 Operating Temperature............2-16 Ethernet Interface Port............ 2-17 External Equipment Mounting........... 3-6 Payload................2-10 Pneumatic Pass-through Ports.......1-10, 2-17 Faults.................5-2 Pollution Degree.............. 2-16 Front Panel..............1-6, 6-2 Protection Class.............. 2-16 i4H Robots with EtherCAT User's Manual (I661)
  • Page 147 Safety Circuits..............3-20 Storage Temperature............2-16 Tool Flange................ 6-2 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 i4H Robots with EtherCAT User's Manual (I661)
  • Page 148 Index i4H Robots with EtherCAT User's Manual (I661)
  • Page 150 4225 Hacienda Drive, Pleasanton, CA 94588 OMRON ASIA PACIFIC PTE. LTD. U.S.A. No. 438A Alexandra Road # 05-05/08 (Lobby 2), © OMRON Corporation 2020 All Rights Reserved. OMRON (CHINA) CO., LTD. Alexandra Technopark, In the interest of product improvement, Room 2211, Bank of China Tower, Singapore 119967 specifications are subject to change without notice.

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