Omron i4L Series User Manual
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Omron i4L Series User Manual

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i4L
Robots
User's Manual
i4-350L
i4-450L
i4-550L
I658-E-01

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Summary of Contents for Omron i4L Series

  • Page 1 Robots User's Manual i4-350L i4-450L i4-550L I658-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

    Introduction Introduction Thank you for purchasing the i4L robot. This manual contains information that is necessary to use the robot (hereafter also referred to as ro- bot). Please read this manual and make sure you understand the functionality and performance of the robot before attempting to use it.
  • Page 4 Introduction i4L Robots User's Manual (I658)

  • Page 5: Sections In This Manual

    Sections in this Manual Sections in this Manual Overview Specifications Installation Operation Troubleshooting Maintenance Appendices i4L Robots User's Manual (I658)

  • Page 6: Table Of Contents

    CONTENTS CONTENTS Introduction ......................1 Intended Audience............................1 Applicable Products ............................1 Sections in this Manual ................... 3 Manual Information....................8 Page Structure..............................8 Special Information ............................9 Terms and Conditions Agreement................ 10 Warranty and Limitations of Liability ......................10 Application Considerations ..........................11 Disclaimers ..............................11 Safety Precautions....................
  • Page 7 CONTENTS Model Numbers ........................1-14 1-5-1 Robot Model Numbers ......................1-14 1-5-2 Controller Model Numbers ......................1-14 Optional Hardware .......................1-15 1-6-1 IO Blox ............................1-15 1-6-2 T20 Pendant..........................1-15 1-6-3 IPC Application Controller ......................1-16 1-6-4 XIO Termination Block.......................1-16 1-6-5 Optional Cables.........................1-17 Section 2 Specifications Physical Specifications ......................2-2 2-1-1 Robot Overall Dimensions ......................2-2 2-1-2...
  • Page 8 CONTENTS 3-9-1 Grounding the System ......................3-28 3-9-2 24 VDC Connections.........................3-29 3-9-3 48 VDC Connections.........................3-29 3-10 Verifying Installation......................3-31 3-10-1 Mechanical Checks ........................3-31 3-10-2 System Cable Checks .......................3-31 3-10-3 Safety Equipment Checks ......................3-31 3-10-4 Switch Position Checks ......................3-33 Section 4 Operation Payload and Speed Considerations..................4-2 Robot Control Modes ......................4-3 4-2-1 Manual Mode ..........................4-3...
  • Page 9 CONTENTS Repacking the Robot for Transport..................A-4 Transportation and Storage Considerations..............A-5 I/O Signal Numbering ......................A-6 A-4-1 Input Signal Numbering......................A-6 A-4-2 Output Signal Numbering ......................A-6 Cable Pinouts ........................A-7 A-5-1 XSYSTEM Cable Pinouts......................A-7 A-5-2 XBELTIO Adapter Cable Pinouts ....................A-8 A-5-3 Belt Encoder Y-adapter Cable Pinouts..................

  • Page 10: Manual Information

    Manual Information Manual Information Page Structure The following page structure is used in this manual. 5 Installation Unpack This section provides details on how to unpack the Industrial Panel PC. 5-1-1 Unpack Procedure Check the package for damage. If there is any visible damage: •...

  • Page 11: Special Information

    Manual Information Special Information Special information in this manual is classified as follows: Precautions for Safe Use Precautions on what to do and what not to do to ensure safe usage of the product. Precautions for Correct Use Precautions on what to do and what not to do to ensure proper operation and performance. Additional Information Additional information to read as required.

  • Page 12: Terms And Conditions Agreement

    Omron’s exclusive warranty is that the Products will be free from defects in materials and work- manship for a period of twelve months from the date of sale by Omron (or such other period ex- pressed 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. i4L Robots User's Manual (I658)

  • Page 15: Safety Precautions

    Safety Precautions Safety Precautions Definition of Precautionary Information The following notation is used in this manual to provide precautions required to ensure safe usage of the i4L robot. The safety precautions that are provided are extremely important to safety. Always read and heed the information provided in all safety precautions. The following notation is used.

  • Page 16: Dangers

    • The robot system must not be used for purposes other than described in 1-1 Intended Use on page 1-2. Contact your local Omron support if you are not sure of the suitabili- ty for your application. •...

  • Page 17: Warnings

    Safety Precautions The robot system must be installed with user-supplied interlock barriers. The interlocked barriers must open the E-Stop circuit in the event of personnel attempting to enter the work cell when High Power is enabled. Failure to install suitable guarding or interlocks could result in injury or death.
  • Page 18 Safety Precautions Provide appropriately-sized Branch Circuit Protection and Lockout / Tagout Capability in accordance with the National Electrical Code and any local codes. Always use proper lifting technique when lifting the robot. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage. If you supply your own Front Panel, its design must comply with the requirements of IEC 60204-1 and ISO 13849.

  • Page 19: Cautions

    Safety Precautions In Automatic mode, the robot can move unexpectedly. Ensure all personnel remain clear of the cell when Automatic mode is enabled. If an operator is going to be in the work cell with the switch in Manual mode, the operator must carry an enabling device such as the T20 pendant.

  • Page 20: 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 21 Precautions for Safe Use • Any person who programs, teaches, operates, maintains, or repairs robots or robot systems shall be trained and can demonstrate competence to safely perform the assigned task. • Any person who programs, teaches, operates, maintains, or repairs robots or robot systems shall be trained on responding to emergency or abnormal situations.

  • Page 22: Precautions For Correct Use

    PC. • Only replace items on the robot system with the parts supplied by OMRON. • Only use the recommended grease on the joint 3 quill. Use THK AFF Grease (part number 20950-000).
  • Page 23 Precautions for Correct Use • If the robot has a bottom Primary Interface Panel orientation, do not temporarily set of the robot up- right on a flat surface because this can damange the Primary Interface Panel connectors. • Avoid rotating the quill / Joint 4 when the brake is released. This could result in an out-of-range con- dition and may prevent program execution.

  • Page 24: Regulations And Standards

    Regulations and Standards Regulations and Standards Conformance to EU Directives The robot complies with the following EN Directives. Directives • 2006/42/EC Machinery Directive • 2014/30/EU EMC Directive EN Harmonized Standards The robot system conforms to the following EN standards. • EN ISO 12100 Safety of Machinery General Principles for Design Risk Assessment and Reduction...

  • Page 25: Software Licenses And Copyrights

    Regulations and Standards Software Licenses and Copyrights This product 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/. i4L Robots User's Manual (I658)

  • Page 26: Related Manuals

    Provides eV+ operating system keyword descriptions. (Cat. No. I607) Robot Safety Guide (Cat. No. I590) Contains safety information for OMRON industrial robots. Automation Control Environment (ACE) Contains information that is necessary to use Automation Control Version 4 User's Manual (Cat. No. I633) Environment (ACE) software.

  • Page 27: Terminology And Abbreviations

    Terminology and Abbreviations Terminology and Abbreviations Term / Abbreviation Description Application Controller Industrial PC that provides additional functionality to the robot to execute PackManager and Robot Vision Manager applications. Automatic Mode Operating state of the robot during normal conditions. In this mode, pro- gram execution will control the robot up to the maximum allowable speed.
  • Page 28 Terminology and Abbreviations i4L Robots User's Manual (I658)

  • Page 29: Overview

    Overview This section provides general information about the robot. Intended Use....................1-2 Robot Features ....................1-3 1-2-1 Basic Robot Components................1-3 1-2-2 Front Panel...................... 1-5 1-2-3 Connectors ...................... 1-7 1-2-4 XSYSTEM Cable..................... 1-9 Information Labels ..................1-10 1-3-1 Robot Label ....................1-10 1-3-2 Controller Label ....................1-11 Robot Configurations ..................

  • Page 30: Intended Use

    1 Overview Intended Use The i4L robot is a selective compliance assembly robot arm (SCARA) for use within factory environ- ments. It is designed to 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 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 hardware features of the i4L robot. • The robot can be mounted on a horizontal surface (table mount) or a vertical surface (wall mount) without the need for additional adapters or brackets. •...
  • Page 32 1 Overview Axes of Motion Use the following diagrams to understand the robot's 4 axes of motion. Joint 1 Joint 2 Joint 3 (Z-axis) Joint 4 Interface Panels Use the information below to identify the robot's interface panels and their functions. Secondary Interface Panel Primary Interface...

  • Page 33: Front Panel

    1 Overview Pneumatic Pass-through Ports USER Connector Encoder Backup Battery Access Mode Switches Control Power Reserved for future use Connector High Power Reserved for future use Connector Ethernet Interface Port XSYSTEM XBELTIO Connector Connector Connector Reserved for future  Secondary Interface Panel The Secondary Interface Panel is located on top of the outer link and provides access to the follow- ing items.
  • Page 34 1 Overview Precautions for Safe Use If the supplied Front Panel is not used, a High Power indicator light must be present in the sys- tem. This indicator light must be amber in color. It must be either mounted to the robot or inte- grated into the work cell where it is visible from all approaches or entry points.

  • Page 35: Connectors

    1 Overview Item Description Mode Selection Switch Controls the robot's operating mode. The left position selects Manual mode. The right position selects Automatic mode. Refer to 4-2 Robot Control Modes on page 4-3 for more information. High Power Indicator Provides an indication of the robot's High Power state with an amber LED.
  • Page 36 1 Overview Precautions for Correct Use Robot motion is not possible until High Power is supplied and has been enabled. Refer to 4-3 Enabling and Disabling the Robot on page 4-5 for more information. High Power Connector The High Power connector is used to supply 48 VDC to the internal servo amplifiers. When power is supplied to this connector and High Power has been enabled, the robot is ready to move.

  • Page 37: Xsystem Cable

    1 Overview Ethernet Interface Port The Ethernet interface port provides communications for programming and configuration. It also pro- vides communications for runtime operation when an IPC Application Controller is present in the sys- tem. Pneumatic Pass-through Ports The pneumatic pass-through ports provide pass-through air lines from the Primary Interface Panel to the Secondary Interface Panel.

  • Page 38: Information Labels

    1 Overview Information Labels The information labels contain relevant information about the robot and the controller. The following examples will be different from your product label. 1-3-1 Robot Label The robot label is described below. Item Name Description The robot part number is displayed. Part number Product type The product type is displayed.

  • Page 39: Controller Label

    1 Overview 1-3-2 Controller Label The controller label is described below. Item Name Description The controller part number is displayed. Part number Product type The product type is displayed. Alerts and compliance General alerts and compliance information is displayed. Controller information The controller model and general electrical power supply information is displayed.

  • Page 40: Robot Configurations

    1 Overview Robot Configurations The i4L robot is offered in a variety of configurations with different work envelopes and z-axis stroke lengths. 1-4-1 i4-350L The i4-350L configuration has a reach of 350 mm and a z-axis stroke of 180 mm. 180 mm 350 mm 1-4-2...

  • Page 41: I4-550L (350 Mm Z)

    1 Overview 1-4-4 i4-550L (350 mm Z) The i4-550L (350 mm Z) configuration has a reach of 550 mm and a z-axis stroke of 350 mm. 350 mm 550 mm 1-4-5 Mounting and Cabling Options The robot has a table mount 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.

  • Page 42: Model Numbers

    1 Overview Model Numbers Models numbers and descriptions associated with the robot are provided below. 1-5-1 Robot Model Numbers The table below provides all robot model numbers and descriptions. Primary Interface Panel Orien- Model Number Reach Z-axis Stroke tation RS4-2053002 350 mm 180 mm Rear...

  • Page 43: Optional Hardware

    IO Blox units are available to expand the I/O capacity of the robot. Each unit offers 8 inputs and 8 out- puts. Up to 4 IO Blox units can be added to the robot. Additional Information Refer to 3-7-3 IO Blox Connections on page 3-19 and the Omron Adept IO Blox User's Guide (04638-000) for more information. 1-6-2...

  • Page 44: Ipc Application Controller

    1 Overview 1-6-3 IPC Application Controller The IPC Application Controller can be added to your system to execute PackManager and Robot Vi- sion Manager applications. Refer to the following manuals for more information. • Automation Control Environment (ACE) Version 4 User's Manual (Cat. No. I633) •...

  • Page 45: Optional Cables

    1 Overview 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 XBELTIO Adapter Cable The optional XBELTIO adapter cable connects to the XBELTIO connector on the Primary Interface Panel.
  • Page 46 1 Overview • The part number for this cable is 13463-000. • The length of this cable is 600 mm. Additional Information Refer to A-5-2 XBELTIO Adapter Cable Pinouts on page A-8 for more information. Belt Encoder Y-adapter Cable The optional belt encoder Y-adapter cable connects to the XBELTIO adapter cable's BELT ENCODER connector.
  • Page 47 1 Overview Additional Information Refer to 3-7-3 IO Blox Connections on page 3-19 for more information. 1-19 i4L Robots User's Manual (I658)
  • Page 48 1 Overview 1-20 i4L Robots User's Manual (I658)

  • Page 49: Specifications

    Specifications This section provides specifications for the robot's hardware, performance, electrical connections, installation environment, and other technical aspects of the system. Physical Specifications ................. 2-2 2-1-1 Robot Overall Dimensions................2-2 2-1-2 Mounting Flange Dimensions................2-4 2-1-3 Tool Flange Dimensions .................. 2-5 2-1-4 Front Panel Dimensions ..................

  • Page 50: Physical Specifications

    2 Specifications Physical Specifications This section provides physical specifications for the i4L robot. 2-1-1 Robot Overall 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...
  • Page 51 2 Specifications i4-450L Dimensions Overall dimensions for the i4-450L are provided below. 160 mm 450 mm 61 mm 642 mm 600 mm +/- 360° 180 mm 242.5 mm 240 mm 180 mm 62.5 mm i4-550L Dimensions Overall dimensions for the i4-550L are provided below. 160 mm 550 mm 61 mm...

  • Page 52: Mounting Flange Dimensions

    2 Specifications i4-550L (350 mm Z) Dimensions Overall dimensions for the i4-550L (350 mm Z) are provided below. 160 mm 61 mm 550 mm 770 mm 642 mm +/- 360° 242.5 mm 240 mm 350 mm 180 mm Cable Clearances There must be at least 183 mm of clearance from the Primary Interface Panel connectors to provide adequate space for cables.

  • Page 53: Tool Flange Dimensions

    2 Specifications Mounting Mounting Mounting Mounting Holes (x4) Holes (x4) Holes (x4) Holes (x4) Front 220 mm 220 mm 79 mm 59 mm R 20 mm R 20 mm 20 mm 20 mm 120 mm 120 mm 2-1-3 Tool Flange Dimensions The robot's tool flange dimensions are provided below.

  • Page 54: Robot Work Envelope Dimensions

    2 Specifications 152 mm 140 mm Ø 4 mm 41 mm 125 mm 76 mm 89 mm 56 mm 16 mm 5 mm 2-1-5 Robot Work Envelope Dimensions Use the diagrams below to understand the robot's working envelope dimensions. i4-350L Work Envelope Work envelope dimensions are provided below.

  • Page 55: Robot Weights

    2 Specifications i4-550L Work Envelope Work envelope dimensions are provided below. 191 mm 20 mm R 275 mm R 550 mm R 275 mm R 150 mm 245 mm 79 mm 180 mm 242.5 mm 148° 135 ° i4-550L (350 mm Z) Work Envelope Work envelope dimensions are provided below.

  • Page 56: Performance Specifications

    2 Specifications Performance Specifications The following sections provide robot performance specifications. 2-2-1 General Performance Information The following table provides general performance information for the robot. Item i4-350L i4-450L i4-550L i4-550L (350 mm Z) Payload 2 kg rated 5 kg maximum Reach 350 mm 450 mm...
  • Page 57 2 Specifications WARNING The stopping time and distance, or angle, of a robot joint from initiation of a stop sig- nal is not negligible and must be taken into account when designing and applying safeguarding devices. The graphs show the time elapsed and distances traveled between the initiation of a stop signal and the cessation of all robot motion.
  • Page 58 2 Specifications Joint 2 Stopping Time (all payloads) Speed (%) Joint 2 Stopping Distance (all payloads) Speed (%) Joint 3 Stopping Time (all payloads) Speed (%) 2-10 i4L Robots User's Manual (I658)
  • Page 59 2 Specifications Joint 3 Stopping Distance (all payloads) Speed (%) 2-11 i4L Robots User's Manual (I658)

  • Page 60: Electrical Specifications

    2 Specifications Electrical Specifications Electrical specifications are provided in the sections below. 2-3-1 Power Supply Specifications Specifications for the 24 VDC and 48 VDC power supplies are provided below. 24 VDC Control Power Supply Specifications Item Specification Supply voltage range 24 VDC ±10% Current / power requirements 5 A / 120 W maximum...
  • Page 61 2 Specifications Type Item Specification Output circuits Type Sourcing Output voltage range 24 VDC ±10% Total current output for all XIO cir- 1.0 A maximum at 50° C ambient tempera- cuits ture 1.5 A maximum at 25° C ambient tempera- ture Total current output for all TIO cir- 1.0 A maximum at 50°...

  • Page 62: Environmental Specifications

    2 Specifications Environmental Specifications Environmental specifications are provided below. WARNING To reduce the risk of fire or electric shock, install the robot in a controlled environment relatively free of contaminants. Item Specification Ambient operating temperature 5 to 40°C Storage temperature –25 to 55°C Humidity 5 to 90%, non-condensing...

  • Page 63: Other Specifications

    2 Specifications Other Specifications Other specifications for associated equipment are provided below. 2-5-1 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 wiring and pin diagrams.
  • Page 64 2 Specifications 2-16 i4L Robots User's Manual (I658)

  • Page 65: Installation

    Installation This section provides information about installing the robot and other necessary equip- ment. Robot Installation Procedure ................ 3-2 Mounting the Robot ..................3-3 3-2-1 Robot Mounting Surface.................. 3-3 3-2-2 Mounting Procedure ..................3-3 Installing End-of-Arm Tooling ............... 3-5 Installing Optional Equipment ..............3-6 3-4-1 Mounting External Equipment to the Robot.............

  • Page 66: Robot Installation Procedure

    3 Installation Robot Installation Procedure The basic installation steps are provided below. WARNING • Ensure that installation and post-installation checks of the product are performed by personnel in charge who possess a thorough understanding of the machinery to be installed. •...

  • Page 67: Mounting The Robot

    3 Installation Mounting the Robot Use the information in the following sections to mount the robot. 3-2-1 Robot Mounting Surface The following considerations must be made when preparing a robot mounting surface. • It must be smooth and flat. • It must be rigid enough to prevent vibration and flexing that is caused by reactionary forces during fast robot motion.
  • Page 68 3 Installation • Assistance to lift and maneuver the robot into the mounting position. • Four socket-head cap screws with flat washers. Refer to 2-5-2 Mounting Hardware and Torques on page 2-15 for more information. Using the dimensions provided in 2-1-2 Mounting Flange Dimensions on page 2-4, prepare four holes in the mounting surface to accommodate the user-supplied machine bolts (specified above).

  • Page 69: Installing End-Of-Arm Tooling

    3 Installation Installing End-of-Arm Tooling You must provide, install, and ground (if necessary) end-of-arm tooling to the tool flange. Use the following details when designing and installing end-of-arm tooling. • Hole diameters and placement on the tool flange comply with ISO-9409-1-50-4-M6 (2004) stand- ards.

  • Page 70: Installing Optional Equipment

    3 Installation Installing Optional Equipment This section provides information about installing the following optional equipment. 3-4-1 Mounting External Equipment to the Robot The robot body has accommodations to mount external equipment such as a camera or solenoid valves. Use the information below to understand how to mount external equipment to the robot. 4 mounting holes are provided on the bottom of the outer link between joint 2 and joint 4.

  • Page 71: Adjustable Hardstops

    3 Installation Adjustable Hardstops The robot is equipped with several mechanical hardstop adjustment points for joints 1, 2, and 3 as de- scribed in the following sections. Adjust these mechanical hardstops to restrict the robot's range of motion in order to prevent collisions within the workspace if necessary. WARNING The robot's physical hardstop devices are not intended to withstand repeated use and if this occurs, the hardstop may become damaged.

  • Page 72: Joint 1 Adjustable Hardstops

    3 Installation Range of Motion Software Limit Setting Joint Hardstop Joint Limita- Position tion i4-350L i4-450L i4-550L / i4-550L (350 mm Z) Joint 1 -109.5° +109.5° Joint 2 -124° -118° +124° +118° -133° See note +133° Joint 3 5 mm from end of travel. The i4-350L model includes pre-installed hardstop screws in positions 5 and 6 to prevent base interference with the quill.
  • Page 73 3 Installation Loosen the clamp collar socket-head 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 a torque of 4.5 N-m. i4L Robots User's Manual (I658)

  • Page 74: System Cable Installation

    3 Installation System Cable Installation This section provides information about installing the robot system cables. WARNING • Never connect or disconnect system cables while power is applied to the robot. Failure to comply may cause unexpected behavior and can result in personnel in- jury and equipment damage.
  • Page 75 3 Installation XUSR Connector Front Panel Connector Extension Cable XSYSTEM Cable XMCP Connector Front T20 Pendant Panel Adapter Cable T20 Pendant Jumper Plug T20 Pendant Optional Connections The following figure shows optional connections to the robot. Additional Information Refer to 3-7 Connecting Digital I/O on page 3-13 for more information about connecting I/O with IO Blox Units or with the XIO connector.

  • Page 76: System Cable Installation Procedure

    3 Installation XIO Breakout XIO Cable Cable EXPIO to IO Blox Cable XBELTIO Adapter Cable Belt Encoder Y-adapter Cable 3-6-2 System Cable Installation Procedure The following procedure provides details about system cable installation. The robot must be mounted before following the steps below. Refer to 3-2 Mounting the Robot on page 3-3 for more information.

  • Page 77: Connecting Digital I/O

    3 Installation Connecting Digital I/O The following sections describe the various methods to connect digital I/O to the robot. 3-7-1 XIO Connector Signals and Wiring The XIO connector on the Primary Interface Panel provides access to built-in digital I/O. The 12 available inputs correspond to V+ signal numbers 1097 to 1108. The 8 available outputs correspond to V+ signal numbers 0097 to 0104.
  • Page 78 3 Installation Pin Number Designation Signal Bank V+ Signal Number Output 1 Output 2 0097 Output 3 0098 Output 4 0099 Output 5 0100 Output 6 0102 Output 7 0103 Output 8 0104 XIO Internal Circuits Use the following information to understand the XIO internal circuits. ...
  • Page 79 3 Installation Precautions for Safe Use Output 8 can be assigned to indicate the robot's High Power state. When High Power is ena- bled, this output will turn ON. When High Power is not enabled, this output will be OFF. This is not a safety-rated means of indicating a High Power state and should only be used for monitor- ing the robot status.
  • Page 80 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 Omron Adept IO Blox User's Guide (04638-000) for more information. 3-16 i4L Robots User's Manual (I658)

  • Page 81: Tio Connector Signals And Wiring

    3 Installation 3-7-2 TIO Connector Signals and Wiring The TIO connector on the Secondary Interface Panel provides access to built-in digital I/O. The 5 available inputs correspond to V+ signal numbers 1033 to 1037. The 4 available outputs correspond to V+ signal numbers 33 to 36. The TIO connector pin assignments are provided below.
  • Page 82 3 Installation Pin Number Designation V+ Signal Number Output 4 Ground –- Input 1 1033 Input 3 1035 Ground –- Output 1 Output 2 Ground –- TIO Internal Circuits Use the following diagram to understand the TIO internal circuits.  TIO Input Signals The 5 input channels are optically isolated and share a common source / sink line.

  • 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 Omron Adept IO Blox User's Guide (04638-000) for more information. XBELTIO Adapter Cable...

  • Page 84: 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 85: Safety Circuits

    3 Installation 152 mm 140 mm Ø 4 mm 41 mm 125 mm 76 mm 89 mm 56 mm 16 mm 5 mm Front Panel Connections The Front Panel is connected directly to the XFP connector on the XSYSTEM cable with the 3 m ex- tension cable supplied with the Front Panel as shown in the figure below.
  • Page 86 3 Installation XFP-1 XFP-2 XFP-14 High Power XFP-13 Indicator / XFP-9 XFP-10 XFP-5 Button XFP-6 XMCP-1 XMCP-2 XMCP-9 XMCP-10 XSYSTEM-5 XFP-3 XFP-4 XUSR-1 XUSR-2 Automatic / Manual Mode Selection XUSR-14 XUSR-15 XFP-11 XFP-12 XUSR-3 XUSR-4 XUSR-16 XUSR-17 Automatic Mode XUSR-17 XUSR-9 XUSR-16 XUSR-10...
  • Page 87 3 Installation Pins Description Additional Information 3, 16 Line emergency stop inputs Normally closed contacts on user-supplied safety devices typically used for other robot or line emergency stop in- 4, 17 terconnection. This does not affect emergency stop indication signals on pins 7, 20.
  • Page 88 3 Installation Pins Description Additional Information 1, 9 Front panel E-stop button channel 1 input Typically connected to normally closed contacts on the E-stop button used with the Front Panel. 2, 10 Front panel E-stop button channel 2 input 3, 11 Automatic / Manual mode selection channel 1 in- Typically connected to the selector switch used with the front panel.
  • Page 89 3 Installation +24 VDC +5 VDC Common PIN 4 +5 VDC PIN 5 PIN 1 +24 VDC Common PIN 3 Common Control Power PIN 12 PIN 10 PIN 13 Indicator PIN 14 PIN 9 PIN 11 Automatic / Manual High Power E-stop Button Mode Switch Button / Indicator...
  • Page 90 3 Installation Additional Information Refer to the T20 Pendant User's Manual (Cat. No. I601) for additional information. Precautions for Correct Use If Teach Pendant cabling is installed, the jumper plug or the Teach Pendant must be connected to satisfy safety circuits and allow High Power to be enabled. Pins Description Additional Information...
  • Page 91 3 Installation Additional Information • The jumper plug is supplied with the Teach Pendant kit. • The part number for the Teach Pendant jumper plug is 10048-000. 3-27 i4L Robots User's Manual (I658)

  • Page 92: Supplying Power And Ground

    3 Installation Supplying Power and Ground The robot requires separate 24 VDC and 48 VDC power supplies. The 24 VDC supply provides Con- trol Power and the 48 VDC supply provides power to the internal servo amplifiers. A lockout tagout main disconnect device must be installed on the AC supply to the 24 VDC and 48 VDC power supplies.

  • Page 93: 24 Vdc Connections

    3 Installation Ground Circuit Use the following diagram to understand the recommended grounding circuit. Robot Main 24 VDC Disconnect Power Supply Device Supply Ground 48 VDC Power Supply Ground 3-9-2 24 VDC Connections The 24 VDC Control Power connector is located on the Primary Interface Panel. A 24 VDC power sup- ply mating connector is provided with the robot.
  • Page 94 3 Installation Additional Information The connector and pins are provided with the robot and require assembly with user-supplied wires. The connector part number is 22009-000L. The pin part number is 02709-000. 0 VDC +48 VDC 3-30 i4L Robots User's Manual (I658)

  • Page 95: 3-10 Verifying Installation

    3 Installation 3-10 Verifying Installation If any modifications have been made to the robot during installation or other actions, make the follow- ing checks before operation. 3-10-1 Mechanical Checks Make the following mechanical checks after any hardware adjustments have been made to the sys- tem.
  • Page 96 3 Installation Safety Setting Function Description Configure E-stop Hardware The objective of the ESTOP hardware delay feature is to comply with safety Delay regulations which require the robot to have the capability of disabling High Power without software intervention in an emergency stop situation. Verify E-stop Hardware Delay Configuration will set the delay for the emergency stop timer circuit.

  • Page 97: Switch Position Checks

    3 Installation Check that the High Power indicator flashes. After the High Power request is made and the in- dicator is checked, the procedure is complete. 3-10-4 Switch Position Checks Switches on the Primary Interface Panel are reserved for future use and have no effect on the opera- tion of the system.
  • Page 98 3 Installation 3-34 i4L Robots User's Manual (I658)
  • Page 99 Operation This section provides information necessary to operate the robot. Payload and Speed Considerations ............. 4-2 Robot Control Modes..................4-3 4-2-1 Manual Mode....................4-3 4-2-2 Automatic Mode ....................4-3 Enabling and Disabling the Robot..............4-5 4-3-1 Enabling Robot High Power ................4-5 4-3-2 Disabling High Power ..................

  • Page 100: Payload And Speed Considerations

    If non-linear moves such as joint moves or arc moves are required with high speeds or high payloads, contact your local OMRON representitive for more information about acceleration and payload limita- tions. Use the following chart to understand the limitations to acceleration and payload when making linear moves.

  • Page 101: Robot Control Modes

    4 Operation Robot Control Modes The robot can operate in Automatic or Manual control modes. These modes are described in the fol- lowing sections. 4-2-1 Manual Mode Manual mode is typically used during functions of commissioning, position teaching, and other setup operations.
  • Page 102 4 Operation Precautions for Safe Use Prior to placing the robot in Automatic Mode, all safeguards must be returned to their safe state. To place the robot in Automatic mode, use the Front Panel key switch and rotate it to the right position as indicated below.

  • Page 103: Enabling And Disabling The Robot

    4 Operation Enabling and Disabling the Robot Enabling the robot energizes all robot servo motors with the 48 VDC power supply. This is also refer- red to as enabling High Power. When the robot is enabled, it is capable of moving. Program execution and I/O control functions are still operational when High Power is disabled.

  • Page 104: Disabling High Power

    4 Operation The AUTO.POWER.OFF system switch controls if the robot prevents or disables High Power for the following errors. Refer to the eV+ Language Reference Guide (Cat. No. I605) for more information. • (-624) Force protect limit exceeded • (-1003) Time-out nulling errors Mtr •...

  • Page 105: Led Indicator

    4 Operation LED Indicator The LED indicator on the top of the outer link provides a visual status of the robot. The LED indica- tions and associated robot states are described below. Precautions for Safe Use The LED indicator does not reflect the robot's High Power status. To see the robot's High Power status, use the Front Panel indicator or a user-supplied indicator connected to the XFP connec- tor.

  • Page 106: Brake Operation

    4 Operation Brake Operation The robot has a mechanical brake on joints 3 and 4. Releasing the brake is typically done when you need to manually position joint 3 or 4. The brake is controlled with the methods described below. The mechanical brake is capable of preventing the z-axis quill from lowering more than 5 mm when up to 100 N of downward force is applied.

  • Page 107: Remote Brake Release

    4 Operation 4-5-2 Remote Brake Release The brake can be released with a signal connected to the XIO connector. This is typically used for re- mote or automated control of the brake. Use the ACE software to configure the robot by selecting Enable Brake Release Input. This setting will change the XIO input 6.2 (pin 18) for use as a brake release signal from another device such as a remote pushbutton or an output from another control device.

  • Page 108: Connecting To The Robot

    4 Operation Connecting to the Robot Use the information in this section to establish a connection to the robot with the ACE software. The following conditions must be present before attempting to connect to the robot. • ACE software must be installed on the PC. •...

  • Page 109: Manually Jogging The Robot

    4 Operation Manually Jogging the Robot Manually jogging the robot is typically performed during setup or when teaching locations. Precautions for Safe Use During manual operation, ensure all persons are a safe distance away from the robot work en- velope. The following considerations should be made when jogging the robot.
  • Page 110 4 Operation 4-12 i4L Robots User's Manual (I658)

  • Page 111: Troubleshooting

    Troubleshooting This section provides robot troubleshooting information. Fault Detection ....................5-2 Emergency Stop Troubleshooting..............5-3 Error Messages ....................5-4 i4L Robots User's Manual (I658)

  • Page 112: Fault Detection

    5 Troubleshooting Fault Detection Robot faults can be detected with the following methods. • Create a V+ program to change the state of an output signal when a fault is present. Refer to the eV + Language Reference Guide (Cat. No. I605) for more information. •...

  • Page 113: Emergency Stop Troubleshooting

    5 Troubleshooting Emergency Stop Troubleshooting If the emergency stop circuit is not operating as expected, the following supplied jumper plugs can be used to troubleshoot the problem. These jumpers can be placed on the XSYSTEM cable to bypass and isolate safety devices. Refer to 3-6-1 System Cable Overview on page 3-10 for jumper installation locations.

  • Page 114: Error Messages

    Delay or Teach Restrict. The Teach Restrict has not been commissioned and verified. -651 *RSC communications There is a failure to communicate Contact your local OMRON sup- failure* with the Robot Signature Card. port. -670 *RSC power failure* The 24 VDC input voltage is out of Check connections and voltage lev- bounds (too high or low).
  • Page 115 Error Message Explanation Corrective Action Code -1009 *Safety System Fault* Robot hardware did not detect Contact your local OMRON sup- Code 0 pressing the Front Panel High port. Power button before the servo system attempted to enable pow- *Safety System Fault* Contact your local OMRON support.
  • Page 116 If the error continues, contact your local OMRON support. -1115 *Power system failure* The dual-channel brake circuit has Contact your local OMRON sup- Code 0 reported a cyclic check error. port. *Power system failure* The power system has unexpect- Code 1 edly turned off power.
  • Page 117 Maintenance This section provides information for maintaining the 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 ............. 6-4 6-2-5 Checking for Oil Leaks ..................

  • Page 118: 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 119: Periodic Maintenance

    6 Maintenance Periodic Maintenance This section lists when to perform periodic maintenance on your robots and the steps for checking each item to inspect. 6-2-1 Periodic Maintenance Overview The following table gives a summary of the periodic maintenance procedures and guidelines on fre- quency.

  • Page 120: Checking Fastener Torques

    6 Maintenance If the robot does not detect a current between 10 mA to 500 mA when High Power is requested, an error condition (-924) *Front panel HIGH POWER lamp failure* will be present and High Power will not be enabled. The High Power indicator needs to be periodically checked for correct functionality.

  • Page 121: Checking For Oil Leaks

    Periodically check the robot for oil leaks. Carefully inspect the following points for oil or excessive de- bris accumulation. Oil and dirt should not be present. If oil or excessive debris accumulation is detect- ed, contact your local OMRON support representative. i4L Robots User's Manual (I658)

  • Page 122: Lubricating Joint 3

    6 Maintenance Joint 2 Joint 3 Joint 1 6-2-6 Lubricating Joint 3 The joint 3 quill needs to be lubricated on a periodic basis of 3 months or 150 km of linear travel, whichever comes first. Precautions for Correct Use Only use the recommended grease on the joint 3 quill.

  • Page 123: Replacing Encoder Backup Batteries

    6 Maintenance Press the brake release button while moving the z-axis to the top of its stroke to expose the upper section of the quill. Remove any existing grease or debris from the exposed quill with a clean, lint-free cloth. Apply a small bead of grease to all grooves on the quill.

  • Page 124: Cleaning The Robot

    6 Maintenance Precautions for Correct Use Only replace items on the robot system with the parts supplied by OMRON. Remove the encoder battery compartment cover fastener screw and then remove the cover. Encoder Battery Compartment Cover Fastener Screw Remove and replace the batteries while observing orientation for correct polarity indicated in the battery compartment (upwards is positive).

  • Page 125: Non-Periodic Maintenance

    6 Maintenance Non-periodic Maintenance This section provides information and instructions for performing maintenance that does not occur at regular intervals. 6-3-1 Replacing the Tool Flange Replace the tool flange if it gets damaged. Before beginning the procedure, have the following tools available. •...
  • Page 126 6 Maintenance Tool Flange Replacement Procedure Use the following procedure to replace the tool flange on the z-axis quill if necessary. Quill Slots Socket-head Screws (x4) Setscrew Take note of the old tool flange position and orientation on the quill. Loosen the setscrew and socket-head screws while holding the old tool flange in place.
  • Page 127 Appendices Unpacking and Inspecting the Robot............A-2 A-1-1 Before Unpacking the Robot ................A-2 A-1-2 Unpacking the Robot..................A-2 Repacking the Robot for Transport ............. A-4 Transportation and Storage Considerations ..........A-5 I/O Signal Numbering..................A-6 A-4-1 Input Signal Numbering................... A-6 A-4-2 Output Signal Numbering ................

  • Page 128: A-1 Unpacking And Inspecting The Robot

    Appendices A-1 Unpacking and Inspecting the Robot This section provides information about unpacking and inspecting the robot. A-1-1 Before Unpacking the Robot Before unpacking the robot, carefully inspect all shipping containers for evidence of damage during transit. Pay special attention to any tilt and shock indication labels on the exteriors of the containers. Precautions for Correct Use If any damage is detected before unpacking the robot, request that the carrier’s agent be present when you unpack the container.
  • Page 129 Fasten the robot to the mounting surface using the 3-2-2 Mounting Procedure on page 3-3. Inspect the entire robot for damage before proceeding with further installation. If any damage is evident, contact your local OMRON representative. After the robot is fastened to the mounting surface, the unpacking procedure is complete.

  • Page 130: A-2 Repacking The Robot For Transport

    Appendices A-2 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 provided in this manual to repack the robot.

  • Page 131: Transportation And Storage Considerations

    Appendices A-3 Transportation and Storage Consider- ations This section provides details about transporting and storing your robot. Precautions for Safe Use • This equipment must be shipped and stored in a temperature-controlled environment, within the range –25 to +55°C. The recommended 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.

  • Page 132: A-4 I/O Signal Numbering

    Appendices A-4 I/O Signal Numbering Digital I/O for the eV+ programming language uses numeric signal numbers in the ranges provided below based on the I/O configuration of the system. A-4-1 Input Signal Numbering Use the table below to understand the digital input signal numbers. Input Type Switch Position Input Signal Numbers...

  • Page 133: A-5 Cable Pinouts

    Appendices A-5 Cable Pinouts Cable pinout information is provided below. A-5-1 XSYSTEM Cable Pinouts Use the following diagrams for XSYSTEM cable pinout information. i4L Robots User's Manual (I658)

  • Page 134: Xbeltio Adapter Cable Pinouts

    Appendices XUSR XSYSTEM PIN 5 PIN 11 PIN 12 PIN 14 PIN 5 PIN 30 PIN 6 PIN 10 PIN 7 PIN 26 PIN 8 PIN 12 PIN 9 PIN 1 PIN 14 PIN 28 PIN 10 PIN 3 PIN 13 PIN 14 PIN 43 PIN 4...

  • Page 135: A-5-3 Belt Encoder Y-Adapter Cable Pinouts

    Appendices XBELTIO BELT ENCODER PIN 2 (ENC1_A+) PIN 15 PIN 3 (ENC1_A-) PIN 7 PIN 11 (ENC1_B+) PIN 14 PIN 12 (ENC1_B-) PIN 6 PIN 19 (ENC1_Z+) PIN 13 PIN 9 PIN 1 PIN 8 PIN 1 PIN 20 (ENC1_Z-) PIN 5 PIN 4 (ENC2_A+) PIN 11...
  • Page 136 Appendices Encoder 1 (M12, Female, 8 PIN) Encoder 2 (M12, Female, 8 PIN) Encoder 1 BELT ENC. PIN 1 PIN 15 (ENC1_A+) PIN 8 PIN 3 PIN 7 (ENC1_A-) PIN 1 PIN 2 PIN 4 PIN 14 (ENC1_B+) PIN 5 PIN 6 (ENC1_B-) PIN 7 PIN 3...
  • Page 137 Index i4L Robots User's Manual (I658)
  • Page 138 Index Index Altitude................2-14 Emergency Stop..............1-5 Encoder Backup Batteries........1-4, 6-2, 6-7 End-of-Arm Tooling............3-5 Error Messages..............5-4 Base.................. 1-3 Ethernet Interface Port........1-4, 1-9, 2-15 Brake Release..............1-5 External Equipment Mounting........... 3-6 Brake Force................4-8 Release Button.............. 4-8 Remote Release............4-9 Faults.................5-2 Flyover................1-3 Front Panel..............1-5, 6-2 Cable Clearances..............
  • Page 139 Index XSYSTEM Cable............A-7 XUSR Connector............3-22 LED Indicator..............1-5, 4-7 XIO Termination Block............. 1-16 Mode Selection Switch............1-5 Model Numbers Controller Model Number..........1-14 Z-axis.................1-4 Robot Model Numbers..........1-14 Modes Automatic............... 4-3 Manual................4-3 Moment of Inertia...............2-8 Mounting Procedure..............3-3 Surface................3-3 Operating Temperature............2-14 Outer Link................
  • Page 140 Index i4L Robots User's Manual (I658)
  • Page 142 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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