Omron eCobra 600 User manual

eCobra 600 and 800 Robot
with EtherCAT
User's Manual
I653-E-02

Copyright Notice
The information contained herein is the property of OMRON Robotics and Safety Technologies, Inc., and
shall not be reproduced in whole or in part without prior written approval of OMRON Robotics and
Safety Technologies, Inc.. The information herein is subject to change without notice and should not be
construed as a commitment by OMRON Robotics and Safety Technologies, Inc. The documentation is
periodically reviewed and revised.
OMRON Robotics and Safety Technologies, Inc., assumes no responsibility for any errors or omissions in
the documentation.
Copyright OMRON Robotics and Safety Technologies, Inc. by OMRON Corporation. All rights
reserved.
Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in Japan and
other countries for OMRON factory automation products.
EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
ODVA, CIP, DeviceNet, and EtherNet/IP are trademarks of ODVA.
Other company names and product names in this document are the trademarks or registered trademarks
of their respective companies.
Created in the United States of America.

Table of Contents
Chapter 1: Introduction 9
Related Manuals 9
1.1 Intended Audience 10
1.2 Robot Overview 12
Robot Amplifier and Controller 13
IP65 and Cleanroom Versions 16
Robot Features 16
Robot Links and Joints 17
Robot Connections 17
iCS-ECAT Robot Interface Panel 24
1.3 Robot Options 25
Solenoid Valve Kit 25
End of Arm Break-away Sensor 26
IO Blox 27
Optional I/O Items 27
T20 Pendant 28
IPC Application Controller 28
Front Panel 29
Camera Bracket Kit 31
Adjustable Hardstops 32
Optional Cables 33
Chapter 2: Safety 37
2.1 Dangers, Warnings, and Cautions 37
Alert Levels 37
Alert Icons 37
Special Information 38
2.2 Safety Precautions 38
2.3 What To Do In An Emergency 39
Stopping the Robot 39
Fire Response 39
Entrapment and Brake Release Button 39
2.4 Robot Behavior 39
Hardstops 39
Limiting Devices 39
Singularities 39
2.5 Intended Use of the Robot 40
2.6 Additional Safety Information 40
Manufacturer’s Declarations 40
Robot Safety Guide 40
T20 Pendant (Option) 40
2.7 Disposal 41
2.8 How Can I Get Help? 41
24402-000 Rev B eCobra 600 and 800 Robots with EtherCAT 3

Chapter 3: Robot Installation 43
3.1 Robot Installation Overview 43
Basic Installation Steps 43
3.2 Mounting an eCobra Robot 43
Mounting Surface 44
Mounting Procedure 44
3.3 Install the Tool Flange 46
Tool Flange InstallationProcedure 47
3.4 Installing the Front Panel 47
Connecting the Front Panel 47
Front Panel Schematic 48
3.5 Installing User-Supplied Safety Equipment 49
Contacts on XUSR Connector 49
Contacts on XFP Connector 51
Remote Pendant Signals on the XMCPConnector 51
E-Stop Circuits on XUSR and XFP Connectors 53
Emergency Stop Circuits 54
Remote Manual Mode 56
User Manual/Auto Indication 56
Remote High Power ON / OFF Control 56
Using a User-Supplied Control Panel 57
Remote Pendant Usage 58
3.6 Setting the EtherCATNodeID 58
Setting the EtherCATNode ID UsingHardware Switches 59
Chapter 4: System Cable Installation 61
4.1 Basic System Cable Layout 61
List of Cables and Parts 62
Cable Installation Steps 64
XBELT IO Belt Encoder Y Adapter Cable 65
4.2 Connecting Digital I/O to the System 67
Digital I/O Signal Configuration 68
XIO Connector Signals 76
4.3 Connecting the 24 VDC Cable to the Robot 78
24 VDC Power Supply Connector 78
Making the 24 VDC Power Supply Cable 79
Connecting the 24 VDC Cable 79
4.4 Connecting 200-240 VAC Power Cable 81
AC Power Diagrams 81
AC Power Supply Connector 83
Making the 200-240 VAC Power Supply Cable 83
Connecting the AC Power Supply Cable 84
4.5 Grounding the Robot System 84
Grounding the Robot Base 85
Grounding Robot-Mounted Equipment 85
Chapter 5: Optional Equipment Installation 87
5.1 Installing End-Effectors 87
4 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B

24402-000 Rev B eCobra 600 and 800 Robots with EtherCAT 5
5.2 Mounting Locations for External Equipment 88
5.3 Installing the Solenoid Valve Kit 89
Solenoid Valve Kit Installation Procedure 90
Testing Solenoid Valve Kit Installation 93
5.4 Installing the Camera Bracket Kit 93
Tools Required 93
Procedure 93
5.5 Installing Adjustable Hardstops 95
Joint 1 Adjustable Hardstop Installation 95
Joint 2 Adjustable Hardstop Installation 96
Chapter 6: System Operation 99
6.1 Verifying Installation 99
Mechanical Checks 99
System Cable Checks 99
User-Supplied Safety Equipment Checks 100
Switch Position Checks 101
6.2 Robot Status LED and Display Panel 101
General Robot States 101
6.3 EtherCAT Communications Description 102
SystemBehavior with EtherCATCommunication Errors 103
6.4 Brakes 103
Brake Release Button 103
Remote Brake Release Feature 104
6.5 Robot Control Modes 104
Manual Mode 104
Automatic Mode 105
Operation Mode 105
Service Mode 105
6.6 Manually Jogging the Robot 106
6.7 Enabling Robot High Power 106
High Power Safety Timeout 106
High Power and Faults 107
High Power Request Methods 107
6.8 Disabling Robot High Power 108
Chapter 7: Maintenance 111
7.1 Periodic Maintenance 111
Periodic Maintenance Schedule 111
Checking Safety Systems 111
Checking Robot Mounting Bolts and CoverPlates 112
Checking Safety and Warning Labels 112
Checking for Oil Leaks 114
Lubricating Joint 3 115
Replacing the Encoder Battery Pack 117
7.2 Non-Periodic Maintenance 119
Field-Replaceable Parts 120
Remove the Tool Flange 120

Replacing the iCS-ECAT Amplifier Chassis 121
Remove and Replace a MicroSD Card 125
Change Front Panel High-Power ON Lamp 126
Chapter 8: Technical Specifications 131
8.1 Robot Physical Dimension Drawings 131
8.2 General Robot Specifications 136
8.3 Performance Specifications 137
General Performance Information 137
Stopping Distances and Times 138
Hardstop and Softstop Limits 144
8.4 Electrical Specifications 145
Internal Connection Specifications 145
External Connection Specifications 145
8.5 Environment and Facility Specifications 147
8.6 Other Specifications 148
Solenoid Valve Kit Specifications 148
ConnectorSpecifications 148
Power Consumption Specifications 149
8.7 Tool Flange Dimensions 149
8.8 Front Panel Dimensions 150
8.9 EtherCAT Communications Specifications 151
Chapter 9: IP65 Option Considerations 153
9.1 IP65 Option Classification 153
9.2 User Requirements to Meet IP65 Rating 153
Sealing the Tool Flange 154
Pressurizing the Robot 154
9.3 Cable Seal Assembly 156
Cable Seal Identification 156
Dimension Drawing for Cable Seal Assembly 158
9.4 Remove and Reinstall Outer Link Cover 159
Outer Link Cover Removal Procedure 159
Outer Link Cover Reinstallation Procedure 160
9.5 IP65 RobotConnections 162
Joint 1 Connections 162
Pneumatic Pass-through Connections 163
Robot Solenoid Option Consideration for IP65 Robots 163
9.6 IP65 Option Maintenance 164
IP65 Bellows Replacement 164
Chapter 10: Cleanroom Option Considerations 167
10.1 Cleanroom Option Classification 167
10.2 User Requirements to Meet Cleanroom Rating 167
10.3 Cleanroom Robot Connections 168
Robot Solenoid Option Consideration for Cleanroom Robots 168
10.4 Cleanroom Option Maintenance 169
Cleanroom Bellows Replacement 169
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24402-000 Rev B eCobra 600 and 800 Robots with EtherCAT 7
Chapter 11: Status Codes 171
11.1 Robot Display Panel 171
11.2 Status Codes Table 171
Appendix 177
A.1 Unpacking and Inspecting the Equipment 177
Before Unpacking 177
After Unpacking 177
Inspecting the Equipment 177
A.2 Repacking for Relocation 177
A.3 Transportation and Storage 177

8 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
Revision History
Revision
Code ReleaseDate Details
A July, 2020 Original release
B August, 2020 Minor corrections and updates

Chapter 1: Introduction
This manual contains information that is necessary to install and use eCobra 600 and 800
Robots with EtherCAT. Please read this manual and make sure you understand the func-
tionality, installation, and performance of the robot before attempting to use it.
Related Manuals
Use the following related manuals for reference.
Table 1-1. Related Manuals
Manual Description
Robot Safety Guide (Cat. No.
I590)
Contains safety information for OMRON industrial robots.
Sysmac Studio Robot Integ-
rated System Building Func-
tion with Robot Integrated
CPU Unit Operation Manual
(Cat. No. W595)
Describes the operating procedures of the Sysmac Studio.
Sysmac Studio Robot Integ-
rated System Building Func-
tion with IPC Application
Controller Operation Manual
(Cat. No. W621)
Describes the operating procedures of the IPC
ApplicationController.
eV+3 User'sManual (Cat.
No. I651)
Provides a description of the eV+ programming language
and functionality.
eV+3 Keyword
ReferenceManual (Cat. No.
I652)
Provides reference to eV+ Keyword use and functionality.
NJ-series Robot Integrated
CPU Unit User's Manual
(Cat. No. O037)
Provides information that is necessary to use the robot con-
trol function of the NJ-series CPU Unit.
IPC Application Controller
User’s Manual (Cat. No.
I632)
Provides information that is necessary to use the robot con-
trol function of the IPC Application Controller.
[[[Undefined variable
Primary.T20User'sGuide]]]
Describes the use of the optional T20 manual control
pendant.
IO Blox User’s Guide (04638-
000)
Describes the IO Blox product, its connections, and input/out-
put signals.
24402-000 Rev B eCobra 600 and 800 Robots with EtherCAT 9

10 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
1.1 Intended Audience
This manual is intended for the following personnel, who must also have knowledge of com-
mon programming practices and robotic control methods.
lPersonnel in charge of introducing FA systems.
lPersonnel in charge of designing FA systems.
lPersonnel in charge of installing and maintaining FA systems.
lPersonnel in charge of managing FA systems and facilities.

12 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
1.2 Robot Overview
The robots detailed in this manual are four-joint Selective Compliance Assembly Robot Arm
(SCARA) industrial robots. These next-generation robots are designed for a variety of auto-
mated applications where high speed and precision is required.
Built-in EtherCAT communications allow this robot to operate together with EtherCATslaves,
other Sysmac products, and the Sysmac Studio AutomationSoftware to achieve optimum func-
tionality and ease of operation.
NA-series
PT
Teaching pendant
T20
(with built-in EtherCAT
communications)
Slave
Terminal
Vision sensor
OMRON
robot
Robot Integrated CPU Unit
NJ501-R
I/O control
external devices
1S-series Servo Drives
G5-series Servo Drives
Server Relational database
USB
Camera
FH-series Vision
Systems
Robots controllable by NJ Robotics function
EtherCAT
Application Controller
Sysmac Studio
EtherNet/IP
Front Panel
Safety
devices Encoder,
digital I/O
Figure 1-1. EtherCATSystem Topology
These robots are offered with two different arm reaches to provide different working envelopes.
The eCobra 600 Robot has a 600 mm radial reach and the eCobra 800 Robot has an 800 mm
radial reach, measured from Joint 1 to Joint 4. Refer to Robot Physical Dimension Drawings on
page 131

Chapter 1: Introduction
eCobra 600 eCobra 800
Figure 1-2. eCobra 600 and 800 Models
There are two tiers of eCobra robots; the eCobra Pro and the eCobra Standard. The Pro and
Standard tiers are physically identical. The Pro models offer faster performance and more fea-
tures and connectivity than the Standard models. Refer to Robot Features on page 16 for more
information.
NOTE: The descriptions and instructions in this manual apply to all eCobra
600 and 800 Robots with EtherCAT. If there are differences based on type or
options, this manual will provide details in the associated sections.
Robot Amplifier and Controller
The robot's amplifier and controller is integrated in the robot's base and referred to as the
Internal Control System, or iCS-ECAT.
The iCS-ECAT unit contains power amplifiers, safety circuitry, and I/O as well as full tra-
jectory, kinematic, and servo robot control hardware.
This robot is intended to operate within an EtherCAT network. It receives commands and con-
trol signals from the NJ-series Robot Integrated CPU Unit over an EtherCAT network.
24402-000 Rev B eCobra 600 and 800 Robots with EtherCAT 13

14 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
Figure 1-3. eCobra Robot with iCS-ECAT Highlighted
Internal Control System
The iCS-ECAT has a dedicated microprocessor to communicate, coordinate, and execute servo
commands. The iCS-ECAT unit receives eV+ commands from the NJ-series Robot Integrated
CPU Unit and processes these commands to execute robots motions and other functions.
The iCS-ECAT contains the robot interface panel which provides connections for power sup-
ply, peripheral devices such as the front panel, pendant, and user-supplied safety equipment,
and EtherCATnetwork cables. The robot interface panel also has switches for setting an expli-
cit EtherCATNode address and operating mode as well as LED's to indicate operating status.
Additional Information: Refer to iCS-ECAT Robot Interface Panel on page 24 for
more information.

Chapter 1: Introduction
Figure 1-4. iCS-ECAT
iCS-ECAT Features
The iCS-ECAT unit has the following general features.
lIntegrated EtherCAT communications for distributed robot control.
lIntegrated digital I/O.
lDual 1 GHz Cortex A9 ARM Processors, 1 GB SDRAM.
l8 GB MicroSD card.
lLow EMI for use with noise sensitive equipment.
lNo external fan.
l8 kHz servo rate to deliver low positional errors and high-performance path following.
lDigital feed-forward control to maximize efficiency, torque, and positioning.
lInternal temperature sensors for hardware protection and troubleshooting.
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16 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
IP65 and Cleanroom Versions
eCobra robots are also available with options for IP65 or Class 10 Cleanroom ratings. These
options provide additional protection from dust and fluid, and are supplied with a bellows
device on the z-axis quill.
The following images show the IP65 version and the Cleanroom version.
Figure 1-5. IP65 Version (left), Cleanroom Version (right)
Robot Features
The following table lists the varying features and functionality that are available with different
system configurations.
Feature eCobra Standard eCobra Pro
Vision Support Yes Yes
Robot position latching No Yes
Local I/O (max. input / output) 44/40 76/72
XIO (max. input / output) 12/8 12/8
IOBlox (max. input / output) 32/32, max. 4 units per robot 64/64, max. units 8 per
robot1
Conveyor tracking No Yes (2 max.)2
T20 Pendant option Yes Yes
IP65 option Yes (only for eCobra 800) Yes
Cleanroom option Yes Yes
Pass-through, J1 to J2 5 air lines
24 user electrical contacts
1 DeviceNet pass-through
1Requires XBELTIO Cablefor 2nd group of 4 units.
2Requires XBELTIO Cable.

Chapter 1: Introduction
Robot Links and Joints
The robot links and joints are described below.
Joints 1, 2, and 4 are rotational. Joint 3 is translational.
Figure 1-6. Robot Joint Motions - eCobra 600 Robot Shown
Key Meaning Key Meaning
A Joint 1 (Shoulder) D Joint 4 (Wrist)
B Joint 2 (Elbow) E Outer link
C Joint 3 (Z) F Inner link
Robot Connections
This section describes the various external and internal ports and connectors that are available
on the standard eCobra robot..
NOTE: Some connections may differ on robots with the IP65 or Cleanroom
options. Refer to IP65 Option Considerations on page 153 and Cleanroom Option
Considerations on page 167 for more information.
The external connections include:
liCS-ECAT robot interface panel connections
lPneumatic pass-through ports
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18 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
lElectrical pass-through connections
lIO Blox connector
The internal connections include:
lSolenoid connector for the optional SolenoidValve Kit
lConnector for a second set of optional robot hand valve solenoids(OP3/4)
lEnd-of-arm power connector (EOAPWR)
lEnd of Arm Break-away Sensor Connector
Pneumatic Pass-through Ports
The pneumatic pass-through ports on the back of Joint 1 are typically used for end-effector con-
trol. Internal air lines are routed internally through the robot to another set of matching con-
nectors on the top of the outer link as shown below.
Additional Information: Refer to Technical Specifications on page 131 for more
information.
Figure 1-7. Pneumatic Pass-through ports on the back of Joint 1 (left) and Joint 2 (right)
Table 1-2. Pneumatic Pass-Through Port Descriptions
Item Description
A / C 4 mm ports
B / D 6 mm ports
Electrical Pass-through Connections
The electrical pass-through connectors on the back of Joint 1 are typically used for end-effector
sensing and control. Internal harnesses are routed through the robot to another set of mating
connectors on the top of the outer link as shown below.
Additional Information: Refer to Technical Specifications on page 131 for more
information.

Chapter 1: Introduction
Figure 1-8. User Electrical Connectors on Joint 1 (left) and Joint 2 (right)
Item Description
A DeviceNet pass-through
B General purpose electrical pass-through.
IO Blox Connector
The IOBlox connector on Joint 1 provides an interface to addIOBlox expansion I/O modules
to a robot.
NOTE: Refer to Connecting Digital I/O to the System on page 67 and the IO Blox
User’s Guide (04638-000) for more information.
Figure 1-9. IOBlox Connector
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20 eCobra 600 and 800 Robots with EtherCAT 24402-000 Rev B
Solenoid Connector
The robot has been pre-wired to accommodate a bank of two 24 VDC solenoid valves. Power
for the internally mounted solenoid valves is accessible with a connector mounted inside the
outer link cover. This 4-pin connector provides the output signals for internally mounted solen-
oid valves. The solenoid connector location and pin details are provided below.
Additional Information: An optional Solenoid Valve Kit (part number 02853-
000) is available for use with the internal solenoid connector. Refer to Robot
Options on page 25 and Technical Specifications on page 131 for more inform-
ation.
Figure 1-10. Solenoid Connector Location
Table 1-3. Solenoid Connector Pinout
Pin # Description Pin Location
1 Output 3001 (+24 VDC)
2 0 VDC
3 Output 3002 (+24 VDC)
4 0 VDC
OP3/4 Connector
This 4-pin connector provides the output signals for a second set of optional robot hand valve
solenoids or other user-supplied devices. The OP3/4 connector location and pin details are
provided below.