Omron eCobra 600 User manual

I593-E-05
eCobra 600, 800 and 800 Inverted Robots
User’s Guide

Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, Inc., assumes no responsibility for any errors or omissions in the doc-
umentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us
in preparation of future documentation. Please submit your comments to: [e-mail].
Copyright 2017 - 2019 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America

Table of Contents
Chapter 1: Introduction 11
1.1 Product Description 11
eCobra Robot Models 12
eAIB (Amplifiers in Base) 13
1.2 eCobra Robot Features And Options 14
SmartController EX 15
ePLC Connect Software 15
IO Blox 15
SmartVision MX 15
T20 Pendant 15
Intelligent Force Sensing 15
ACE PackXpert Process Manager 15
1.3 How Can I Get Help? 16
Related Manuals 16
Chapter 2: Safety 17
2.1 Dangers, Warnings, and Cautions 17
Alert Levels 17
Alert Icons 17
Falling Hazards 17
Special Information 18
2.2 What to Do in an Emergency/Abnormal Situation 18
Releasing the Brakes 18
Releasing an E-Stop 18
Emergency Stop Circuit and Buttons 19
General Hazards 19
2.3 Safety Precautions 19
User's Responsibilities 19
Qualification of Personnel 20
2.4 Robot Behavior 21
Hardstops 21
Limiting Devices 21
Singularities 21
2.5 Intended and Non-intended Use 21
Intended Use 21
Non-Intended Use 22
Robot Modifications 22
2.6 Additional Safety Information 22
Manufacturer’s Declaration of Incorporation 22
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Table of Contents
Robot Safety Guide 23
T20 Manual Control Pendant (Option) 23
Disposal 23
Chapter 3: Robot Installation 25
3.1 Installation Overview 25
3.2 Transport and Storage 25
3.3 Unpacking and Inspecting the Equipment 26
Before Unpacking 26
Upon Unpacking 26
3.4 Repacking for Relocation 26
3.5 Environmental and Facility Requirements 27
3.6 Mounting an Upright eCobra Robot 27
Mounting Surface 28
Mounting Procedure 29
3.7 Mounting an eCobra 800 Inverted Robot 30
Mounting Surface 30
Mounting Procedure 30
3.8 Mounting the Front Panel 32
3.9 Connectors on Robot Interface Panel (eAIB) 33
Chapter 4: System Installation 35
4.1 System Cables, without SmartController EX 35
List of Cables and Parts 36
Cable Installation Overview 38
4.2 System Cables, with SmartController EX 40
Installing a SmartController EX Motion Controller 41
List of Cables and Parts 41
Cable Installation Overview 43
4.3 OptionalCables 44
XIOBreakout Cable 44
DB9 Splitter Cable 44
eAIB XBELTIOAdapterCable 44
SmartController EX Belt Encoder Y-Adapter Cable 44
4.4 ACE Software 49
User-supplied PC 49
Installing ACESoftware 49
4.5 Connecting 24 VDC Power to Robot 50
Specifications for 24 VDC Power 50
24 VDC Mating Connector 51
Creating 24 VDC Cable 52
Connecting 24 VDC Cable 52
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Table of Contents
4.6 Connecting 200-240 VAC Power to Robot 54
Specifications for AC Power 54
AC Mating Connector 58
Creating the 200-240 VAC Cable 58
Connecting AC Power Cable 59
4.7 Grounding the Robot System 59
Grounding the Robot Base 59
Grounding Robot-Mounted Equipment 60
4.8 Configuring a PLC 60
4.9 Installing User-Supplied Safety Equipment 62
Emergency Stop Circuits 68
Remote Manual Mode 70
User Manual/Auto Indication 70
User High Power On Indication 70
Remote High Power On/Off Control 71
High Power On/Off Lamp 71
Remote Front Panel or User-Supplied Control Panel Usage 71
Remote Pendant Usage 72
Chapter 5: System Operation 73
5.1 Robot Status LED Description 73
5.2 Status Panel Fault Codes 73
Status Panel 74
5.3 Brakes 80
Brake Release Button 80
Remote Brake Release Feature 81
5.4 Front Panel 81
5.5 Connecting Digital I/O to the System 83
Optional I/O Products 83
Default Digital I/O Signal Configuration 84
eAIB XIO Connector Signals 86
XIO Input Signals 87
XIO Output Signals 90
XIO Breakout Cable 93
5.6 Starting the System for the First Time 94
Verifying Installation 95
Turning on Power 96
Starting ACE 96
Enabling High Power 97
Verifying E-Stop Functions 97
Verify Robot Motions 97
5.7 Learning to Program the eCobra Robot 97
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Table of Contents
Chapter 6: Maintenance 99
6.1 Field-Replaceable Parts 99
6.2 Periodic Maintenance Schedule 99
6.3 Warning Labels 100
6.4 Checking Safety Systems 103
6.5 Checking Robot Mounting Bolts 103
6.6 Checking for Oil Leakage 103
6.7 Lubricating Joint 3 104
6.8 Replacing the eAIB Chassis 107
Removing the eAIB Chassis 107
Installing a New eAIB Chassis 109
6.9 Commissioning a System With An eAIB 110
Safety Commissioning Utilities 110
E-Stop Configuration Utility 112
E-Stop Verification Utility 113
Teach Restrict Configuration Utility 113
Teach Restrict Verification Utility 114
6.10 Replacing a MicroSD Card 115
Removing a MicroSD Card from an eAIB 115
Installing a MicroSD Card into an eAIB 117
6.11 Replacing the Encoder Battery Pack 117
Battery Replacement Time Periods 118
Battery Replacement Procedure 118
6.12 Changing the Lamp In the Front Panel High-Power Indicator 119
Chapter 7: Optional Equipment Installation 123
7.1 Installing End-Effectors 123
7.2 Removing and Installing the Tool Flange 123
Removing the Flange 123
Installing the Flange 124
7.3 User Connections on the Robot 125
User Air Lines 125
User Electrical Lines 126
7.4 Internal User Connectors 126
SOLND Connector 127
OP3/4 Connector 128
EOAPWR Connector 129
Internal User Connector Output Specifications 129
ESTOP Connector 130
7.5 Mounting Locations for External Equipment 132
7.6 Installing the Robot Solenoid Kit 132
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Table of Contents
Tools Required 133
Signal Setup 133
134
Installation 134
Testing 139
7.7 Installing the Camera Bracket Kit 140
Tools Required 140
Procedure 141
7.8 Installing Adjustable Hardstops 142
Joint 1 Adjustable Hardstops 142
Joint 2 Adjustable Hardstops 146
Chapter 8: Technical Specifications 153
8.1 Dimension Drawings 153
8.2 Robot Specifications 166
Physical 166
Performance 167
Stopping Distances and Times 167
Key to Graphs 168
Hardstops and Softstops 174
Chapter 9: IP65 Option 175
9.1 eCobra 800 Robots IP65 Classification 175
9.2 Installing Cable Seal Assembly 176
Cable Seal Identification 176
Installation Procedure 176
9.3 Robot Outer Link Cover Removal and Reinstallation 178
Cover Removal Procedure 178
Cover Reinstallation Procedure 180
9.4 Customer Requirements 181
Sealing the Tool Flange 181
Pressurizing the Robot 182
9.5 User Connectors 183
User Electrical and DeviceNet 183
User Air Lines 184
Robot Solenoid Option 184
9.6 Maintenance 185
IP65 Bellows Replacement 185
9.7 Dimension Drawing for Cable Seal Assembly 186
Chapter 10: Cleanroom Robots 189
Cleanroom Specifications 189
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Table of Contents
10.1 Connections 190
10.2 Requirements 190
10.3 Exclusions and Incompatibilities 191
10.4 Cleanroom Maintenance 191
Bellows Replacement 191
Lubrication 192
8 eCobra User's Guide 14402-000 Rev. F

Revision History
Revision
code Date Revised Content
01 June,
2016
Original release.
02 February,
2017
lFixed default signal #s when no SmartController EX is present
lUpdated Safety chapter, misc. regulatory.
lClarified text about eAIB's RS-232 port when using a SmartCon-
troller EX.
03 August,
2017
lClarified the use of "axis" and "joint".
lRemoved duplicate row in Chapter 8 table.
lMinor clarifications to IP65 Option chapter to differentiate
between upright and inverted robots.
04 April,
2018
lUpdated safety chapter and alert levels throughout manual.
lUpdated recommended power supply part numbers, T20 part
numbers, and XMCPjumper cable part numbers.
lError reporting and Line E-Stop clarification.
lUpdate ACE software disk to ACEsoftware media.
lCorrected "SmartVisionEX" to "SmartVision MX" in system
cable drawing.
05 March,
2019
lAdded WEEE Icon and Disposal section to Safety chapter.
lRemoved www.adept.com.
lAdded English condition to www.ia.omron.com.
lRevised encoder battery replacement interval.
lUpdated Safety chapter.
lUpdated status code table in Chapter 5: Operation.
lUpdated illustrations with call-outs and tables for translation
compatibility. Other minor illustration improvements applied.
lRemoved references to obsolete sDIOunit.
lCorrections applied to Chapter 4: System Installation.
lAdded new figures to illustrate all encoder cable configurations
and pinouts in Chapter 4: System Installation.
lRemoved Class 1 cleanroom note in Chapter 10: Cleanroom
Robots.
lAdjusted vacuum flow rates and air supply specifications for reg-
ular and inverted robots in Chapter 10: Cleanroom Robots.
lAdjusted text in Emergency Stop Circuits section in Chapter 4:
System Installation.
lAdded a note about typical IO Blox configurations in Chapter 5:
System Operation.
lDual-Robot Configuration Guide renamed to Single and Multiple
Robot Configuration Guide.
14402-000 Rev. F eCobra User's Guide 9

Chapter 1: Introduction
1.1 Product Description
eCobra robots are four-joint SCARA industrial robots (Selective Compliance Assembly Robot
Arm). Joints 1, 2, and 4 are rotational, Joint 3 is translational. See Figure 1-2.
NOTE: The descriptions and instructions in this manual apply to the eCobra
600, eCobra 800, and eCobra 800 Inverted robots. When there are differences,
such as in dimensions and work envelopes, the different models will be covered
separately.
Figure 1-1. eCobra 800 Robot
By adding a SmartController EX or a PLC, the eCobra series robots replace the previous sCobra
and Cobra ePLC series robots, so this manual replaces previous eCobra, sCobra, and Cobra
ePLC User Guides.
14402-000 Rev. F eCobra User's Guide 11

12 eCobra User's Guide 14402-000 Rev. F
1.1 Product Description
1
2
6
54
3
Figure 1-2. Robot Joint Motions - eCobra 600 Robot Shown
Table 1-1. Robot Joint Descriptions
Item Description
1 Joint 1
2 Joint 2
3 Joint 3
4 Joint 4
5 Inner Link
6 Outer Link
eCobra Robot Models
There are three tiers of eCobra robots, with 600 and 800 mm upright models and an 800 mm
Inverted robot in each tier. In increasing order of performance and features, they are:
leCobra Lite
leCobra Standard
leCobra Pro

Chapter 1: Introduction
eCobra robots of any given size and orientation are identical physically for each of the three
tiers. The Pro models offer the fastest performance and the most features and connectivity. The
Lite models offer the least. All nine models are covered in this manual.
All eCobra robots will typically be connected to a user-supplied PC running the ACE software.
eCobra robots can optionally be used with a SmartController EX motion controller, if more fea-
tures and connectivity are needed. A SmartVision MX industrial PC can be added for more vis-
ion support. The eCobra Standard and eCobra Pro robots can be used with a user-supplied
PLC and the ePLCConnect software option.
eAIB (Amplifiers in Base)
eCobra robots use an eAIB amplifier. The robots are programmed and controlled using the
eAIB. The eAIB, embedded in the robot's base, contains the amplifiers and full servo control for
the eCobra robots. The eAIB also provides the platform for running the eV+ OS and language.
eAIBFeatures
lOn-board digital I/O
lLow EMI for use with noise sensitive equipment
lNo external fan, for quiet robot operation
l8 kHz servo rate to deliver low positional errors and superior path following
lSine wave commutation to lower cogging torque and improve path following
lDigital feed-forward design to maximize efficiency, torque, and velocity
lTemperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
lHardware-based E-Stop and Teach Restrict controls
For improved safety relative to European standards implemented in 2012
The eAIB fits all eCobra robots.
1
Figure 1-3. (1) eAIB Amplifier on eCobra Robot
14402-000 Rev. F eCobra User's Guide 13

14 eCobra User's Guide 14402-000 Rev. F
1.2 eCobra Robot Features And Options
1.2 eCobra Robot Features And Options
The eAIB controller provides varying levels of vision support and connectivity. Some applic-
ations might call for more, in which case you could add a SmartController EX and/or a
SmartVision MX industrial PC.
Feature eCobra Lite eCobra
Standard eCobra Pro SmartController EX Option
Vision - Yes Yes -
on-the-fly - - Yes -
I/O - max212/8 44/40 76/72 524/520
XIO 12/8 12/8 12/8 eAIB +12/8
IEEE1394 2 2 2 eAIB + 3
IOBlox option - 8/8 x max 4 8/8 x max 8 -
RS-422/485 - - - 1
RS-232 - 11113
DeviceNet - - - Option
Conveyors
tracked
- - 214
PLC support - Yes Yes -
ePLCI/O - - Yes -
PackXpert - Yes Yes Yes
Force Sensing - Yes1Yes1-
T20 Pendant
option
Yes Yes Yes n/a
IP65 option Yes Yes Yes n/a
Cleanroom
option
Yes Yes Yes n/a
Max Robots 1 1 1 4
Dual Robots - - - Yes
Max Joints 4 4 4 16
Pass-through,
J1 to J2
5 air
24 user electric
1 DeviceNet
5 air
24 user electric
1 DeviceNet
5 air
24 user electric
1 DeviceNet
-
1Requires eAIB XBELT IO Adapter cable.
2More I/Ocan be attained using DeviceNet and combinations of RS- ports, if needed.

Chapter 1: Introduction
SmartController EX
The SmartController EX motion controller can coordinate up to 4 robots, increasing the number
of robot joints to 16 from the eCobra’s 4. It increases the I/O available, raises the number of
serial ports by 3, and provides for tracking up to 4 additional conveyors.
NOTE: Since the eAIB has only one RS-232 port, adding a SmartController EX to
the RS-232 port renders the port unusable. If using eV+, "SERIAL:0" will access
the eAIB's RS-232 port.
TheSmartController EX supports the DeviceNet option, and allows for the use of third-party
vision systems. One RS-485 port is available.
The SmartController EX is covered in the SmartController EX User's Guide.
ePLC Connect Software
The ePLC Connect software allows programming and operation of an eCobra robot directly
from a PLC, using the software as an interface between the PLC and the robot. Refer to ePLC
Connect 3.0 Software User's Guide.
IO Blox
Up to 8 IO Blox units can be added to increase the available I/O ports by 8 inputs and 8 out-
puts per unit. The IOBlox does not require a SmartController EX. Refer to the IO Blox User’s
Guide.
SmartVision MX
The SmartVision MX is an industrial PC that provides vision-oriented connectivity, as well as
extra I/O. It can drive up to 4 Gigabit and 4 USB 3.0 cameras. The Gigabit ports are PoE, so no
extra power is needed to the cameras. Refer to the SmartVision MX User's Guide.
T20 Pendant
The T20 pendant provides manual control of an eCobra robot. This is generally used when
teaching pick and place locations. Refer to the T20 Pendant User's Guide.
NOTE: Omron Adept Technologies, Inc. does not offer a cableless (wireless)
pendant.
Intelligent Force Sensing
The Intelligent Force Sensing system is a hardware and software package that allows eCobra
robots to react to sensed forces and moments at the tool flange, reducing force overshoot and
stopping time when forces or moments exceed preset thresholds. Refer to the Intelligent Force
Sensing System User's Guide.
ACE PackXpert Process Manager
PackXpert provides a point-and-click interface for configuring and programming the workcell.
The PackXpert Process Manager is the recommended method for programming most applic-
ations. Refer to the ACE User’s Guide.
14402-000 Rev. F eCobra User's Guide 15

16 eCobra User's Guide 14402-000 Rev. F
1.3 How Can I Get Help?
1.3 How Can I Get Help?
Refer to the corporate website:
http://www.ia.omron.com
Related Manuals
This manual covers the installation, operation, and maintenance of an eCobra robot system.
For additional manuals covering programming the system, reconfiguring installed com-
ponents, and adding optional components, see the following table.
Table 1-2. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for robots.
ACE User’s Guide Instruction for the use of the ACE software.
SmartController EX User's
Guide
Instructions for use of the optional SmartController EX
motion controller.
SmartVision MX User's Guide Instructions for use of the optional SmartVision MX indus-
trial PC.
T20 Pendant User's Guide Describes the use of the optional T20 manual control
pendant.
IO Blox User’s Guide Describes the IO Blox product.
Single and Multiple Robot Con-
figuration Guide
Contains cable diagrams and configuration procedures for a
single and multi-robot system.

Chapter 2: Safety
2.1 Dangers, Warnings, and Cautions
Alert Levels
There are three levels of alert notation used in our manuals. In descending order of import-
ance, they are:
!
DANGER: Identifies an imminently hazardous situation which, if not
avoided, is likely to result in serious injury, and might result in fatality or
severe property damage.
!
WARNING: Identifies a potentially hazardous situation which, if not avoided,
will result in minor or moderate injury, and might result in serious injury, fatal-
ity, or significant property damage.
!
CAUTION: Identifies a potentially hazardous situation which, if not avoided,
might result in minor injury, moderate injury, or property damage.
Alert Icons
The icon that starts each alert can be used to indicate the type of hazard. These will be used
with the appropriate signal word - Danger, Warning, or Caution - to indicate the severity of the
hazard. The text following the signal word will specify what the risk is, and how to avoid it.
Icon Meaning Icon Meaning
!
This is a generic alert
icon. Any specifics on
the risk will be in the
text following the sig-
nal word.
This identifies a hazardous electrical situ-
ation.
Falling Hazards
!
WARNING: PERSONALINJURYORPROPERTYDAMAGERISK
If mounted incorrectly, the robot can fall over and cause serious injury to per-
sonnel or damage to itself or other equipment.
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18 eCobra User's Guide 14402-000 Rev. F
2.2 What to Do in an Emergency/Abnormal Situation
Safety Barriers
To protect personnel from coming in contact with robot unintentionally or objects entering
robot’s operation zone, install user-supplied safety barriers in the workcell.
Special Information
There are several types of notation used to call out special information.
IMPORTANT: Information to ensure safe use of the product.
NOTE: Information for more effective use of the product.
Additional Information: Offers helpful tips, recommendations, and best prac-
tices.
Version Information: Information on differences in specifications for different
versions of hardware or software.
2.2 What to Do in an Emergency/Abnormal Situation
Press any E-Stop button (a red push-button on a yellow background) and then follow the
internal procedures of your company or organization for an emergency situation. If a fire
occurs, use a type D extinguisher: foam, dry chemical, or CO2.
Releasing the Brakes
In case of entrapment of a person by the robot, or any other emergency of abnormal situation,
the robot can be manually moved to a safe state without high voltage electric power. However
only qualified personnel who have read and understood this manual and the Robot Safety
Guide should manually move the robot. See Brake Release Button on page 80.
!
WARNING: PERSONALINJURYRISK
eCobras are not collaborative robots. They require a dedicated work area that
will prevent personnel from coming into contact with them during operation.
Releasing an E-Stop
!
CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK
If the robot’s E-Stop is triggered, ensure that the cause of the E-Stop is resolved,
and all surrounding areas are clear before releasing the E-Stop.
After the E-Stop button has been manually released, the robot will wait until the motors are
manually enabled.
There are two ways to enable the motors:
lEnable power through ACE software installed on your PC.
ll Press the ROBOTPOWER button on the Pendant.

Chapter 2: Safety
Once the motors are enabled, the robot will wait two seconds and then resume commanded
motion, if there is adequate space to maneuver.
Emergency Stop Circuit and Buttons
The E-Stop provided complies with ISO 10218-1 (Clause 5.5.2), with stop category 1 (per IEC
60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d
per ISO 13849.
If you design your own front panel, it must meet the requirements of ISO13849, and be at least
PL-d. The E-Stop button must comply with IEC 60204-1 and ISO13850, Clause 5.5.2.
If you choose to use your own E-Stop buttons, they must meet the requirements of IEC 60204-1
and ISO 13850, Clause 5.5.2.
General Hazards
IMPORTANT: The following situations could result in injury or damage to the
equipment.
lDo not place objects on the robot.
lDo not exceed the maximum payload capacity.
lDo not exceed the maximum recommended moment of Inertia, speed, and rotation lim-
its. See Technical Specifications on page 153.
lDo not drop the robot, put weights on it or otherwise operate it irresponsibly.
lDo not use unauthorized parts.
2.3 Safety Precautions
!
WARNING: PERSONALINJURYORPROPERTYDAMAGERISK
An eCobra robot can cause serious injury or death, or damage to itself and
other equipment, if the safety precautions in this manual are not observed.
WARNING: ELECTROCUTIONRISK
During maintenance, disconnect AC power from the robot, and install a lock-
out tag-out to prevent anyone from reconnecting power.
User's Responsibilities
Safe use of the eCobra robot is your responsibility. To ensure compliance with safety rules and
regulations:
lAll personnel who install, operate, teach, program, or maintain an eCobra robot system
must read this guide, read the Robot Safety Guide, and complete a training course for
their responsibilities in regard to the robot.
14402-000 Rev. F eCobra User's Guide 19

20 eCobra User's Guide 14402-000 Rev. F
2.3 Safety Precautions
lAll personnel who design an eCobra robot system must read this guide, read the Robot
Safety Guide, and must comply with all local and national safety regulations for the loc-
ation in which the robot is installed.
Figure 2-1. Read Manual and Impact Warning Labels
lThe eCobra robot system must not be used for purposes other than described in Inten-
ded Use on page 21. Contact Omron Adept Technologies, Inc. if you are not sure of the
suitability for your application.
lThe environment must be suitable for safe operation of the robot.
lThe user is responsible for providing safety barriers around the robot to prevent anyone
from accidentally coming into contact with the robot when it is in motion.
lPower to the robot and its power supply must be locked out and tagged out before any
maintenance is performed.
lThe eCobra Robots must be well maintained, so that their control and safety functions
continue to work properly.
Qualification of Personnel
It is the end-user’s responsibility to ensure that all personnel who will work with or around
robots have attended an appropriate Omron training course and have a working knowledge of
the system. The user must provide the necessary additional training for all personnel who will
be working with the system.
As noted in this and the Robot Safety Guide, certain procedures should be performed only by
skilled or instructed persons. For a description of the level of qualification, we use the standard
terms:
lSkilled persons have technical knowledge or sufficient experience to enable them to
avoid the dangers, electrical and/or mechanical
lInstructed persons are adequately advised or supervised by skilled persons to enable
them to avoid the dangers, electrical and/or mechanical
All personnel must observe industry-prescribed safety practices during the installation, oper-
ation, and testing of all electrically-powered equipment.
IMPORTANT: Before working with the robot, every entrusted person must con-
firm that they:
lHave the necessary qualifications
lHave received the guides (both this user’s guide, and the Robot Safety Guide)