Omron Hornet 565 User manual

I596-E-03
Hornet 565 Robot
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 2015 - 2017 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

Hornet 565 Robot User's Guide, 14608-000 Rev F
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Revision History
Revision
code Date Revised Content
01 June,
2016
Original release
02 January,
2016
Updated graphics with platform oriented correctly, showing current
drive shaft. Updated to OAT logo on status panel, front panel. Updated
safety chapter, minor changes to stopping distance graph section in
Technical Specifications. Fixed rotation of tool flange in Fig. 5-2, added
graphic for J4 alignment.
03 July,
2017
Updated drawing of tool flange to show 41.14 mm pilot bore that was
added since original release.

Table of Contents
Chapter 1: Introduction 11
1.1 Hornet 565, Product Description 11
eAIB Amplifier 11
Hornet 565 Base 12
Inner Arms 12
Ball Joints, Outer Arms 13
Platforms 13
SmartController EX 15
1.2 Installation Overview 16
1.3 How Can I Get Help? 17
Corporate Addresses 17
Related Manuals 17
Chapter 2: Safety 19
2.1 Warnings, Cautions, and Precautions 19
2.2 What to Do in an Emergency/Abnormal Situation 19
Stopping the Robot 19
Fire Response 19
Entrapment and Brake Release Button 20
2.3 Safety Precautions 20
2.4 Robot Behavior 21
Hardstops 21
Limiting Devices 21
Singularities 21
2.5 Intended Use of the Robots 21
2.6 Additional Safety Information 21
Manufacturer’s Declaration of Incorporation 22
Robot Safety Guide 22
Emergency Stop Circuit and Buttons 22
Manual Control Pendant 22
Chapter 3: Robot Installation 23
3.1 Transport and Storage 23
3.2 Unpacking and Inspecting the Hornet 565 23
Before Unpacking 23
Upon Unpacking 23
Unpacking 23
3.3 Repacking for Relocation 25
3.4 Environmental and Facility Requirements 25
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Table of Contents
3.5 Mounting Frame 25
Robot-to-Frame Considerations 26
Mounting 26
3.6 Mounting the Robot Base 27
Robot Orientation 27
Mounting Surfaces 27
Mounting Procedure 27
Install Mounting Hardware 28
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft 29
Aligning the Platform with the Base 29
Attaching the Outer Arms 30
Attaching the Theta Drive Shaft 34
3.8 Mounting the Front Panel 35
3.9 End-Effectors 35
Attaching an End-Effector 35
Aligning an End-Effector 35
Grounding 36
Accessing Vacuum 36
Routing End-effector Lines 36
Chapter 4: System Installation 39
4.1 System Cables, eAIB Only (no SmartController EX) 39
List of Cables and Parts 40
Cable Installation Overview 41
Optional Cables 42
4.2 System Cables, with SmartController EX 43
Installing a SmartController EX Motion Controller 43
List of Cables and Parts 44
Cable Installation Overview 45
Less Common Cables 45
4.3 System Cables for Systems with Belt Encoders 46
List of Cables and Parts 46
Cable Installation Overview 47
Pinouts for eAIB XBELT IO Adapter 48
4.4 ACE Software 49
User-supplied PC 49
Installing ACESoftware 49
4.5 Robot Interface Panel 50
4.6 Connecting 24 VDC Power to Robot 51
Specifications for 24 VDC Robot and Controller Power 51
Details for 24 VDC Mating Connector 51
Procedure for Creating 24 VDC Cable 52
Installing 24 VDC Robot Cable 52
4.7 Connecting 200-240 VAC Power to Robot 53
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Table of Contents
Specifications for AC Power 54
Details for AC Mating Connector 56
Procedure for Creating 200-240 VAC Cable 56
Installing AC Power Cable to Robot 57
4.8 Grounding the Hornet 565 57
Grounding Robot-Mounted Equipment 57
Grounding Robot Base to Frame 58
4.9 Installing User-Supplied Safety Equipment 59
Emergency Stop Circuits 63
Remote Manual Mode 65
User Manual/Auto Indication 65
User High Power On Indication 65
Remote High Power On/Off Control 65
High Power On/Off Lamp 66
Remote Front Panel or User-Supplied Control Panel Usage 66
Remote Pendant Usage 67
Chapter 5: System Operation 69
5.1 Robot Status Display Panel 69
5.2 Status Panel Fault Codes 70
5.3 Using the Brake-Release Button 70
Robot Brakes 70
Brake-Release Button 71
5.4 Optional Front Panel 72
5.5 Connecting Digital I/O to the System 74
I/O on the eAIB 74
I/O with an Optional SmartController EX 74
5.6 Using Digital I/O on eAIB XIO Connector 76
Optional I/O Products 78
XIO Input Signals 78
XIO Output Signals 80
XIO Breakout Cable 82
5.7 Starting the System for the First Time 84
Verifying Installation 84
Turning on Power and Starting ACE 85
Enabling High Power 86
Verifying E-Stop Functions 86
Aligning the Platform and J4 Motor 86
Verify Robot Motions 87
5.8 Robot Motions 88
Straight-line Motion 88
Containment Obstacles 88
5.9 Learning to Program the Hornet 565 88
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Table of Contents
Chapter 6: Options 89
6.1 Tall Frame Adapters 89
6.2 ePLC Connect 90
Configuration 90
Setting the Robot IP Address 90
Configuring the Omron PLC 92
Enabling High Power 92
6.3 SmartVision MX Industrial PC 92
6.4 SmartController EX Motion Controller 92
6.5 sDIO Module 92
6.6 IOBlox I/ODevice 92
6.7 eAIB XBELT IOAdapter Cable 92
6.8 Cable Inlet Box 93
Overview 93
Installation Procedure 94
6.9 Intelligent Force Sensor 99
6.10 Ball Stud Locks 99
Installing a Ball Stud Lock 100
Removing a Ball Stud Lock 101
Chapter 7: Maintenance 103
7.1 Cleaning 103
Water Shedding 103
Wash-Down 103
Chemical Compatibility 104
7.2 Periodic Maintenance Schedule 104
7.3 Checking Labels 106
Warning Labels 106
Informative Labels 107
7.4 Checking Safety Systems 107
7.5 Checking Robot Mounting Bolts 108
7.6 Checking for Gear Drive Oil Leakage 108
7.7 Checking Fan Operation 109
7.8 Theta Drive Shaft 110
Replacing the Drive Shaft Bushings 110
Removing the Drive Shaft 113
Installing a Drive Shaft 114
Aligning the Platform and J4 Motor 115
7.9 Replacing the Encoder Battery Pack 115
7.10 Non-Periodic Maintenance 118
7.11 Changing the Front Panel High-Power Indicator Lamp 118
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7.12 Replacing a Platform 120
7.13 Replacing a Ball Joint Insert 120
7.14 Replacing Outer Arm Spring Assemblies 120
7.15 Replacing the eAIB Chassis 124
Removing the eAIB Chassis 124
Installing a New eAIB Chassis 128
7.16 Commissioning a System with an eAIB 128
Safety Commissioning Utilities 129
E-Stop Configuration Utility 130
E-Stop Verification Utility 131
Teach Restrict Configuration Utility 131
Teach Restrict Verification Utility 132
Chapter 8: Technical Specifications 135
8.1 Dimension Drawings 135
8.2 Robot Specifications 139
8.3 Environmental Specifications 139
Operating 139
Shipping and Storage 139
8.4 Payload Specifications 140
Payload 140
Torque 140
8.5 Performance 141
Repeatability, Unidirectional 141
Cycle Times 141
Power Consumption 141
Stopping Time and Distance 142
Payload Mass vs. Acceleration 148
Payload Inertia vs. Acceleration 148
8.6 Robot Mounting Frame 149
Chapter 9: Environmental Concerns 155
9.1 Ambient Environment 155
9.2 Cleanroom Classification 155
9.3 Design Factors 155
Robot Base and Components 156
Inner Arms 156
Ball Joints 156
Outer Arms 156
Spring Assemblies 157
Platforms 157
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