Omron i4H User manual

i4H
Robots
User's Manual
i4-650H
i4-750H
i4-850H
I660-E-02

NOTE
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or other-
wise, without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because OMRON is constantly striving to improve its high-quality products, the information contained
in this manual is subject to change without notice. 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.
Trademarks
Company names and product names in this document are the trademarks or registered trademarks of
their respective companies.
Copyrights
Microsoft product screen shots reprinted with permission from Microsoft Corporation.

Introduction
Thank you for purchasing the i4H robot.
This manual is OMRON's original instructions describing the setup, operations, and user maintenance
of the i4H robot robot (herein also referred to as robot).
Please read this manual and make sure you understand the functionality and performance of the robot
before attempting to use it.
Keep this manual in a safe place where it will be available for reference during operation.
Intended Audience
This manual is intended for the following personnel, who must also have knowledge of factory automa-
tion (FA) systems and robotic control methods.
• Personnel in charge of introducing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of installing and maintaining FA systems.
• Personnel in charge of managing FA systems and facilities.
Applicable i4L Robot Models
This manual provides information for all i4H-series robot models..
When information varies between different robot models, details are provided. When information is
common to all robot models, an illustration of a single robot model is typically shown.
Units
Unless otherwise noted, length dimensions are in millimeters and all units are metric.
Introduction
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i4H Robots User's Manual (I660)

Manual Information
Page Structure
The following page structure is used in this manual.
A
B
C
C D
E
F
B
C
H
5 Installation
5 - 3
NY-series User's Manual (W555)
5-1 Unpack
5
5-1-1 Unpack Procedure
G
5-1 Unpack
This section provides details on how to unpack the Industrial Panel PC.
5-1-1 Unpack Procedure
1Check the package for damage.
If there is any visible damage:
• Take photos of the package and save them.
• Inform your supplier immediately.
2Open the package.
Ensure not to damage the contents.
3Ensure that all items are present.
Additional Information
Refer to 5-1-2 Items Supplied with the Product for the items supplied.
Note: This illustration is provided as a sample. It will not literally appear in this manual.
Item Explanation Item Explanation
A Level 1 heading E Special Information
B Level 2 heading F Manual name
C Level 3 heading G Page tab with the number of the main section
D Step in a procedure H Page number
Special Information
Special information in this manual is classified as follows:
Manual Information
2i4H Robots User's Manual (I660)

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.
This information is provided to increase understanding or make operation easier.
Version Information
Information on differences in specifications and functionality between different versions.
Manual Information
3
i4H Robots User's Manual (I660)

Manual Information
4i4H Robots User's Manual (I660)

Sections in this Manual
Sections in this Manual
5
i4H Robots User's Manual (I660)
Maintenance
Operation
Troubleshooting
Installation
Specifications
Overview
1
2
3
4
5
6
1
2
3
4
6
5
1
A
A
Appendices

CONTENTS
Introduction .............................................................................................................. 1
Intended Audience...........................................................................................................................................1
Applicable i4L Robot Models ...........................................................................................................................1
Units.................................................................................................................................................................1
Manual Information.................................................................................................. 2
Page Structure.................................................................................................................................................2
Special Information ..........................................................................................................................................2
Sections in this Manual ........................................................................................... 5
Terms and Conditions Agreement........................................................................ 10
Warranty and Limitations of Liability ..............................................................................................................10
Application Considerations ............................................................................................................................10
Disclaimers .................................................................................................................................................... 11
Safety Precautions................................................................................................. 12
Definition of Precautionary Information..........................................................................................................12
Symbols .........................................................................................................................................................12
Dangers .........................................................................................................................................................13
Warnings........................................................................................................................................................14
Cautions.........................................................................................................................................................17
Precautions for Safe Use ...................................................................................... 18
Precautions for Correct Use ................................................................................. 20
Regulations and Standards .................................................................................. 22
Software Licenses and Copyrights ...................................................................... 23
Related Manuals..................................................................................................... 24
Glossary.................................................................................................................. 25
Revision History..................................................................................................... 26
Section 1 Overview
1-1 Intended Use ..........................................................................................................................1-2
1-2 Robot Features.......................................................................................................................1-3
1-2-1 Robot System..............................................................................................................................1-3
1-2-2 Basic Robot Components ...........................................................................................................1-4
1-2-3 Other Components......................................................................................................................1-6
1-2-4 Front Panel..................................................................................................................................1-6
1-2-5 Connectors and Ports .................................................................................................................1-8
1-2-6 IP65 Rating ...............................................................................................................................1-11
1-2-7 Food-grade Rating ....................................................................................................................1-12
1-2-8 Electrostatic Discharge Protection ............................................................................................1-12
1-2-9 Cleanroom Rating .....................................................................................................................1-12
1-3 Information Labels...............................................................................................................1-13
1-3-1 Robot Label...............................................................................................................................1-13
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6i4H Robots User's Manual (I660)

1-3-2 Controller Label.........................................................................................................................1-13
1-4 Robot Configurations ..........................................................................................................1-15
1-4-1 i4-650H......................................................................................................................................1-15
1-4-2 i4-750H......................................................................................................................................1-15
1-4-3 i4-850H......................................................................................................................................1-15
1-5 Model Numbers ....................................................................................................................1-16
1-5-1 Robot Model Numbers ..............................................................................................................1-16
1-5-2 Controller Model Numbers ........................................................................................................1-16
1-6 Optional Hardware ...............................................................................................................1-17
1-6-1 IO Blox ......................................................................................................................................1-17
1-6-2 T20 Pendant..............................................................................................................................1-17
1-6-3 IPC Application Controller .........................................................................................................1-18
1-6-4 XIO Termination Block...............................................................................................................1-18
1-6-5 Optional Cables.........................................................................................................................1-19
1-6-6 eCobra Mount Adapter..............................................................................................................1-22
1-6-7 Camera Mounting Bracket and Adapter....................................................................................1-23
1-6-8 eCobra Tool Flange...................................................................................................................1-24
1-6-9 Bellows......................................................................................................................................1-24
1-6-10 Wall Mount Bracket ...................................................................................................................1-24
1-6-11 Integrated Pneumatic Valves.....................................................................................................1-25
1-6-12 Cable Seal.................................................................................................................................1-26
Section 2 Specifications
2-1 Physical Specifications .........................................................................................................2-2
2-1-1 Robot Overall Dimensions ..........................................................................................................2-2
2-1-2 Mounting Flange Dimensions......................................................................................................2-6
2-1-3 Tool Flange Dimensions..............................................................................................................2-6
2-1-4 Front Panel Dimensions..............................................................................................................2-7
2-1-5 eCobra Mount Adapter Dimensions ............................................................................................2-7
2-1-6 Camera Mounting Bracket and Adapter Dimensions ..................................................................2-8
2-1-7 Robot Weights.............................................................................................................................2-8
2-1-8 Wall Mount Bracket Dimensions .................................................................................................2-9
2-1-9 Cable Seal Dimensions...............................................................................................................2-9
2-2 Performance Specifications................................................................................................2-10
2-2-1 General Performance Information.............................................................................................2-10
2-2-2 Stopping Distances and Times..................................................................................................2-10
2-3 Electrical Specifications......................................................................................................2-14
2-3-1 Power Supply Specifications.....................................................................................................2-14
2-3-2 XIO I/O Specifications ...............................................................................................................2-14
2-3-3 TIO Specifications .....................................................................................................................2-15
2-3-4 Belt Encoder Specifications ......................................................................................................2-16
2-4 Environmental Specifications.............................................................................................2-17
2-5 Other Specifications ............................................................................................................2-18
2-5-1 Ethernet Communication Specifications ...................................................................................2-18
2-5-2 Connector and Port Specifications............................................................................................2-18
2-5-3 Mounting Screws and Torques..................................................................................................2-19
Section 3 Installation
3-1 Robot Installation Procedure................................................................................................3-3
3-2 Mounting the Robot ...............................................................................................................3-4
3-2-1 Robot Mounting Surface .............................................................................................................3-4
3-2-2 Mounting Procedure....................................................................................................................3-4
3-3 Installing End-of-Arm Tooling...............................................................................................3-6
3-4 Installing Optional Equipment ..............................................................................................3-7
CONTENTS
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i4H Robots User's Manual (I660)

3-4-1 Mounting External Equipment to the Robot ................................................................................3-7
3-4-2 Tool Ethernet Connector Wiring ..................................................................................................3-7
3-4-3 USER Connector Wiring .............................................................................................................3-8
3-4-4 Bellows Installation Procedure ....................................................................................................3-8
3-4-5 Pneumatic Valve Kit Installation Procedure...............................................................................3-15
3-5 Adjustable Hardstop Details ...............................................................................................3-20
3-5-1 Joint 1 Adjustable Hardstops ....................................................................................................3-20
3-6 System Cable Installation ...................................................................................................3-22
3-6-1 System Cable Overview............................................................................................................3-22
3-6-2 System Cable Installation Procedure ........................................................................................3-24
3-7 Connecting Digital I/O .........................................................................................................3-26
3-7-1 XIO Connector Signals and Wiring ...........................................................................................3-26
3-7-2 TIO Connector Signals and Wiring............................................................................................3-30
3-7-3 IO Blox Connections .................................................................................................................3-32
3-8 Connecting Pneumatic Equipment ....................................................................................3-33
3-8-1 Pass-through Ports ...................................................................................................................3-33
3-8-2 Pneumatic Valve Kit ..................................................................................................................3-33
3-9 Installing Safety Equipment................................................................................................3-35
3-9-1 Installing the Front Panel ..........................................................................................................3-35
3-9-2 Safety Circuits ...........................................................................................................................3-36
3-10 Supplying Power and Ground ............................................................................................3-43
3-10-1 Grounding the System ..............................................................................................................3-43
3-10-2 DC Connections ........................................................................................................................3-44
3-10-3 AC Connections ........................................................................................................................3-45
3-11 Verifying Installation............................................................................................................3-46
3-11-1 Mechanical Checks ...................................................................................................................3-46
3-11-2 System Cable Checks...............................................................................................................3-46
3-11-3 Safety Equipment Checks.........................................................................................................3-46
3-11-4 Switch Position Checks.............................................................................................................3-48
Section 4 Operation
4-1 Connecting to the Robot .......................................................................................................4-2
4-1-1 Initial Connection Procedure .......................................................................................................4-2
4-2 Payload and Acceleration Considerations ..........................................................................4-3
4-3 Robot Control Modes ............................................................................................................4-4
4-3-1 Manual Mode ..............................................................................................................................4-4
4-3-2 Automatic Mode ..........................................................................................................................4-4
4-4 Enabling and Disabling the Robot .......................................................................................4-6
4-4-1 Robot High Power Operations ....................................................................................................4-6
4-5 LED Light Ring .......................................................................................................................4-8
4-6 LCD Display............................................................................................................................4-9
4-6-1 LCD Display Status Messages....................................................................................................4-9
4-7 Brake Operation ...................................................................................................................4-10
4-7-1 Built-in Brake Release Button ...................................................................................................4-10
4-7-2 Remote Brake Release .............................................................................................................4-11
4-8 Manually Jogging the Robot...............................................................................................4-12
4-9 Robot Positioning ................................................................................................................4-13
4-9-1 Joint Zero Position ....................................................................................................................4-13
4-9-2 Ready Position ..........................................................................................................................4-13
4-9-3 Right-Left Arm Configurations...................................................................................................4-14
CONTENTS
8i4H Robots User's Manual (I660)

Section 5 Troubleshooting
5-1 Fault Detection .......................................................................................................................5-2
5-2 Emergency Stop Troubleshooting .......................................................................................5-3
5-3 Error Messages ......................................................................................................................5-4
Section 6 Maintenance
6-1 Periodic Maintenance ............................................................................................................6-2
6-1-1 Periodic Maintenance Overview..................................................................................................6-2
6-1-2 Checking Safety Functions .........................................................................................................6-3
6-1-3 Checking Fastener Torques ........................................................................................................6-4
6-1-4 Checking Safety and Warning Labels .........................................................................................6-4
6-1-5 Checking for Oil Leaks ................................................................................................................6-4
6-1-6 Lubricating Joint 3 .......................................................................................................................6-4
6-1-7 Replacing Encoder Batteries.......................................................................................................6-6
6-1-8 Harmonic Drive Oil Change ........................................................................................................6-7
6-1-9 Cleaning the Robot .....................................................................................................................6-8
6-1-10 Bellows Inspection ......................................................................................................................6-8
6-1-11 Bellows Replacement Procedure ................................................................................................6-8
6-2 Non-periodic Maintenance ..................................................................................................6-12
6-2-1 Replacing the Tool Flange.........................................................................................................6-12
6-2-2 Replacing the Amplifier Chassis ...............................................................................................6-13
6-2-3 Replacing the Outer Link Cover ................................................................................................6-17
Appendix
A-1 Cable Seal Kit Installation Procedure ................................................................................. A-2
A-2 Repacking the Robot for Transport..................................................................................... A-4
A-3 Transportation and Storage Considerations...................................................................... A-5
A-4 I/O Signal Numbering ........................................................................................................... A-6
A-4-1 Input Signal Numbering.............................................................................................................. A-6
A-4-2 Output Signal Numbering........................................................................................................... A-6
A-5 Cable Pinouts ........................................................................................................................ A-7
A-5-1 XSYSTEM Cable Pinouts........................................................................................................... A-7
A-5-2 XBELTIO Adapter Cable Pinouts ............................................................................................... A-9
A-5-3 Belt Encoder Y-adapter Cable Pinouts....................................................................................... A-9
A-5-4 USER Cable Pinouts................................................................................................................ A-10
A-5-5 TIO Cable Pinouts.....................................................................................................................A-11
A-6 Parts List.............................................................................................................................. A-12
Index
CONTENTS
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i4H Robots User's Manual (I660)

Terms and Conditions Agreement
Warranty and Limitations of Liability
Warranty
•Exclusive Warranty
Omron’s exclusive warranty is that the Products will be free from defects in materials and workman-
ship for a period of twelve months from the date of sale by Omron (or such other period expressed
in writing by Omron). Omron disclaims all other warranties, expressed or implied.
•Limitations
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT
NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF
THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE
PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.
Omron further disclaims all warranties and responsibility of any type for claims or expenses based
on infringement by the Products or otherwise of any intellectual property right.
•Buyer Remedy
Omron’s sole obligation hereunder shall be, at Omron’s election, to (i) replace (in the form originally
shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-com-
plying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal
to the purchase price of the non-complying Product; provided that in no event shall Omron be re-
sponsible for warranty, repair, indemnity or any other claims or expenses regarding the Products un-
less Omron’s analysis confirms that the Products were properly handled, stored, installed and main-
tained and not subject to contamination, abuse, misuse or inappropriate modification. Return of any
Products by Buyer must be approved in writing by Omron before shipment. Omron Companies shall
not be liable for the suitability or unsuitability or the results from the use of Products in combination
with any electrical or electronic components, circuits, system assemblies or any other materials or
substances or environments. Any advice, recommendations or information given orally or in writing,
are not to be construed as an amendment or addition to the above warranty.
See http://www.omron.com/global/ or contact your Omron representative for published information.
Limitations of Liability
OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CON-
SEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY
WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT,
WARRANTY, NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of Omron Com-
panies exceed the individual price of the Product on which liability is asserted.
Application Considerations
Terms and Conditions Agreement
10 i4H Robots User's Manual (I660)

Suitability for Use
Omron Companies shall not be responsible for conformity with any standards, codes or regulations
which apply to the combination of the Product in the Buyer’s application or use of the Product. At Buy-
er’s request, Omron will provide applicable third party certification documents identifying ratings and
limitations of use which apply to the Product. This information by itself is not sufficient for a complete
determination of the suitability of the Product in combination with the end product, machine, system, or
other application or use. Buyer shall be solely responsible for determining appropriateness of the par-
ticular Product with respect to Buyer’s application, product or system. Buyer shall take application re-
sponsibility in all cases.
NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND IN-
STALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Programmable Products
• 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.
Disclaimers
Performance Data
Data presented in Omron Company websites, catalogs and other materials is provided as a guide for
the user in determining suitability and does not constitute a warranty. It may represent the result of
Omron’s test conditions, and the user must correlate it to actual application requirements. Actual per-
formance is subject to the Omron’s Warranty and Limitations of Liability.
Change in Specifications
Product specifications and accessories may be changed at any time based on improvements and oth-
er reasons. It is our practice to change part numbers when published ratings or features are changed,
or when significant construction changes are made. However, some specifications of the Product may
be changed without any notice. When in doubt, special part numbers may be assigned to fix or estab-
lish key specifications for your application. Please consult with your Omron’s representative at any
time to confirm actual specifications of purchased Product.
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.
Terms and Conditions Agreement
11
i4H Robots User's Manual (I660)

Safety Precautions
Definition of Precautionary Information
The following notation is used in this manual to provide precautions required to ensure safe usage of
the i4H robot. The safety precautions that are provided are extremely important to safety.
Always read and heed the information provided in all safety precautions.
The following notation is used.
DANGER
Identifies an imminently hazardous situation which, if not avoid-
ed, is likely to result in serious injury, and might result in fatality
or severe property damage.
WARNING
Indicates a potentially hazardous situation which, if not avoid-
ed, could result in death or serious injury. Additionally, there
may be severe property damage.
CAUTION
Indicates a potentially hazardous situation which, if not avoid-
ed, may result in minor or moderate injury, or property damage.
Symbols
The circle and slash symbol indicates operations that you must not do. The specific opera-
tion is shown in the circle and explained in text.
This example indicates prohibiting disassembly.
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in text.
This example indicates a precaution for electric shock.
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in text.
This example indicates a general precaution.
The filled circle symbol indicates operations that you must do.
The specific operation is shown in the circle and explained in text.
This example shows a general precaution for something that you must do.
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in text.
This example indicates a precaution for high temperatures.
Safety Precautions
12 i4H Robots User's Manual (I660)

Dangers
DANGER
General
An i4H robot can cause serious injury or death, or damage to itself and other equipment,
if the following safety precautions are not observed:
•All personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Robot Safety Guide (Cat. No. I590), and complete a training
course for their responsibilities in regard to the robot.
•All personnel who design the robot system must read this guide, read the Robot
Safety Guide (Cat. No. I590), and must comply with all local and national safety regu-
lations for the location in which the robot is installed.
•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.
•The user is responsible for providing safety barriers around the robot to prevent any-
one from accidentally coming into contact with the robot when it is in motion.
•Power to the robot and its power supply must be locked out and tagged out before any
maintenance is performed.
•When the robot or robotic equipment is not investigated in conjunction with a system
work cell, the instructions shall call attention to the following: the interlocked portion of
barrier shall be installed, applied, and maintained so that it has the capability of being
easily unlocked from the inside of the safeguarded space, with or without power avail-
able, when the possibility of full body access exists.
i4H robots are not collaborative robots. They require a dedicated work area that will pre-
vent personnel from coming into contact with them during operation.
The normal and intended use of these robots does not create hazards.
These robots have been designed and constructed in accordance with the relevant re-
quirements of IEC 60204-1.
These robots are intended for use in parts assembly and material handling for payloads
up to 15.0 kg.
Refer to the Robot Safety Guide (Cat. No. I590) for details on the intended use of our
robots.
These robots are intended for industrial use only.
Perform a risk assessment before using.
These robots are not intended for:
•Use in the presence of ionizing or non-ionizing radiation.
•Use in potentially explosive atmospheres.
•Use in medical or life saving applications.
•Use in a residential setting.
Installation
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. We strictly prohibit installation, commissioning, or opera-
tion of any robot without adequate safeguards. These must be compliant with applicable
local and national standards.
Safety Precautions
13
i4H Robots User's Manual (I660)

The placement of safety controls shall avoid requiring a person to enter a hazardous
area to actuate them.
Controls shall be located outside of the safeguarded space, except for certain controls
such as emergency stops or a teach pendant, where based on a risk assessment they
may be located within the safeguarded space.
After installing the robot, you must test it before you use it for the first time. Failure to do
this could cause death, serious injury, or equipment damage.
Failure to ground robot-mounted equipment or tooling that uses hazardous voltages
could lead to injury or fatality of a person touching the end-effector during an electrical
fault.
Any High Power push-buttons must be installed outside of the robot's workspace.
Warnings
WARNING
General
The instructions for operation, installation, and maintenance given in this document must
be strictly observed.
If air pressure is present, disconnect it from the robot when servicing end-of-arm tooling
or other pneumatic components to prevent unsecured pneumatic air lines from acciden-
tally injuring personnel.
Do not move the robot links if the robot is not secured. Failure to comply could result in
the robot falling and causing either personnel injury or property damage.
Installation
Ensure that installation and post-installation checks of the product are performed by per-
sonnel in charge who possess a thorough understanding of the machinery to be instal-
led.
The AC power installation must be performed by a skilled, and instructed person. For
more information on this refer to the Robot Safety Guide (Cat. No. I590). During the AC
power installation, unauthorized third parties must be prevented from turning the power
on through the use of fail-safe lockout measures.
Ensure compliance with all local and national safety and electrical codes for the installa-
tion and operation of the robot system.
Safety Precautions
14 i4H Robots User's Manual (I660)

Provide appropriately-sized Branch Circuit Protection and Lockout / Tagout Capability in
accordance with the National Electrical Code and any local codes.
Use a crane and straps to lift the robot by the inner arm and controller handle. Never lift
the robot by the quill. 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. The E-Stop's push button must comply with ISO 13850 (Clause
5.5.2).
Disabling the High Power button violates IEC 60204-1. Do not alter its functionality.
If a robot is mounted to a surface with inadequate stiffness, damage to the z-axis quill or
other mechanical components can result from excessive oscillation during operation.
The robot can fall over if it is not properly secured with mounting hardware.
The robot must be installed to avoid interference with buildings, structures, utilities, other
machines and equipment that may create trapping or pinch points. It must be installed in
accordance with Standard for Robots and Robotic Devices – Safety Requirements for In-
dustrial Robots – Part 2: Robot Systems and Integration, ISO 10218-2.
Ensure that interconnecting cables or pneumatic lines are routed away from the robot
workspace.
To reduce the risk of fire or electric shock, install the robot in a controlled environment
relatively free of contaminants.
Do not remove the shipping brackets or move the robot links until the robot has been se-
cured to its mounting surface. Failure to comply could result in the robot falling and caus-
ing either personnel injury or property damage.
Operation
Before starting the operation of equipment, always confirm that the safety equipment of
the robot works properly. If a malfunction of the safety equipment is detected, follow the
troubleshooting procedure.
Use the total weight of the end-of-arm tooling and the payload to stay within the payload
rating of the robot. Ensure that the system never exceeds that maximum payload.
Perform a full risk assessment which includes the end-of-arm tooling and any payload to
prevent crushing, shearing, payload ejection, entanglement, stabbing or puncture haz-
ard.
Releasing a brake may cause the quill, tool flange, end-of-arm tooling, and payload to
drop. To prevent possible injury to personnel or damage to the equipment, make sure
that the equipment is supported when releasing the brake and verify that the end-of-arm
tooling and payload are clear of all obstructions.
Safety Precautions
15
i4H Robots User's Manual (I660)

All signals that pass-through the USER connectors are not associated with any robot
controls, emergency stop circuits, or robot power. Implement appropriate safety meas-
ures to ensure that these signals are not active during emergency stop conditions or
while the robot is powered OFF.
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.
Whenever possible, perform Manual mode operations with all personnel outside the
workspace.
The stopping time and distance, or angle, of a robot joint from initiation of a stop signal is
not negligible and must be taken into account when designing and applying safeguarding
devices.
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 injury and equip-
ment damage.
Never run a robot system with all jumpers installed. This would leave the system with no
E-Stops.
Do not use the robot in hazardous environments (explosive gas, and oil mist).
The robot shall be operated within its specified temperature range to ensure proper oper-
ation.
The robot's physical hardstop devices are not intended to withstand repeated use. If this
occurs, the hardstop may become damaged. Implement proper programming and config-
uration of joint range limits to prevent hardstop impacts.
Maintenance
Do not use organic solvents to clean any part of the robot. Organic solvents might dam-
age electronics resulting in an unsafe operating state that could cause injury or damage
to equipment.
You must perform the Lockout and tagout procedure prior to servicing the robot.
The access covers on the robot are not interlocked. You must turn OFF and disconnect
the power before the covers of the robot are removed.
The procedures and replacement of the parts mentioned in this manual must be per-
formed only by the skilled or instructed persons.
Safety Precautions
16 i4H Robots User's Manual (I660)

Cautions
CAUTION
The design and installation of the complete system must comply with the safety stand-
ards and regulations in the country of use. The integrators of the robot should under-
stand the safety laws and regulations in their countries and prevent major hazards from
occurring in the complete system.
Safety Precautions
17
i4H Robots User's Manual (I660)

Precautions for Safe Use
• The Joint 3 quill and the tool flange are not grounded to protective earth. If hazardous voltages are
present at any user-supplied robot-mounted equipment or tooling, you must install a ground connec-
tion from that equipment or tooling to the ground point on the robot base.
• Output 8 can be assigned to indicate the robot's High Power state. When High Power is enabled,
this output will turn ON. When High Power is not enabled, this output will be OFF. This is not a safe-
ty-rated means of indicating a High Power state and should only be used for monitoring the robot
status. Use the ACE Software to make this configuration if needed.
• Do not apply the AC power until all installation steps are complete and verified and all safety meas-
ures are in place.
• High power cannot be enabled unless all safety circuits are satisfied.
• The LED light ring 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 connector.
• The braking mechanism operates passively. If 24 VDC Control Power is removed from the system,
the brake mechanism will automatically activate. 24 VDC Control Power must be supplied to release
the brake. To prevent possible damage to the equipment, remove any payload from the end-of-arm
tooling, make sure that Joint 3 is supported while releasing the brake, and verify that the end-of-arm
tooling or other installed equipment is clear of all obstructions.
• To comply with ISO 10218-1 when using a remote brake release button, ensure the brake release
button displays a warning label to indicate that the z-axis of the robot may fall due to gravity if the
brake is released.
• The High Power indicator must be operational to satisfy safety requirements.
• You can contribute to resource conservation and protecting the environment by the proper disposal
of Waste Electronics and Electrical Equipment (WEEE). All electrical and electronic products should
be disposed of separately from the municipal waste system according to local ordinances using des-
ignated collection facilities.
• 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. Special handling may apply. Refer to https://dtsc.ca.gov for more
information.
• Dispose of any battery that has been dropped or otherwise subjected to excessive shock. Batteries
that have been subjected to shock may leak if they are used.
• Batteries may leak, rupture, heat, or ignite. Never short-circuit, charge, disassemble, heat, or incin-
erate a battery or subject it to strong shock.
• 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.
• Do not connect user-supplied Manual / Automatic contacts or other control signals in parallel with
the Front Panel switch contact. This would violate the Single Point of Control principle and might al-
low Automatic mode to be selected while an operator is in the cell.
Precautions for Safe Use
18 i4H Robots User's Manual (I660)