Omron iX3 565 User manual

iX3 Robot with EtherCAT
User's Manual
I655-E-01

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 10
Robot Amplifier and Controller 11
IP65 Versions 14
Robot Base 14
Outer Arms and Ball Joints 14
Inner Arms 15
Platforms 15
Robot Motions and Obstacles 16
1.3 Robot Options 16
IO Blox 16
Optional I/O Items 17
T20 Pendant 17
IPC Application Controller 18
Front Panel 19
Optional Cables 20
Tall Frame Mounting Adapters 23
Cable Inlet Box 23
Ball Stud Locks 24
Chapter 2: Safety 25
2.1 Dangers, Warnings, and Cautions 25
Alert Levels 25
Alert Icons 25
Falling Hazards 25
Special Information 26
2.2 What to Do in an Emergency or Abnormal Situation 26
Stopping the Robot 26
Entrapment and Brake Release Button 26
Releasing an E-Stop 26
2.3 Safety Precautions 27
User's Responsibilities 27
General Hazards 27
Qualification of Personnel 28
2.4 Robot Behavior 28
Hardstops 28
Limiting Devices 29
Singularities 29
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2.5 Intended and Non-intended Use 29
Intended Use of the Robots 29
Non-Intended Use 29
2.6 Additional Safety Information 30
Manufacturer’s Declaration of Incorporation 30
Robot Safety Guide (Cat. No. I590) 30
Emergency Stop Circuit and Buttons 30
2.7 How CanIGet Help? 30
T20 Manual Control Pendant (Option) 31
Disposal 31
Chapter 3: Robot Installation 33
3.1 Robot Installation Overview 33
Basic Installation Steps 33
3.2 Mounting an iX3 Robot 34
Mounting Frame Overview 34
Robot Orientation 35
Mounting Surfaces 35
Mounting Procedure 35
3.3 Attaching the Theta Drive Shaft 36
Theta Drive Shaft Attachment Procedure 37
3.4 Installing the Platform 37
Align the Platform with the Robot Base 38
Attach the Outer Arms 39
3.5 Installing the FrontPanel 41
Mounting the Front Panel 41
Connecting the Front Panel 41
3.6 Installing User-Supplied Safety Equipment 43
Contacts on XUSR Connector 44
Contacts on XFP Connector 45
Remote Pendant Signals on the XMCPConnector 45
E-Stop Circuits on XUSR and XFP Connectors 46
Emergency Stop Circuits 48
Remote Manual Mode 50
User Manual/Auto Indication 50
Remote High Power ON / OFF Control 51
Using a User-Supplied Control Panel 52
Remote Pendant Usage 52
3.7 Setting the EtherCATNodeID 52
Setting the EtherCATNode ID UsingHardware Switches 53
3.8 Installing End-of-Arm Tooling 55
3.9 Installing a Cable Inlet Box 55
3.10 Installing or Removing Ball Stud Locks 58
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Installing Ball StudLocks 58
Removing Ball StudLocks 59
Chapter 4: System Cable Installation 61
4.1 Basic System Cable Layout 61
List of Cables and Parts 63
Cable Installation Steps 64
XBELT IO Belt Encoder Y Adapter Cable 65
4.2 Connecting Digital I/O to the System 68
Digital I/O Signal Configuration 68
XIO Connector Signals 75
4.3 Connecting the 24 VDC Cable to the Robot 77
24 VDC Power Supply Connector 77
Making the 24 VDC Power Supply Cable 77
Connecting the 24 VDC Cable 78
4.4 Connecting AC Power Cable 79
AC Power Diagrams 80
AC Power Supply Connector 81
Making the AC Power Supply Cable 82
AC Power Supply Cable ConnectionProcedure 83
4.5 Grounding the Robot System 84
Grounding the Robot Base 84
Chapter 5: System Operation 87
5.1 Verifying Installation 87
Mechanical Checks 87
System Cable Checks 87
User-Supplied Safety Equipment Checks 88
Switch Position Checks 89
5.2 Robot Status LED and Display Panel 89
General Robot States 90
5.3 EtherCAT Communications Description 90
5.4 Brakes 91
Brake Release Button 91
Remote Brake Release Feature 92
5.5 Robot Control Modes 93
Manual Mode 93
Automatic Mode 93
Operation Mode 93
Service Mode 94
5.6 Manually Jogging the Robot 94
5.7 Enabling Robot High Power 94
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High Power Safety Timeout 95
High Power and Faults 95
High Power Request Methods 95
5.8 Disabling Robot High Power 97
Chapter 6: Maintenance 99
6.1 Periodic Maintenance Schedule 99
6.2 Non-periodic Maintenance Schedule 101
6.3 Cleaning 101
Wash Down 101
Water Shedding 102
6.4 Checking Safety Systems 102
High Power Indicator Check 102
6.5 Checking Labels 103
Warning Labels 103
Information Labels 104
6.6 Checking for Gear Drive Leaks 105
6.7 Checking Fan Operation 106
6.8 Theta Drive Shaft Bushing Replacement 106
Theta Drive Shaft Bushing Replacement Procedure 107
6.9 Theta Drive Shaft Replacement 109
6.10 Aligning the Platform with the Joint 4 Motor 110
6.11 Replacing the Encoder Battery Pack 110
Encoder Battery Pack Replacement Interval 110
Encoder Battery Pack Replacement Procedure 110
6.12 Replacing a Platform 112
6.13 Replacing a Ball Joint Socket Insert 113
6.14 Replacing the iCS-ECAT Unit 113
6.15 Remove and Replace a MicroSD Card 116
Removing a MicroSD Card from an iCS-ECAT 116
Replacing a MicroSD Card in an iCS-ECAT 117
Chapter 7: Technical Specifications 119
7.1 Robot Physical Dimension Drawings 119
7.2 Arm Travel Volumes 120
7.3 Tool Flange Dimensions 123
7.4 General Robot Specifications 124
7.5 Performance Specifications 124
Payload Inertia and Acceleration Specifications 124
Cycle Time and Acceleration Specifications 125
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Payload Center ofGravity Specifications 127
Stopping Time and Distance 128
7.6 Electrical Specifications 132
External Connection Specifications 132
7.7 EtherCAT Communications Specifications 135
7.8 Mounting Frame Specifications 135
7.9 Environmental and Facility Specifications 142
Environmental Requirements 142
Design Considerations 143
7.10 Weights 144
7.11 Power Connector Specifications 144
Chapter 8: Status Codes 145
8.1 Robot Display Panel 145
8.2 Status Codes Table 146
Appendix 153
A.1 Unpacking and Inspecting the Equipment 153
Before Unpacking 153
After Unpacking 153
Inspecting the Equipment 153
A.2 Repacking for Relocation 153
Unpacking Procedure 153
A.3 Transportation and Storage 154
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Chapter 1: Introduction
This manual contains information that is necessary to install and use iX3 565 Robot with
EtherCAT. Please read this manual and make sure you understand the functionality, install-
ation, 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 User'sManual (Cat.
No. I651)
Provides reference to eV+ Keyword use and functionality.
eV+3 Keyword
ReferenceManual (Cat. No.
I652)
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.
NJ-series Robot Integrated
CPU Unit User's Manual
(Cat. No. O037)
Describes the settings and operation of the CPU Unit and
programming concepts for OMRON robot control.
T20 Pendant User's Manual
(Cat. No. I601)
Describes the use of the optional T20 manual control
pendant.
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10 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.1 Intended Audience
Manual Description
IO Blox User’s Guide (04638-
000)
Describes the IO Blox product, its connections, and input/out-
put signals.
1.1 Intended Audience
This manual is intended for the following personnel, who must also have knowledge of fact-
ory automation (FA) systems 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.
1.2 Robot Overview
The iX3 565 Robot with EtherCAT is a three-arm parallel robot. Servo motors in the robot base
control movement of the robot platform through mechanical links, arms, and an optional drive
shaft when platform rotation is needed. A tool flange is provided on the bottom of the platform
for mounting end-of-arm tooling.
Servo and other control functions are provided with an integrated controller(iCS-ECAT) that is
mounted on the top of the robot base.
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
Two models of the iX3 565 Robot with EtherCAT are available: