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
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 3

Table of Contents
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
4 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A

Table of Contents
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
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 5

Table of Contents
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
6 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A

Table of Contents
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
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 7

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.
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 9

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:

Chapter 1: Introduction
l3 axis unit with a fixed platform and no tool flange rotation.
l4 axis unit with ±360° of rotation at the tool flange driven by a theta motor and drive
shaft.
Robot Base
Inner Arm (x 3)
Outer
Arm (x 6)
iCS-ECAT
Status Display
Panel
Ball Joints (x 12)
Theta Drive
Shaft
Platform
Tool Flange
Mounting
Pads (x 3)
Joint 2
Joint 3
Joint 1
Joint 4
Figure 1-2. iX3 565 Robot with EtherCAT (4 axis model shown)
NOTE: The descriptions and instructions in this manual apply to all iX3 565
Robot with EtherCAT types. If there are differences based on type or options, this
manual will provide details in the associated sections.
Robot Amplifier and Controller
The amplifier and controller is integrated in the robot's base and referred to as the Internal Con-
trol 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.
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 11

12 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.2 Robot Overview
Internal Control System
The iCS-ECAT has a dedicated microprocessor to communicate, coordinate, and execute servo
commands. The iCS-ECAT unit receives V+ 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 12 for
more information.
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.
iCS-ECAT RobotInterfacePanel
The iCS-ECAT includes the robot interface panel. It has connections for power (200 to 240
VAC, 24 VDC), communications, and other peripheral devices such as a pendant, IO Blox, or a
Front Panel.
Figure 1-3. iCS-ECAT Robot InterfacePanel

Chapter 1: Introduction
Table 1-2. iCS-ECAT RobotInterfacePanelDescriptions
Item Description
A ACPower Supply Connector
Used for connecting 200 to 240 VAC, single-phase input power to the robot.
A connector is provided with the robot.
Refer to Connecting the 24 VDC Cable to the Robot on page 77
B DCPower Supply Connector
Used for connecting the user-supplied 24 VDC power to the robot.
A connector is provided with the robot.
Refer to Connecting the 24 VDC Cable to the Robot on page 77 for more
information.
C Ground Terminal
D XSYSTEM Connector
Refer to Basic System Cable Layout on page 61
E EtherCAT Ports
Used for inbound and outbound EtherCAT communications.
FNode ID Switches
Used to set the robot's EtherCATnodeID.
Refer to Setting the EtherCATNodeID on page 52
GLEDs
Indicates the status of the EtherCAT connection.
Refer to EtherCAT Communications Description on page 90 for more inform-
ation.
H4-Position Mode Switches
Used to adjust the operating mode of the robot.
Refer to Robot Control Modes on page 93 for more information.
Additional Information: Switch 1 should remain in the NX / left
position. Functionality associated with switch 1 in the 3P / right
position is reserved for future use.
IXBELTIO Connector
Used to connect up to two external belt encoders and IO Blox external I/O. This
requires the XBELTIO Adapter cable.
Refer to Basic System Cable Layout on page 61 for more information.
XBELTIO
J XIO Connector
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 13

14 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.2 Robot Overview
Item Description
Used for user I/O signals for peripheral devices.
Refer to Basic System Cable Layout on page 61 for more information.
IP65 Versions
This robot is available with an IP65 rating to provide additional protection from dust and
fluid ingress. The base of the robot and inner arms are IP65 rated while the platform and outer
arms are IP67 rated for this option.
Robot Base
The robot base is an aluminum casting that houses the drive motors and supports the iCS-
ECAT. It provides three mounting pads for attaching the base to a rigid support frame. The
Status Display panel is mounted on the side of the robot base.
Outer Arms and Ball Joints
The inner arm motion is transmitted to the platform through the outer arms, which are con-
nected between the inner arms and platform with precision ball joints. The outer arms are car-
bon fiber epoxied assemblies with identical ball joint sockets at each end. A bearing insert in
each socket accepts the ball joint studs on the inner arms and platform and allows for approx-
imately ± 60° of relative motion. No ball joint lubrication is required.
Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints
which allows the outer arms to be installed and removed without tools.
The ball joint assembly is shown below.
Ball Joint
Socket
Outer Arms
Outer Arm
Springs Spring
Retainer
Pressed
Pin
Ball Joint
Socket Insert
Ball Joint
Stud
Inner Arm
Figure 1-4. Ball Joint Assembly

Chapter 1: Introduction
Inner Arms
Three robot motors attach directly to the inner arms through high-performance gear reducers. If
the robot has a theta rotation motor, it is mounted at the top of the robot base. RIA-compliant
hard stops limit the inner arm motion to -53° and +114.6°.
Platforms
The platform converts the motion of the robot motors into Cartesian motion. The 4 axis version
platform is capable of theta rotation of ±360°.
The 3 axis version's platform is made from stainless steel. The 4 axis version's platform is
made from electroless-nickel-plated aluminum and is rotated by a stainless steel drive shaft
driven by the 4th axis motor.
Both platforms have a 38 mm hole through their center for routing air lines or electric cables to
the tool flange.
Images of the two types of platforms are shown below.
Figure 1-5. 3 Axis Robot Platform
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 15

16 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.3 Robot Options
Figure 1-6. 4 Axis RobotPlatform
Robot Motions and Obstacles
Considerations for robot motions and obstacles are described below.
Robot Motions
Joint-interpolated motion is not possible with the robot because the positions of all the joints
must always be coordinated in order to maintain the connections to the platform. As a result,
the control system automatically performs a straight-line motion when a joint-interpolated
motion request is encountered.
Containment Obstacle
The work space of the robot is defined by an inclusion obstacle. This is done because, unlike
other robots, joint limits are not meaningful in defining the work space. The system defines a
cylindrical shape tapered at the bottom as a containment obstacle as the work envelope. Other
obstacles can be defined within this area.Refer to theSysmac Studio Robot Integrated System
Building Function with Robot Integrated CPU Unit Operation Manual (Cat. No. W595) for more
information.
1.3 Robot Options
This section describes the various options available for the robot.
!
WARNING: Ensure all optional equipment is installed properly and securely
fastened to the robot before operation. Failure to do so may result in personal
injury or equipment damage.
IO Blox
IO Blox units extend the robot's capabilities by providing expandable I/O capacity.

Chapter 1: Introduction
You can add up to 4 IO Blox units to the system.
Additional Information: Refer to IO Blox Connections on page 68 and the IO
Blox User’s Guide (04638-000) for more information.
Figure 1-7. IO Blox
Optional I/O Items
The following optional items are available for use with digital I/O.
lXIO Breakout Cable (part number 04465-000)
Refer to Optional Cables on page 20 for more information.
NOTE: This cable is not compatible with the XIO Termination Block
described below.
lXIO Termination Block (part number 90356-40100)
Includes terminals for user wiring and I/O status LEDs. Connects to the XIO connector
with 2m cable.
T20 Pendant
The T20 pendant is an optional hand held device that allows you to move the robot, teach loc-
ations, and debug programs without a PC. The pendant can also be used to move the robot
before calibration has occurred.
Additional Information: Refer to the T20 Pendant User's Manual (Cat. No. I601)
for more information about operating a robot with the T20 pendant.
IMPORTANT: The T20 pendant can only communicate with the robot it is dir-
ectly connected to.
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 17

18 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.3 Robot Options
Figure 1-8. T20 Pendant
IPC Application Controller
The IPCApplicationController can be added to your system to execute PackManager and
Robot VisionManager applications.
The Pack Manager application controls automated pick-and-place systems with cameras, con-
veyors, and robots based on the data that you set up in the Sysmac Studio. It is executed on
the IPC Application Controller to control the process data and recipe data.
The Robot Vision Manager application processes images captured by cameras based on the
data that you set up in the Sysmac Studio. It is executed on the IPC Application Controller.
Refer to the following manuals for more information.
lAutomationControl Environment (ACE)Version 4 User'sManual (Cat. No. I633)
lNJ-series Robot Integrated CPU Unit User's Manual (Cat. No. O037)
lIPC Application Controller User’s Manual (Cat. No. I632)

Chapter 1: Introduction
Figure 1-9. IPC Application Controller
Front Panel
The Front Panel is an optional device that provides the following functions.
lSetting the robot mode to manual or automatic. Refer to Robot Control Modes on page
93 for more information.
lIndicating the robot high power and system power state.
lRobot high power indicator burnout detection (see note below).
lEnabling robot high power. Refer to Enabling Robot High Power on page 94 for more
information.
lEmergency stop / disable robot high power.
Additional Information: Design of the factory-supplied Front Panel E-stop is in
accordance with the requirements of IEC 60204-1 and ISO 13849.
IMPORTANT: If the Front Panel high power ON / OFF lamp (part number
27400-29006) fails, you might incorrectly assume that High Power is OFF and
the robot is safe. To prevent this, a failed lamp causes an error (-924) *Front
panel HIGHPOWERlamp failure* and locks out the High Power enabling until
you replace the lamp. Refer to the eV+3 User'sManual (Cat. No. I651) for more
information about error handling.
!
WARNING: PERSONALINJURYRISK
If you supply your own Front Panel, its design must comply with the require-
ments of IEC 60204-1 and ISO 13849. The E-Stop's push button must comply
with ISO 13850 (Clause 5.5.2).
22792-000 Rev. A iX3 565 Robot with EtherCAT User’s Manual 19

20 iX3 565 Robot with EtherCAT User’s Manual 22792-000 Rev. A
1.3 Robot Options
Control Power
LED Indicator
Mode Selection
Switch
High Power
Enable Button
Emergency
Stop Button
High Power
Indicator
Figure 1-10. Front Panel
Optional Cables
The following table provides details about optional cables.
Table 1-3. Optional Cables
P/N Description
13463-000 XBELT I/O Adapter Cable (600 mm)
The optional XBELT IO Adapter cable splits the XBELTIO port on the robot
interface panel into a belt encoder branch and an IO Blox branch, and an RS-
232 branch.
NOTE: You can use the FORCE / EXPIO connector on this cable
to connect up to 4 IOBlox devices. For details on the pinouts for
this cable, refer to Pinouts for XBELT IO Adapter on page 66.
09443-000 Belt Encoder to M12 Y Adapter Cable (3 m)
This optional adapter cable splits the belt encoder connection on the XBELTIO
cable into two belt encoder branches.