Omron iX4 User manual

iX4 650 H/HS and 800 H/HS Robot
with EtherCAT
User's Manual
I656-E-01

Copyright Notice
The information contained herein is the property of OMRON, and shall not be reproduced in whole or in
part without prior written approval of OMRON. The information herein is subject to change without
notice and should not be construed as a commitment by OMRON. The documentation is periodically
reviewed and revised.
OMRON assumes no responsibility for any errors or omissions in the documentation.
Copyright 2020 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
1.1 Related Manuals 9
1.2 Intended Audience 10
1.3 Robot Overview 10
Major Differences Between iX4-650H/800H and iX4-650HS/800HS Robots 11
Robot Amplifier and Controller 12
Robot Base 15
Outer Arms and Ball Joints 15
Inner Arms 16
Platforms 16
Robot Motions and Obstacles 18
1.4 Robot Options 18
I/O Options 18
T20 Pendant 19
IPC Application Controller 20
Front Panel 20
Optional Cables 21
Cable Inlet Box 24
Ball Stud Locks 25
Chapter 2: Safety 27
2.1 Dangers, Warnings, and Cautions 27
Alert Levels 27
Alert Icons 27
Falling Hazards 27
Special Information 28
2.2 What to Do in an Emergency or Abnormal Situation 28
Stopping the Robot 28
Entrapment and Brake Release Button 28
Releasing an E-Stop 28
2.3 Safety Precautions 29
User's Responsibilities 29
General Hazards 29
Qualification of Personnel 30
2.4 Robot Behavior 30
Hardstops 30
Limiting Devices 31
Singularities 31
2.5 Intended and Non-intended Use 31
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Table of Contents
Intended Use of the Robots 31
Non-Intended Use 31
2.6 Additional Safety Information 32
Manufacturer’s Declaration of Incorporation 32
Robot Safety Guide (Cat. No. I590) 32
Emergency Stop Circuit and Buttons 32
2.7 How CanIGet Help? 32
T20 Manual Control Pendant (Option) 33
Disposal 33
Chapter 3: Robot Installation 35
3.1 Robot Installation Overview 35
Basic Installation Steps 35
3.2 Mounting Frame 35
Frame Orientation 37
Frame Construction 37
Frame Mounting Tabs 37
Robot-to-Frame Considerations 38
Mounting Surfaces 38
Gussets 39
3.3 Mounting the Robot Base 39
Robot Orientation 39
Mounting Procedure 39
3.4 Installing the Platform 42
Align the Platform with the Robot Base 42
Attach the Outer Arms 43
Outer Arm Attachment Procedure 46
3.5 Installing the FrontPanel 47
Mounting the Front Panel 47
Connecting the Front Panel 48
3.6 Installing User-Supplied Safety Equipment 49
Contacts on XUSR Connector 50
Contacts on XFP Connector 51
Remote Pendant Signals on the XMCPConnector 51
E-Stop Circuits on XUSR and XFP Connectors 52
Emergency Stop Circuits 54
Remote Manual Mode 56
User Manual/Auto Indication 56
Remote High Power ON / OFF Control 57
Using a User-Supplied Control Panel 58
Remote Pendant Usage 58
3.7 Setting the EtherCATNodeID 58
Setting the EtherCATNode ID UsingHardware Switches 59
3.8 Installing or Removing Ball Stud Locks 61
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Table of Contents
Installing Ball StudLocks 61
Removing Ball StudLocks 62
Chapter 4: System Cable Installation 63
4.1 Basic System Cable Layout 63
List of Cables and Parts 65
Cable Installation Steps 66
XBELT IO Belt Encoder Y Adapter Cable 67
4.2 Connecting Digital I/O to the System 70
Digital I/O Signal Configuration 70
XIO Connector Signals 77
4.3 Connecting the 24 VDC Cable to the Robot 79
24 VDC Power Supply Connector 79
Making the 24 VDC Power Supply Cable 79
Connecting the 24 VDC Cable 80
4.4 Connecting 200 to 240 VAC Power Cable 82
AC Power Diagrams 83
AC Power Supply Connector 84
Making the 200 to 240 VAC Power Supply Cable 85
AC Power Supply Cable Connection Procedure 86
4.5 Grounding the Robot System 86
Grounding the iX4-650H/800H Robot Base 87
Grounding the iX4-650HS/800HS Robot Base 88
Grounding Robot-Mounted Equipment 88
4.6 Installing a Cable Inlet Box for iX4-650H/800H Robots 88
4.7 Installing a Cable Inlet Box for iX4-650HS/800HS Robots 91
Assembling the Cable Inlet Box 91
Connecting the Cables 96
Installing the Cable Inlet Box 96
4.8 Attaching the Cable Tray 98
Chapter 5: System Operation 103
5.1 Verifying Installation 103
Mechanical Checks 103
System Cable Checks 103
Safety Equipment Checks 104
Switch Position Checks 105
5.2 Robot Status LED and Display Panel 105
General Robot States 105
5.3 EtherCAT Communications Description 106
5.4 Brakes 107
Brake Release Button 107
Remote Brake Release Feature 108
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Table of Contents
5.5 Robot Control Modes 109
Manual Mode 109
Automatic Mode 109
Operation Mode 109
Service Mode 110
5.6 Manually Jogging the Robot 110
5.7 Enabling Robot High Power 110
High Power Safety Timeout 111
High Power and Faults 111
High Power Request Methods 111
5.8 Disabling Robot High Power 113
Chapter 6: Maintenance 115
6.1 Periodic Maintenance Schedule 115
6.2 Non-periodic Maintenance Schedule 117
6.3 Cleaning iX4-650H/800H Robots 118
Caustic Compatibility 118
Wash Down 119
Water Shedding 119
Design Factors 119
6.4 Cleaning iX4-650HS/800HS Robots 120
Chemical Compatibility 121
Wash Down 121
Water Shedding 122
Design Factors 122
6.5 Checking Safety Systems 123
High Power Indicator Check 123
6.6 Checking Labels 124
Warning Labels 124
6.7 Checking for Gear Drive Leaks 125
6.8 Checking Fan Operation 126
6.9 Replacing the Encoder Battery Pack 126
Encoder Battery Pack Replacement Interval 127
Encoder Battery Pack Replacement Procedure 127
6.10 Replacing a Platform 130
Configuration 131
6.11 Replacing Outer Arm Spring Assemblies 131
6.12 Replacing a Ball Joint Socket Insert 133
6.13 Replacing the iCS-ECAT Unit for an iX4-650H/800H Robot 135
Removing the iCS-ECAT Chassis 135
Installing a New iCS-ECAT Chassis 137
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Table of Contents
6.14 Replacing the iCS-ECAT Unit for an iX4-650HS/800HS Robot 138
Removing the iCS-ECAT Chassis from an iX4-650HS/800HS Robot 138
Installing a new iCS-ECAT Chassis 141
6.15 Remove and Replace a MicroSD Card 142
Removing a MicroSD Card from an iCS-ECAT 142
Replacing a MicroSD Card in an iCS-ECAT 143
Chapter 7: Technical Specifications 145
7.1 Robot Physical Dimension Drawings 145
7.2 Arm Travel Volumes 149
7.3 Tool Flanges 152
7.4 General Robot Specifications 154
7.5 Performance Specifications 156
Payload Specifications 156
Payload Center ofGravity Specifications 158
Stopping Time and Distance 158
7.6 Electrical Specifications 166
External Connection Specifications 166
Facility Overvoltages Protection 169
7.7 EtherCAT Communications Specifications 169
7.8 Mounting Frame Specifications 170
7.9 Environmental and Facility Specifications 176
Environmental Requirements 176
Design Considerations 177
7.10 Weights 178
7.11 Power Connector Specifications 178
Chapter 8: Status Codes 179
8.1 Status Display Panel 179
8.2 Status Codes Table 179
Appendix 187
9.1 Unpacking and Inspecting the Equipment 187
Before Unpacking 187
After Unpacking 187
Unpacking Procedure 187
9.2 Repacking for Relocation 189
9.3 Transportation and Storage 189
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Chapter 1: Introduction
This manual contains information that is necessary to install and use an iX4 robot. Please read
this manual and make sure you understand the functionality, installation, and performance of
the robot before attempting to use it.
1.1 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 V+ programming language
and functionality.
eV+3 User'sManual (Cat.
No. I651)
Provides reference to V+ 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 use of the NJ-series Robot Integrated CPU Unit.
T20 Pendant User's Manual
(Cat. No. I601)
Describes the use of the optional T20 manual control
pendant.
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1.2 Intended Audience
Manual Description
IO Blox User’s Guide (04638-
000)
Describes the IO Blox product, its connections, and input/out-
put signals.
1.2 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.
1.3 Robot Overview
The iX4 is a four-arm parallel robot. Servo motors in the robot base control movement of the
robot platform through mechanical links and arms. 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 in 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
T20Teach pendant
(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

Chapter 1: Introduction
Four models of the iX4 are available:
liX4-650H
This is a standard iX4 robot with a 650 mm radius work envelope.
liX4-650HS
This is a USDA-accepted iX4 robot with a 650 mm radius work envelope.
liX4-800H
This is a standard iX4 robot with an 800 mm radius work envelope.
liX4-800HS
This is a USDA-accepted iX4 robot with an 800 mm radius work envelope
Outer
Arm (x 8)
Platform
Cable Inlet Box
iCS-ECAT
Mounting
Pads (x 4) Robot Base
Ball Joints
(x 16)
Inner
Arm (x 4)
Motor
Cover
(x 4)
High Power Lamp
Status Display Panel
Figure 1-2. iX4 Robot with EtherCAT
Major Differences Between iX4-650H/800H and iX4-650HS/800HS
Robots
In most aspects, the robots are similar enough that they will be covered together. In areas
where there are significant differences, the iX4-650H/800H and iX4-650HS/800HS robots will
be presented separately.
Note that either anodized aluminum or stainless steel platforms can be used on the iX4-650H
and iX4-800H robots.
The iX4-650HS and iX4-800HS are only available with stainless steel platforms.
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1.3 Robot Overview
Table 1-2. iX4-650H/800H and iX4-650HS/800HS Robot Differences
iX4-650H/800H iX4-650HS/800HS
USDA Accepted
(Meat and Poultry)
No Yes
IP rating IP65, Option IP66, Standard
P30 Platform, no rotation Hard-anodized or Stainless Steel Stainless Steel
P31 Platform, 46.25° Hard-anodized or Stainless Steel Stainless Steel
P32 Platform, 92.5° Hard-anodized or Stainless Steel Stainless Steel
P34 Platform, 185° Hard-anodized or Stainless Steel Stainless Steel
Outer Arm Ball Joint Sockets Hard-Anodized Stainless Steel
Base Mounting Pad Holes M16-2.0, through-hole M16-2.0, blind, 40 mm
bolt
Base Coating material polyurethane powder ETFE, USDA approved
iCS-ECAT Black Anodized, Single-bolt
installation
Electroless Nickel,
6-bolt installation
Cable Inlet box Hard-Anodized, Option Electroless Nickel,
Standard
Cable Tray Not required Required (for USDA)
Labels On exterior of robot All labels protected
Protective Earth Ground On base-mounting pad In cable inlet box
Motor covers OMRON label No label
Exposed bolts and screws all
gasketed
No Yes
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.
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.

Chapter 1: Introduction
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 LEDs to indicate operating status.
Additional Information: Refer to iCS-ECAT RobotInterfacePanel on page 13 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
Table 1-3. iCS-ECAT RobotInterfacePanelDescriptions
Item Description
A ACPower Supply Connector
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1.3 Robot Overview
Item Description
Used for connecting 200 to 240 VAC, single-phase input power to the robot.
A connector is provided with the robot.
Refer to Connecting 200 to 240 VAC Power Cable on page 82
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 79 for more
information.
C Ground Terminal
D XSYSTEM Connector
Refer to Basic System Cable Layout on page 63
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 58
GLEDs
Indicates the status of the EtherCAT connection.
Refer to EtherCAT Communications Description on page 106 for more inform-
ation.
H4-Position Mode Switches
Used to adjust the operating mode of the robot.
Refer to Robot Control Modes on page 109 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 63 for more information.
XBELTIO
J XIO Connector
Used for user I/O signals for peripheral devices.
Refer to Basic System Cable Layout on page 63 for more information.

Chapter 1: Introduction
Robot Base
The robot base is an aluminum casting that houses the four drive motors and supports the
iCS-ECAT. It provides four 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 Stud
Inner Arm
Ball Joint
Socket
Spring
Retainer
Pin
Ball Joint
Socket Insert
Outer Arm Spring
Spring Retainer
Inner Arm
Figure 1-4. Ball Joint Assembly
Table 1-4. Ball Joint Assembly Descriptions
Key Desctription Key Description
A Inner Arm E Outer Arms
B Ball Joint Socket F Ball Joint Socket Insert
C Ball Joint Stud G Pressed Pin
D Outer Arm Springs H Spring Holder
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1.3 Robot Overview
Inner Arms
Four robot motors attach directly to the inner arms through high-performance gear reducers.
RIA-compliant hard stops limit the inner arm motion to -52° and +124°.
Platforms
The platform converts the motion of the robot motors into Cartesian motion and, for all but the
fixed platform, theta rotation of the tool flange.
The iX4 robot supports four models of platforms, depending on the amount of Theta rotation
and inertia needed. Each model is available in either Anodized Aluminum or Stainless Steel.
NOTE: The four models of platforms require different robot parameters.
Part Number Platform Rotation Material
These platforms can be used with iX4-650H/800H robots.
09730-000 P30 0° Anodized Aluminum
09503-000 P31 ±46.25° Anodized Aluminum
09732-000 P32 ±92.5° Anodized Aluminum
09734-000 P34 ±185° Anodized Aluminum
These platforms can be used with any iX4 robots.
09730-200 P30 0° Stainless Steel
09503-200 P31 ±46.25° Stainless Steel
09732-200 P32 ±92.5° Stainless Steel
09734-200 P34 ±185° Stainless Steel
P30 Platform
The P30 platform is a fixed platform that provides no Theta rotation. The tool flange is
machined into the one-piece platform.
Figure 1-5. P30 Platform

Chapter 1: Introduction
P31 Platform
The P31 platform has a rotation range of ±46.25°. The tool flange is machined into one of the
pivot links. It does not rotate in relation to the pivot link, so there are no gears or belts
involved.
Figure 1-6. P31 Platform
P32 Platform
The P32 platform has a rotation range of ±92.5°. The tool flange is mounted on one of the pivot
links.
Figure 1-7. P32 Platform
P34 Platform
P34 platform has a rotation range of ±185°. The tool flange is mounted on one of the pivot
links.
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1.4 Robot Options
Figure 1-8. P34 Platform
NOTE: The only visible difference between the P32 and P34 platforms is the
model number, and the dots immediately below that number. Two dots des-
ignate a P32 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
cone-like shape 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.
1.4 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.
I/O Options
The following optional items are available for use with digital I/O.
lXIO Breakout Cable (p/n 04465-000)
Refer to Optional Cables on page 21 for more information.
NOTE: This cable is not compatible with the XIO Termination Block
described below.
lXIO Termination Block (p/n 90356-40100)
Includes terminals for user wiring and I/O status LEDs. Connects to the XIO connector
with 2m cable.
lIO Blox (p/n 30410-220)
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 70 and the
IO Blox User’s Guide (04638-000) for more information.
Figure 1-9. IO Blox
T20 Pendant
The T20 pendant is an optional hand held device that allows you to move the robot and teach
locations. 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.
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1.4 Robot Options
Figure 1-10. 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)
Figure 1-11. 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
109 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 110 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.