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
4 iX4 650 H/HS and 800 H/HS Robot with EtherCAT
User’s Manual (Cat. No. I656)
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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
6 iX4 650 H/HS and 800 H/HS Robot with EtherCAT
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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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User’s Manual (Cat. No. I656)
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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.
22793-000 Rev. A iX4 650 H/HS and 800 H/HS Robot with EtherCAT
User’s Manual (Cat. No. I656)
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10 iX4 650 H/HS and 800 H/HS Robot with EtherCAT
User’s Manual (Cat. No. I656)
22793-000 Rev. A
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