Omron Quattro 650H User manual

I597-E-01
User’s Guide
Quattro
650H/650HS/800H/800HS

Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, Inc., assumes no responsibility for any errors or omissions in the doc-
umentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us
in preparation of future documentation. Please submit your comments to: [e-mail].
Copyright 2010-2016 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America

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Table of Contents
Chapter 1: Introduction 11
1.1 Quattro Robots, Product Description 11
Controllers 11
Sizes and Materials 11
Major Differences between Quattro H and HS Robots 11
eAIB 13
Quattro Robot Base 14
Inner Arms 14
Ball Joints, Outer Arms 14
Platforms 15
SmartController EX 18
1.2 Installation Overview 19
1.3 How Can I Get Help? 20
Related Manuals 20
Chapter 2: Safety 21
2.1 Warnings, Cautions, and Precautions 21
2.2 Safety Precautions 22
2.3 What to Do in an Emergency/Abnormal Situation 22
2.4 Robot Behavior 23
Hardstops 23
Limiting Devices 23
Singularities 23
2.5 Additional Safety Information 23
Manufacturer’s Declaration of Incorporation 23
Robot Safety Guide 23
Manual Control Pendant 23
2.6 Intended Use of the Robots 24
Chapter 3: Robot Installation - H 25
3.1 Transport and Storage 25
3.2 Unpacking and Inspecting the Equipment 25
Unpacking 25
3.3 Repacking for Relocation 27
3.4 Environmental and Facility Requirements 27
3.5 Mounting Frame 27
Frame Orientation 29

Frame Construction 29
Robot-to-Frame Considerations 29
Mounting 29
Gussets 30
3.6 Mounting the Robot Base 30
Robot Orientation 30
Mounting Surfaces 30
Mounting Options 31
Mounting Procedure from Above the Frame 31
Mounting Procedure from Below the Frame 33
Install Mounting Hardware 33
3.7 Attaching the Outer Arms and Platform 35
Clocking the Platform to the Base 35
Attaching the Outer Arms 37
3.8 Mounting the Front Panel 40
Chapter 4: Robot Installation - HS 41
4.1 Transport and Storage 41
4.2 Unpacking and Inspecting the Quattro Equipment 41
Before Unpacking 41
Upon Unpacking 41
Unpacking 41
4.3 Repacking for Relocation 44
4.4 Environmental and Facility Requirements 44
4.5 Mounting Frame 44
Frame Mounting Tabs 45
Robot-to-Frame Considerations 45
Mounting 46
Gussets 46
4.6 Cable Inlet Box 46
Assembling Cable Inlet Box 46
Connecting the Cables 52
Installing the Cable Inlet Box 52
4.7 Mounting the Robot Base 54
Robot Orientation 54
Mounting Surfaces 54
Mounting Options 54
Mounting Procedure from Above the Frame 55
Mounting Procedure from Below the Frame 56
Install Mounting Hardware 57
4.8 Attaching the Outer Arms and Platform 58
Clocking the Platform to the Base 59
Attaching the Outer Arms 60
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4.9 Mounting the Front Panel 63
4.10 Attaching the Cable Tray 63
Chapter 5: System Installation 69
5.1 System Cable Diagram 69
5.2 Cable Parts List 70
5.3 Installing the SmartController EX Motion Controller 70
5.4 Connecting User-Supplied PC to Robot 70
PC Requirements 71
5.5 Installing ACE Software 71
5.6 Description of Connectors on Robot Interface Panel 72
5.7 Cable Connections from Robot to SmartController 73
5.8 Connecting 24 VDC Power to Robot 73
Specifications for 24 VDC Robot and Controller Power 73
Details for 24 VDC Mating Connector 74
Procedure for Creating 24 VDC Cable 74
Installing 24 VDC Robot Cable 75
5.9 Connecting 200-240 VAC Power to Robot 76
Specifications for AC Power 77
Details for AC Mating Connector 78
Procedure for Creating 200-240 VAC Cable 79
Installing AC Power Cable to Robot 80
5.10 Grounding the Quattro Robot System 80
Quattro Robot Base 80
Quattro HS Robot Base 81
Robot-Mounted Equipment 81
5.11 Installing User-Supplied Safety Equipment 82
Emergency Stop Circuits 86
Remote Manual Mode 88
User Manual/Auto Indication 88
User High Power On Indication 88
Remote High Power On/Off Control 89
High Power On/Off Lamp 89
Remote Front Panel or User-Supplied Control Panel Usage 89
Remote Pendant Usage 90
Chapter 6: System Operation 91
6.1 Robot Status Display Panel 91
6.2 Status Panel Fault Codes 92
6.3 Using the Brake-Release Button 93
Brakes 93
Brake-Release Button 93
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6.4 Front Panel 94
6.5 Connecting Digital I/O to the System 95
6.6 Using Digital I/O on Robot XIO Connector 96
Optional I/O Products 98
XIO Input Signals 98
XIO Output Signals 100
XIO Breakout Cable 101
6.7 Starting the System for the First Time 103
Verifying Installation 103
Turning on Power and Starting ACE 104
Enabling High Power 104
Verifying E-Stop Functions 105
Verify Robot Motions 105
6.8 Quattro Motions 106
Straight-line Motion 106
Containment Obstacles 106
Tool Flange Rotation Extremes 106
6.9 Learning to Program the Quattro Robot 110
Chapter 7: Optional Equipment Installation 111
7.1 End-Effectors 111
Attaching 111
Aligning 111
Grounding 111
Accessing Vacuum 111
7.2 Routing End-effector Lines 112
7.3 Ball Stud Locks 113
Installing a Ball Stud Lock 114
Removing a Ball Stud Lock 115
Chapter 8: Technical Specifications 117
8.1 Dimension Drawings 117
8.2 Internal Connections 125
8.3 XSYS/XSYSTEM Connector 125
8.4 Robot Specifications 126
8.5 Payload Specifications 127
Torque and Rotation Limits 127
Payload Mass vs. Acceleration 128
Payload Inertia vs. Acceleration 129
8.6 Stopping Times and Distances 130
8.7 Robot Mounting Frame, Quattro 650H Robot 138
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Chapter 9: Maintenance - H 143
9.1 Periodic Maintenance Schedule 143
9.2 Warning Labels 146
9.3 Checking Safety Systems 147
9.4 Checking Robot Mounting Bolts 147
9.5 Checking Robot Gear Drives 147
9.6 Checking Fan Operation 148
9.7 Replacing the eAIB Chassis 148
Removing the eAIB Chassis 148
Installing a New eAIB Chassis 151
9.8 Commissioning a System with an eAIB 152
Safety Commissioning Utilities 153
E-Stop Configuration Utility 154
E-Stop Verification Utility 155
Teach Restrict Configuration Utility 155
Teach Restrict Verification Utility 156
9.9 Replacing the Encoder Battery Pack 157
Battery Replacement Interval 158
Battery Replacement Procedure 158
9.10 Replacing a Platform 160
Replacement 160
Configuration 160
9.11 Replacing a Ball Joint Insert 161
9.12 Replacing Outer Arm Spring Assemblies 161
Removing Outer Arm Spring Assemblies 161
Installing Outer Arm Spring Assemblies 163
9.13 Changing the Lamp in the Front Panel High-Power Indicator 165
Chapter 10: Maintenance - HS 167
10.1 Cleaning 167
Water Shedding 167
Wash-Down 167
Chemical Compatibility 168
10.2 Warning Labels 168
10.3 Periodic Maintenance 169
10.4 Checking Safety Systems 172
10.5 Checking Robot Mounting Bolts 173
10.6 Checking Robot Gear Drives 173
10.7 Checking Fan Operation 174
10.8 Removing and Installing the Cable Inlet Box 175
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Removing the Cable Inlet Box 175
Installing the Cable Inlet Box 176
10.9 Replacing the eAIB Chassis 177
Removing the eAIB Chassis 177
Installing a New eAIBChassis 179
10.10 Commissioning a System with an eAIB 180
Safety Commissioning Utilities 181
E-Stop Configuration Utility 182
E-Stop Verification Utility 183
Teach Restrict Configuration Utility 183
Teach Restrict Verification Utility 184
10.11 Replacing the Encoder Battery Pack 185
Battery Replacement Interval 186
Battery Replacement Procedure 186
10.12 Replacing a Platform 189
Replacement 189
Configuration 190
10.13 Replacing a Ball Joint Insert 190
10.14 Replacing Outer Arm Spring Assemblies 191
Removing Outer Arm Spring Assemblies 191
Installing Outer Arm Spring Assemblies 193
10.15 Replacing the Front Panel 195
Chapter 11: Robot Cleaning/ Environmental Concerns- H 197
11.1 Ambient Environment 197
Humidity 197
Temperature 197
11.2 Cleaning 198
Caustic Compatibility 198
Water Shedding 198
Wipe-Down 198
11.3 Cleanroom Classification 198
11.4 Design Factors 198
Robot Base and Components 198
Inner Arms 199
Ball Joints 199
Outer Arms 199
Springs 199
Platforms 199
11.5 Installing Cable Seal Kit 200
Overview 200
Installation Procedure 200
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Chapter 12: Environmental Concerns - HS 207
12.1 Ambient Environment 207
Humidity 207
Temperature 207
12.2 Cleanroom Classification 208
12.3 Design Factors 208
Robot Base and Components 208
Inner Arms 208
Ball Joints 208
Outer Arms 209
Spring Assemblies 209
Platforms 209
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Chapter 1: Introduction
1.1 Quattro Robots, Product Description
The Quattro robot is a four-axis parallel robot. The four identical axis motors control move-
ment of the robot tool in X, Y, and Z directions, as well as Theta rotation.
Controllers
The Quattro robot requires a SmartController EX motion controller for control. That controller
can be combined with a user-supplied PLC, for programming.
The robot servo code runs on an SmartServo distributed-motion control platform embedded in
the robot base as part of the power amplifiers.
Sizes and Materials
There are two sizes of Quattro robots, each available with anodized or electroless nickel (EN)
aluminum platforms and anodized aluminum or stainless steel outer arm spoons:
lQuattro 650H (Anodized) and Quattro 650HS (EN &SS)
and
lQuattro 800H (Anodized) and Quattro 800HS (EN &SS)
The Quattro 650H and 650HS arealso available with stainless steel (SS) plat-
forms.
The eAIB and cable box used with the two HS models are electroless nickel.
The electroless nickel/stainless steel versions of the Quattro 650HS robot are USDA Accepted.
In most aspects, the robots are similar enough that they will be covered together. In areas
where there are significant differences, the Quattro H and Quattro HS robots will be presented
in two chapters, using titles such as Robot Installation - H for the 650H and 800H robots, and
Robot Installation—HS for the 650HS and 800HS robots.
Major Differences between Quattro H and HS Robots
Note that any of the available aluminum platforms can be used on the Quattro 650H and
800H robots.
The Quattro 650HS is also available with stainless steel for platforms.

Chapter 1: Introduction
Table 1-1. Quattro H/HS Differences
Standard (650H/800H) HS (650HS/800HS)
USDA Accepted
(Meat and Poultry)
No 650HS - Yes/800HS - No
IP rating IP65, Option IP66, Standard
P30 Platform, no rotation Hard-anodized, EN, or Stain-
less Steel (SS1)
Electroless Nickel (EN) or Stain-
less Steel (SS1)
P31 Platform, 46.25° Hard-anodized, EN, or SS1EN or SS1
P32 Platform, 92.5° Hard-anodized, EN, or SS1EN or SS1
P34 Platform, 185° Hard-anodized, EN, or SS1EN or SS1
Outer Arm Spoons Hard-Anodized Stainless Steel
Base Mounting Pad Holes M16-2.0, through-hole M16-2.0, blind, 40 mm bolt
Base Coating material White polyurethane
powder
White ETFE, USDA approved
eAIB Black Anodized, Single-bolt
installation
EN, 6-bolt installation
Cable Inlet box Hard-Anodized, Option EN, Standard
Cable Tray Not required Required (for USDA)
Status Display Half-height Full-height, to shield labels
Protective Earth Ground On base-mounting pad In cable inlet box
Motor covers White Solid white, no label
Exposed bolts and screws
all gasketed
No Yes
1: Stainless steel platform is only available on 650 Quattro robots (H or HS)
Similarities Between the Quattro Robots
lAll models use the same motors
lAll models share the same base casting, although the H and HS have some machining
and coating differences. Platform coatings/materials differ for HS robots, but dimensions
do not.
lThe mounting hole pattern for the bases is the same.
lAll share the same inner arm design.
lAll have an eAIB.
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Chapter 1: Introduction
Outer
Arms
Platform
Cable Inlet Box
Inner
Arm Motor
Cover
eAIB
Mounting
Pads Base
Ball Joints
(Spring
Assemblies
not shown)
Inner
Arm
Figure 1-1. Major Robot Components, Isometric View (650HS shown)
eAIB
The power amplifiers for the Quattro robot are embedded in the base of the robot. This amp-
lifier section is known as the Amplifiers in Base (eAIB)distributed motion control platform,
and provides closed-loop servo control of the robot amplifiers, as well as robot I/O. The eAIB is
available in either an anodized or electroless nickel finish.
The eAIB features:
lOn-board digital I/O: 12 inputs, 8 outputs
lLow EMI for use with noise-sensitive equipment
lNo external fan for quiet operation
l8 kHz servo rate to deliver low positional errors and superior path following
lSine-wave commutation to lower cogging torque and improve path following
lDigital feed-forward design to maximize efficiency, torque, and velocity
lTemperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
lHardware-based E-Stop and Teach Restrict controls
These are for improved safety relative to European standards implemented in 2012.
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Chapter 1: Introduction
NOTE:The H and HSamplifiers and their cable inlet boxes are not inter-
changeable.
Quattro Robot Base
The Quattro robot base is an aluminum casting that houses the four drive motors, and sup-
ports the power amplifiers. 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.
Inner Arms
The four robot motors attach directly to the inner arms through a high-performance gear redu-
cer. Other than optional, user-supplied hardware mounted on the platform, these are the only
drive motors in the Quattro robot. The following figure shows an inner arm from a Quattro
robot. RIA-compliant hard stops limit the inner arm motion to -52° and +124°.
Figure 1-2. Inner Arm, with Ball Studs
Ball Joints, Outer Arms
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.
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Chapter 1: Introduction
Inner
Arm
Ball Joint
Socket
Ball Joint Socket Insert
Pressed
Pin
Outer
Arms
Outer Arm Springs
Ball Joint Stud
Spring Horseshoe
Figure 1-3. Quattro Ball Joint Assembly, Quattro HS Robot shown
Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints.
The outer arms can be installed and removed without tools.
Platforms
The platform converts the motion of the four Quattro motors into Cartesian motion and, for all
but the fixed platform, Theta rotation of the robot tool.
The Quattro robot currently supports four models of platforms, depending on the amount of
Theta rotation and inertia needed.
NOTE:The four models of platforms require different robot parameters.
The suffix on the part numbers that follow indicates the finish or material of the platform.
Refer to Materials and Finishes on page 18.
P31 Platform (P/N 09503-xxx)
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. See P31 Platform, Hard-Anodized Version on page 16.
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Chapter 1: Introduction
P30 Platform (P/N 09730-xxx)
The P30 platform is a fixed platform that provides no Theta rotation. The tool flange is
machined into the one-piece platform. See P30 Platform, Electroless Nickel and Stainless Steel
Versions on page 17.
P32 Platform (P/N 09732-xxx)
The P32 platform has a rotation range of ±92.5°. The tool flange is mounted on one of the pivot
links. See P32 Platform, Hard-Anodized Version on page 17.
P34 Platform (P/N 09734-xxx)
The P34 platform has a rotation range of ±185°. The tool flange is mounted on one of the pivot
links.
Figure 1-4. P31 Platform, Hard-Anodized Version
NOTE:The joint numbers, and axes will not be etched on the electroless nickel plat-
forms.
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Chapter 1: Introduction
Figure 1-5. P30 Platform, Electroless Nickel and Stainless Steel Versions
Model Number
& Two Dots
Figure 1-6. P32 Platform, Hard-Anodized Version
NOTE:The only visible difference between the P32 and P34 platforms is the model
number, and the two or four dots immediately below that number. Two dots des-
ignate a P32 platform.
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Chapter 1: Introduction
Materials and Finishes
Platforms are available in:
lAluminum with hard-anodized finish
lAluminum with electroless nickel finish
lStainless steel
The following table shows which materials and finishes are compatible with which robots:
650H 650HS 800H 800HS Part Number
Hard
Anodized
Yes No Yes No XXXXX-000
Electroless
Nickel
Yes Yes Yes Yes XXXXX-100
Stainless
Steel
Yes Yes No No XXXXX-200
Platform Clocking
Rotational platforms are constructed such that the clocking, or rotational alignment, of the plat-
form relative to the robot base is critical. This is detailed in Clocking the Platform to the Base
on page 35.
Platform Shipping
lThe platform and outer arms are removed.
lThe platform is shipped pre-assembled as a unit.
You will need to connect the outer arms between the inner arms and the platform to
reassemble the robot. The outer-arm assemblies are interchangeable.
Any end-effectors and their air lines and wiring are user-supplied.
SmartController EX
The SmartController motion controller is the foundation of our family of high-performance, dis-
tributed motion controllers. The SmartController EX is designed for use with:
lQuattro robots
leCobra 600/800 robots
lViper robots
The controller supports a conveyor tracking option, as well as other options. The SmartCon-
troller EX uses the eV+ operating system. It offers scalability and support for IEEE 1394-based
digital I/O and general motion expansion modules. The IEEE 1394 interface is the backbone of
SmartServo, our distributed controls architecture supporting our products. The SmartController
EX also includes Fast Ethernet and DeviceNet.
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Chapter 1: Introduction
Figure 1-7. SmartController EX
Refer to the SmartController EX User’s Guide for SmartController specifications.
1.2 Installation Overview
The system installation process is summarized in the following table. Also, refer to System
Cable Diagram on page 69.
NOTE:For dual-robot installations, see the Dual-Robot Configuration Procedure.
Table 1-2. Installation Overview
Task to be Performed Reference Location
Mount the cable box (Quattro HS robot or Quattro H
robot with IP65 option).
Cable Inlet Box on page 46 and
Installing Cable Seal Kit on page
200.
Mount the robot to a level, stable mounting frame. Mounting the Robot Base on page
30.
Attach the robot outer arms and platform. Attaching the Outer Arms and Plat-
form on page 35.
Install the SmartController, Front Panel, Pendant (if
purchased), and ACE software.
Installing the SmartController EX
Motion Controller on page 70.
Install the IEEE 1394 and XSYS cables between the
robot and SmartController.
Cable Connections from Robot to
SmartController on page 73.
Create a 24 VDC cable and connect it between the
SmartController and the user-supplied power supply.
Installing the SmartController EX
Motion Controller on page 70.
Create a 24 VDC cable and connect it between the
robot and the user-supplied 24 VDC power supply.
Connecting 24 VDC Power to Robot
on page 73.
Create a 200-240 VAC cable and connect it between
the robot and the facility AC power source.
Connecting 200-240 VAC Power to
Robot on page 76.
Install user-supplied safety barriers in the workcell. Installing User-Supplied Safety
Equipment on page 82.
Connect digital I/O through the robot XIO connector. Using Digital I/O on Robot XIO Con-
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Chapter 1: Introduction
Task to be Performed Reference Location
nector on page 96.
Start the system, including system start-up and test-
ing operation.
Starting the System for the First Time
on page 103.
Install optional equipment, including end-effectors,
user air and electrical lines, external equipment, etc.
End-Effectors on page 111.
1.3 How Can I Get Help?
For support or service, contact Omron Adept Technologies, Inc.
refer to additional information sources on our corporate website:
http://www.ia.omron.com
Related Manuals
This manual covers the installation, operation, and maintenance of an Quattro robot system.
There are additional manuals that cover programming the system, reconfiguring installed com-
ponents, and adding optional components. See the following table. These manuals are avail-
able on the software disk shipped with each system.
Table 1-3. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for our robots.
SmartController EX User’s
Guide
Contains complete information on the installation and oper-
ation of the SmartController EX and the optional sDIO
product.
ePLC Connect 3 User’s Guide Describes the installation and use of the ePLC Connect 3 soft-
ware, for using a user-supplied PLC as controller.
ACE User’s Guide Describes the installation and use of ACE software.
Dual-Robot Configuration Pro-
cedure
Contains cable diagrams and configuration procedures for a
dual-robot system.
T20 Pendant User's Guide Describes the use of the optional T20 manual control pendant.
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