Omron Quattro 650H User manual

I597-E-05
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 2010-2019 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

Table of Contents
Chapter 1: Introduction 13
1.1 Quattro Robots, Product Description 13
Controllers 13
Sizes and Materials 13
Major Differences between Quattro H and HS Robots 13
eAIB 15
Quattro Robot Base 16
Inner Arms 16
Ball Joints, Outer Arms 16
Platforms 17
SmartController EX 20
1.2 Installation Overview 21
1.3 How Can I Get Help? 22
Related Manuals 22
Chapter 2: Safety 23
2.1 What to Do in an Emergency / Abnormal Situation 23
Releasing the Brakes 23
General Hazards 23
Releasing an E-Stop 23
2.2 Dangers, Warnings, and Cautions 24
Alert Levels 24
Alert Icons 24
Special Information 25
2.3 User's Responsibilities 25
Electrical Hazards 25
Pinch Hazard 25
Qualification of Personnel 25
2.4 Robot Behavior 26
Hardstops 26
2.5 Intended and Non-intended Use 26
Intended Use 26
Non-Intended Use 27
Robot Modifications 27
2.6 Additional Safety Information 27
Robot Safety Guide 28
T20 Manual Control Pendant (Option) 28
Disposal 28
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Table of Contents
Chapter 3: Robot Installation - H 29
3.1 Transport and Storage 29
3.2 Unpacking and Inspecting the Equipment 29
Before Unpacking 29
Upon Unpacking 29
Unpacking 29
3.3 Repacking for Relocation 31
3.4 Environmental and Facility Requirements 31
3.5 Mounting Frame 32
Frame Orientation 33
Frame Construction 33
Robot-to-Frame Considerations 33
Mounting 34
Gussets 34
3.6 Mounting the Robot Base 34
Robot Orientation 34
Mounting Surfaces 35
Mounting Options 35
Mounting Procedure from Above the Frame 35
Mounting Procedure from Below the Frame 37
Install Mounting Hardware 37
3.7 Attaching the Outer Arms and Platform 39
Clocking the Platform to the Base 40
Attaching the Outer Arms 41
3.8 Mounting the Front Panel 44
Chapter 4: Robot Installation - HS 45
4.1 Transport and Storage 45
4.2 Unpacking and Inspecting the Quattro Equipment 45
Before Unpacking 45
Upon Unpacking 45
Unpacking 45
4.3 Repacking for Relocation 47
4.4 Environmental and Facility Requirements 47
4.5 Mounting Frame 48
Frame Mounting Tabs 48
Robot-to-Frame Considerations 49
Mounting 49
Gussets 49
4.6 Cable Inlet Box 50
Assembling Cable Inlet Box 50
Connecting the Cables 54
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Table of Contents
Installing the Cable Inlet Box 55
4.7 Mounting the Robot Base 56
Robot Orientation 56
Mounting Surfaces 56
Mounting Options 56
Mounting Procedure from Above the Frame 57
Mounting Procedure from Below the Frame 58
Install Mounting Hardware 59
4.8 Attaching the Outer Arms and Platform 60
Clocking the Platform to the Base 61
Attaching the Outer Arms 62
4.9 Mounting the Front Panel 65
4.10 Attaching the Cable Tray 65
Chapter 5: System Installation 71
5.1 System Cable Diagram 71
5.2 Installing the SmartController EX 72
List of Cables and Parts 72
Cable Installation Overview 74
5.3 Optional Cables 75
XIOBreakout Cable 75
DB9 Splitter Cable 75
eAIB XBELTIOAdapterCable 75
SmartController Belt Encoder Y-Adapter Cable 75
5.4 Connecting User-Supplied PC to Robot 80
PC Requirements 80
5.5 Installing ACE Software 81
5.6 Description of Connectors on Robot Interface Panel 81
5.7 Cable Connections from Robot to SmartController 82
5.8 Connecting 24 VDC Power to Robot 83
Specifications for 24 VDC Robot and Controller Power 83
Details for 24 VDC Mating Connector 84
Procedure for Creating 24 VDC Cable 84
Installing 24 VDC Robot Cable 85
5.9 Connecting 200-240 VAC Power to Robot 86
Specifications for AC Power 86
Details for AC Mating Connector 89
Procedure for Creating 200-240 VAC Cable 89
Installing AC Power Cable to Robot 90
5.10 Grounding the Quattro Robot System 90
Quattro Robot Base 90
Quattro HS Robot Base 91
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Table of Contents
Robot-Mounted Equipment 91
Configuration 92
5.11 Installing User-Supplied Safety Equipment 94
Emergency Stop Circuits 99
Remote Manual Mode 100
User Manual/Auto Indication 101
User High Power On Indication 101
Remote High Power On/Off Control 101
High Power On/Off Lamp 102
Remote Front Panel or User-Supplied Control Panel Usage 102
Remote Pendant Usage 103
Chapter 6: System Operation 105
6.1 Robot Status Display Panel 105
6.2 Status Panel Fault Codes 106
6.3 Using the Brake-Release Button 107
Brakes 107
Brake-Release Button 107
6.4 Front Panel 109
6.5 Connecting Digital I/O to the System 110
6.6 Using Digital I/O on Robot XIO Connector 112
Optional I/O Products 114
XIO Input Signals 114
XIO Output Signals 116
XIO Breakout Cable 119
6.7 Starting the System for the First Time 121
Verifying Installation 121
Turning on Power and Starting ACE 122
Enabling High Power 123
Verifying E-Stop Functions 123
Verify Robot Motions 123
6.8 Quattro Motions 124
Straight-line Motion 124
Containment Obstacles 124
Tool Flange Rotation Extremes 124
6.9 Learning to Program the Quattro Robot 128
Chapter 7: Optional Equipment Installation 129
7.1 End-Effectors 129
Attaching 129
Aligning 129
Grounding 129
Accessing Vacuum 129
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Table of Contents
7.2 Routing End-effector Lines 130
7.3 Ball Stud Locks 131
Installing a Ball Stud Lock 132
Removing a Ball Stud Lock 133
Chapter 8: Technical Specifications 135
8.1 Dimension Drawings 135
8.2 Internal Connections 144
8.3 XSYS/XSYSTEM Connector 145
8.4 Robot Specifications 145
8.5 Payload Specifications 147
Torque and Rotation Limits 147
Payload Mass vs. Acceleration 147
Payload Inertia vs. Acceleration 149
8.6 Stopping Times and Distances 150
8.7 Robot Mounting Frame, Quattro 650H Robot 158
Chapter 9: Maintenance - H 165
9.1 Periodic Maintenance Schedule 165
9.2 Warning Labels 168
9.3 Checking Safety Systems 169
9.4 Checking Robot Mounting Bolts 169
9.5 Checking Robot Gear Drives 169
9.6 Checking Fan Operation 170
9.7 Replacing the eAIB Chassis 170
Removing the eAIB Chassis 170
Installing a New eAIB Chassis 173
9.8 Commissioning a System with aneAIB 174
Safety Commissioning Utilities 175
E-Stop Configuration Utility 176
E-Stop Verification Utility 177
Teach Restrict Configuration Utility 177
Teach Restrict Verification Utility 178
9.9 Replacing the Encoder Battery Pack 179
Battery Replacement Interval 179
Battery Replacement Procedure 180
9.10 Replacing a Platform 182
Replacement 182
9.11 Configuration 182
9.12 Replacing a Ball Joint Insert 182
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Table of Contents
9.13 Replacing Outer Arm Spring Assemblies 182
Removing Outer Arm Spring Assemblies 183
Installing Outer Arm Spring Assemblies 184
9.14 Changing the Lamp in the Front Panel High-Power Indicator 186
Chapter 10: Maintenance - HS 189
10.1 Cleaning 189
Water Shedding 189
Wash-Down 189
Chemical Compatibility 190
10.2 Warning Labels 190
10.3 Periodic Maintenance 191
10.4 Checking Safety Systems 195
10.5 Checking Robot Mounting Bolts 195
10.6 Checking Robot Gear Drives 195
10.7 Checking Fan Operation 196
10.8 Removing and Installing the Cable Inlet Box 197
Removing the Cable Inlet Box 197
Installing the Cable Inlet Box 198
10.9 Replacing the eAIB Chassis 199
Removing the eAIB Chassis 199
Installing a New eAIBChassis 201
10.10 Commissioning a System with aneAIB 202
Safety Commissioning Utilities 203
E-Stop Configuration Utility 204
E-Stop Verification Utility 205
Teach Restrict Configuration Utility 205
Teach Restrict Verification Utility 206
10.11 Replacing the Encoder Battery Pack 207
Battery Replacement Interval 207
Battery Replacement Procedure 208
10.12 Replacing a Platform 211
Replacement 211
Configuration 212
10.13 Replacing a Ball Joint Insert 212
10.14 Replacing Outer Arm Spring Assemblies 213
Removing Outer Arm Spring Assemblies 213
Installing Outer Arm Spring Assemblies 214
10.15 Replacing the Front Panel 216
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Table of Contents
Chapter 11: Robot Cleaning/ Environmental Concerns- H 217
11.1 Ambient Environment 217
Humidity 217
Temperature 217
11.2 Cleaning 218
Caustic Compatibility 218
Water Shedding 218
Wipe-Down 218
11.3 Cleanroom Classification 218
11.4 Design Factors 218
Robot Base and Components 218
Inner Arms 219
Ball Joints 219
Outer Arms 219
Springs 219
Platforms 219
11.5 Installing Cable Seal Kit 220
Overview 220
Installation Procedure 221
Chapter 12: Environmental Concerns - HS 227
12.1 Ambient Environment 227
Humidity 227
Temperature 227
12.2 Cleanroom Classification 228
12.3 Design Factors 228
Robot Base and Components 228
Inner Arms 228
Ball Joints 228
Outer Arms 228
Spring Assemblies 229
Platforms 229
Chapter 13: Status Codes 231
13.1 Status Panel Display 231
13.2 Status Codes 232
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10 Quattro User's Guide 09955-000 Rev. N
Revision History
Revision
Code Date Revised Content
01 June,
2016
Original release.
02 May, 2017 Regulatory updates.
03 November,
2017
lAdded the Quattro 800HS to USDA approved list.
lClarified that Line E-Stop Input can be used for pro-
duction lines.
lClarified note on emergency stop circuits.
lClarified that the ball joint inserts are made of special
acetal material.
04 April, 2018 lUpdated safety chapter format and alert levels through-
out user guide.
lClarified that USDA approved platforms are stainless
steel.
lUpdated unpacking instructions with new crate con-
figuration.
lUpdated recommended power supply model numbers.
lUpdated images of platform to show Omron Adept logo.
lChanged ACE software disk to ACEsoftware media.
lUpdated pictures to show painted inner arms.
lAdd note to firmly hold end of arm tooling when attach-
ing to the flange to prevent damage to platform belt.
lMinor updates to fix broken links and incorrect ref-
erences.
05 March,
2019
lUpdated copyright for 2019.
lAdded WEEEdisposal information.
lRemoved www.adept.com from Chapter 1: Introduction.
lUpdated safety chapter format and added fire and ESD
alert icons.
lAdded addition information regarding intended and non-
intended use of Quattro robots.
lMade a note that Hardstops have been moved to the
base.
lAdded Max Allowable Center of Gravity (CG) table in
chapter 8.
lGraphics improved and modified for translation and
added call-out tables.
lAdded Status Codes chapter.
lAdded Platform configuration procedure to System
Installation chapter and removed configuration pro-
cedure from Maintenance chapters.
lRevised encoder battery replacement interval.
lRevised Ball Stud Lock section with new part number for
individual locks.

Revision
Code Date Revised Content
lMany changes to Chapter 5: System Installation includ-
ing new and improved figures, content removal and addi-
tions.
lOperating temperature range, changed to 1 to 40°C
from previously noted 5 to 40°C.
lAdded red CADversion of status codes to Status Panel
Fault Codes section in chapter 5.
lDual robot configuration renamed to single and multiple
robot configuration.
lRemoved references to obsolete sDIO module.
lAdded IOBlox device to Table 6-3. Digital I/O Connection
Options
lAdded a note about typical IOBlox configurations in
Chapter 6: System Operation.
09955-000 Rev. N Quattro User's Guide 11

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 aluminum or stainless
steel platforms:
lQuattro 650H (AnodizedAluminum & SS) and Quattro 650HS (SS)
and
lQuattro 800H (Anodized Aluminum &SS) and Quattro 800HS (SS)
The Quattro 650H and 800H areavailable with anodized aluminum or stainless
steel (SS) platforms, and anodized aluminum outer arm spoons. The eAIB and
cable box used with the two H models are anodized aluminum.
The Quattro 650HS and 800HS are USDAAccepted, and therefore only available
with stainless steel platforms and stainless steel outer arm spoons. The eAIB and
cable box used with the two HS models are electroless nickel (EN).
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 either anodized aluminum or stainless steel platforms can be used on the Quattro
650H and 800H robots.
The Quattro 650HS and 800HS are only available with stainless steel platforms.
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14 Quattro User's Guide 09955-000 Rev. N
1.1 Quattro Robots, Product Description
Table 1-1. Quattro H/HS Differences
Standard (650H/800H) HS (650HS/800HS)
USDA Accepted
(Meat and Poultry)
No Yes
IP rating IP65, Option IP66, Standard
P30 Platform, no rotation Hard-anodized or Stainless Steel
(SS)
Stainless Steel (SS)
P31 Platform, 46.25° Hard-anodized or SS SS
P32 Platform, 92.5° Hard-anodized or SS SS
P34 Platform, 185° Hard-anodized or SS SS
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
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.

Chapter 1: Introduction
Figure 1-1. Major Robot Components, Isometric View (650HS shown)
Callout Description Callout Description
A Mounting Pads F Motor Cover
B eAIB G Outer Arms
C Cable Inlet Box H Platform
D Base J Ball Joints (Spring Assemblies not shown)
E Inner Arm
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
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16 Quattro User's Guide 09955-000 Rev. N
1.1 Quattro Robots, Product Description
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.
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
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

Chapter 1: Introduction
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.
D
A
E
F
C
G
H
B
Figure 1-3. Quattro Ball Joint Assembly, Quattro HS Robot shown
Callout Description Callout Description
A Ball Joint Stud E Ball Joint Socket Insert
B Inner Arm F Outer Arm Springs
C Ball Joint Socket G Spring Horseshoe
D Pressed Pin H Outer Arms
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.
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18 Quattro User's Guide 09955-000 Rev. N
1.1 Quattro Robots, Product Description
The suffix on the part numbers that follow indicates the finish or material of the platform.
Refer to Materials and Finishes on page 20.
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 on page 18.
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 on page 19.
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 on page 19.
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

Chapter 1: Introduction
Figure 1-5. P30 Platform
Figure 1-6. P32 Platform
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 designate a P32 platform.
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20 Quattro User's Guide 09955-000 Rev. N
1.1 Quattro Robots, Product Description
Materials and Finishes
Platforms are available in:
lAluminum with hard-anodized 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
Stainless
Steel
Yes Yes Yes Yes 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 40.
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.