Omron Regular Payload Series Assembly instructions

Original Instruction I623-E-04
Regular Payload Series
Hardware Installation Manual
Corresponding models: TM5 Series

Regular Payload Series-Hardware Installation Manual TM5 Series 2
This Manual contains information of the Techman Robot product series (hereinafter referred to as the TM Robot).The
information contained herein is the property of Techman Robot Inc. (hereinafter referred to as the Corporation). No part
of this publication may be reproduced or copied in any way, shape or form without prior authorization from the
Corporation. No information contained herein shall be considered an offer or commitment. It may be subject to change
without notice. This Manual will be reviewed periodically. The Corporation will not be liable for any error or omission.
logo is registered trademark of TECHMAN ROBOT INC. in Taiwan and other countries and the company
reserves the ownership of this manual and its copy and its copyrights.

Regular Payload Series-Hardware Installation Manual TM5 Series 3
Contents
Revision History Table.......................................................................................................................................................8
1. Product Dscription......................................................................................................................................................... 9
1.1 Product Description..............................................................................................................................................9
1.2 How Can I Get Help? ........................................................................................................................................... 9
2. Safety Information .......................................................................................................................................................10
2.1 Overview ............................................................................................................................................................10
2.2 Warning and Caution Symbols ..........................................................................................................................10
2.3 Safety Precautions.............................................................................................................................................10
2.4 Validation and Liability ....................................................................................................................................... 11
2.5 Limitations on Liability........................................................................................................................................ 11
2.6 General Safety Warning..................................................................................................................................... 11
2.7 Risk Assessment................................................................................................................................................12
2.8 Emergency Stop ................................................................................................................................................12
2.9 Movement without Drive Power .........................................................................................................................12
2.10 Labels ..............................................................................................................................................................14
3. Transportation and Storage.........................................................................................................................................16
4. System Hardware........................................................................................................................................................17
4.1 Overview ............................................................................................................................................................17
4.2 System Overview ...............................................................................................................................................17
4.2.1 Robot Arm ...................................................................................................................................................18
4.2.2 Robot End Module.......................................................................................................................................35
4.2.3 Control Box..................................................................................................................................................38
4.3 Operating Position of TM Robot with AGV/AIV.................................................................................................. 40
4.4 Working distance and field of view of TM Robot’s EIH camera.........................................................................41
5. Electrical Interface.......................................................................................................................................................42
5.1 Overview ............................................................................................................................................................42
5.2 Electrical Warnings and Cautions ......................................................................................................................42
5.3 Control Box ........................................................................................................................................................42
5.3.1 Safety Connector.........................................................................................................................................43
5.3.2 Power Connector.........................................................................................................................................45
5.3.3 Digital In/Out................................................................................................................................................ 46
5.3.4 Analog In .....................................................................................................................................................50
5.3.5 Analog Out...................................................................................................................................................51
5.3.6 System Remote Power ON/OFF.................................................................................................................51
5.3.7 EtherCAT: For EtherCAT Slave I/O Expansion ...........................................................................................52

Regular Payload Series-Hardware Installation Manual TM5 Series 4
5.3.8 USB Port ..................................................................................................................................................... 52
5.4 Tool End I/O Interface ........................................................................................................................................52
5.4.1 I/O Terminals ...............................................................................................................................................52
5.4.2 Connecting Tool End Digital Output ............................................................................................................54
5.4.3 Connecting Tool End Digital Input ...............................................................................................................55
5.4.4 Connecting Tool End Analog Input ..............................................................................................................55
5.5 Control Box Interfaces .......................................................................................................................................56
5.6 Control Box Power Interface and Robot Interface .............................................................................................58
5.6.1 Control Box Power Interface .......................................................................................................................58
5.6.2 Robot Interface............................................................................................................................................59
5.6.3 Control Box EMO (Emergency Off) Interface..............................................................................................60
6. Unboxing & Installation ...............................................................................................................................................61
6.1 Overview ............................................................................................................................................................61
6.2 Inspecting the Equipment ..................................................................................................................................61
6.2.1 Before Unpacking........................................................................................................................................61
6.2.2 Upon Unpacking..........................................................................................................................................61
6.3 Unboxing............................................................................................................................................................62
6.3.1 Carton Types ...............................................................................................................................................62
6.3.2 Contents of Each Carton .............................................................................................................................62
6.4 Installing Your Robot .......................................................................................................................................... 65
6.4.1 Remove the Control Box .............................................................................................................................65
6.4.2 Verification Before Removal of the Robot Arm............................................................................................67
6.4.3 Removal of the Robot Arm and Tightening .................................................................................................67
6.4.4 Connect the Robot and the Control Box .....................................................................................................69
7. Maintenance and Repair .............................................................................................................................................70
Appendix A. Technical Specifications..............................................................................................................................71
Tables
Table 1: Manual Title & Description .................................................................................................................... 9
Table 2: Warning and Caution Symbols............................................................................................................ 10
Table 3: Denotation of Labels ........................................................................................................................... 15
Table 4: Rated Torque and Limit for Repeated Peak Torque of Regular Payload Robot Series......................33
Table 5: Robot Stick Basic Functions ...............................................................................................................39
Table 6: Robot Stick Advanced Functions ........................................................................................................40
Table 7: The Relation between the Working Distance and the Field of View ...................................................41
Table 8: 8-pin Digital I/O Connectors of Cable .................................................................................................53

Regular Payload Series-Hardware Installation Manual TM5 Series 5
Table 9: 8-pin Digital I/O Connector of Robot ................................................................................................... 53
Table 10: 5-pin Analog I/O Connector of Cable ................................................................................................54
Table 11: 5-pin Analog I/O connector of Robot .................................................................................................54
Table 12: TM5-700 / TM5-900 / TM5X-700 /TM5X-900 Electrical Specifications.............................................59
Table 13: TM5M-700/ TM5M-900 Series Electrical Specifications ...................................................................59
Table 14: The Robot Arm Carton Contents.......................................................................................................63
Table 15: The Control Box Carton Contents.....................................................................................................65
Table 16: Summary of the Preventive Maintenance Procedures and Guidelines ............................................70
Table 17: Technical Specifications ....................................................................................................................71
Figures
Figure 1: References of Joints by Mode...........................................................................................................13
Figure 2: Reference of Brake Solenoid by Joints .............................................................................................14
Figure 3: Locations of Labels ...........................................................................................................................15
Figure 4: System Overview...............................................................................................................................17
Figure 5: Dimension of TM5-700 / TM5M-700..................................................................................................18
Figure 6: Dimension of TM5-900 / TM5M-900..................................................................................................19
Figure 7: Dimension of TM5X-700....................................................................................................................20
Figure 8: Dimension of TM5X-900....................................................................................................................21
Figure 9: Assembly of TM5-700 / TM5M-700 ...................................................................................................22
Figure 10: Assembly of TM5-900 / TM5M-900 .................................................................................................23
Figure 11: Assembly of TM5X-700.................................................................................................................... 24
Figure 12: Assembly of TM5X-900 ...................................................................................................................25
Figure 13: Side View of TM5-700 / TM5M-700 /TM5X-700 Movement Range Diagram .................................26
Figure 14: Pictorial view of TM5-700 / TM5M-700 /TM5X-700 Movement Range Diagram ............................27
Figure 15: Top View of TM5-700 / TM5M-700 /TM5X-700 Movement Range..................................................27
Figure 16: Side View of TM5-900 / TM5M-900 /TM5X-900 Movement Range Diagram .................................28
Figure 17: Pictorial Views of TM5-900 / TM5M-900 /TM5X-900 Movement Range.........................................28
Figure 18: Top View of TM5-900 / TM5M-900 /TM5X-900 Movement Range..................................................29
Figure 19: Robot Hazard Zone Diagram and Operator Position Diagram of TM5-700 / TM5M-700 /TM5X-700
................................................................................................................................................................... 30
Figure 20: Robot Hazard Zone Diagram and Operator Position Diagram of TM5-900 / TM5M-900 /TM5X-900
................................................................................................................................................................... 31
Figure 21: Relationship between Payload and the Center of Gravity Offset in TM5-700 / TM5M-700
/TM5X-700.................................................................................................................................................32
Figure 22: Relationship between Payload and the Center of Gravity Offset in TM5-900 / TM5M-900

Regular Payload Series-Hardware Installation Manual TM5 Series 6
/TM5X-900.................................................................................................................................................32
Figure 23: Bottom View of Robot Base ............................................................................................................34
Figure 24: References of TM5-700/ TM5M-700/ TM5-900 / TM5M-900 End Module Components ................35
Figure 25: References of TM5X-700 / TM5X-900 End Module Components ..................................................36
Figure 26: References of End Flange Surface .................................................................................................37
Figure 27: The Exterior and Diagram of the Control Box .................................................................................38
Figure 28: Robot Stick ...................................................................................................................................... 39
Figure 29: Top View of TM Robot Placed on the AGV/AIV...............................................................................40
Figure 30: Working Distance and Field of View of TM Robot’s EIH camera ....................................................41
Figure 31: Control Box I/O Configuration (1/2) .................................................................................................42
Figure 32: Control Box I/O Configuration (2/2) .................................................................................................43
Figure 33: Safety Connector.............................................................................................................................43
Figure 34: The Wiring Diagram Example of Switch Type Safety Device..........................................................44
Figure 35: The Wiring Diagram Example of PNP Output Type Safety Device .................................................45
Figure 36: Power Connector.............................................................................................................................46
Figure 37: Digital Input......................................................................................................................................46
Figure 38: Set to Sink Input Type .....................................................................................................................47
Figure 39: Set to Source Input Type.................................................................................................................48
Figure 40: Digital Output...................................................................................................................................48
Figure 41: Set to Sink Output Type ..................................................................................................................49
Figure 42: Set to Source Output Type ..............................................................................................................50
Figure 43: Analog In..........................................................................................................................................51
Figure 44: Analog Out....................................................................................................................................... 51
Figure 45: System Remote Power ON/OFF .....................................................................................................52
Figure 46: Connecting Tool End Digital Output ................................................................................................54
Figure 47: Connecting Tool End Digital Input ...................................................................................................55
Figure 48: Connecting Tool End Analog Input ..................................................................................................55
Figure 49: Front View of the Control Box .........................................................................................................56
Figure 50: Interfaces of the TM5-700 / TM5X-700 / TM5-900 / TM5X-900 Series...........................................56
Figure 51: Interfaces of the TM5M-700 / TM5MX-700 / TM5M-900 / TM5MX-900 Series...............................57
Figure 52: Interfaces of the TM5M-700 SEMI / TM5M-900 SEMI Series.........................................................57
Figure 53: Control Box Power Interfaces..........................................................................................................58
Figure 54: Robot Interface ................................................................................................................................59
Figure 55: Control Box EMO (Emergency Off) Interface of the TM5M-700 SEMI / TM5M-900 SEMI Series ..60
Figure 56: Robot Arm Carton............................................................................................................................62
Figure 57: Control Box Carton .......................................................................................................................... 62

Regular Payload Series-Hardware Installation Manual TM5 Series 7
Figure 58: Moving the Control Box (1/2)...........................................................................................................66
Figure 59: Moving the Control Box (2/2)...........................................................................................................66
Figure 60: Moving the Robot Arm (1/2) ............................................................................................................67
Figure 61: Moving the Robot Arm (2/2) ............................................................................................................68
Figure 62: Connecting the Robot and the Control Box.....................................................................................69

Regular Payload Series-Hardware Installation Manual TM5 Series 8
Revision History Table
Revision Date Revised Content
01 October 2018 Original release
02 December 2018 Updated cover page, minor text fixes
03 July 2019 Minor text fixes. Added cables length.
04 August 2019
Added Table of Rated Torque and Limit for Repeated Peak Torque.
Added X Model information.

Regular Payload Series-Hardware Installation Manual TM5 Series 9
1. Product Dscription
1.1 Product Description
The TM Robot is a six-axis robot with power and force limiting function, which features simple programming,
innovative integrated vision capabilities together with the latest safety functionality.
1.2 How Can I Get Help?
You can access information sources on the corporate website:
http://www.ia.omron.com/
Related Manuals
This manual covers the hardware installation, operation and user maintenance of TM Robot. See the following
table for additional available manuals.
Manual Title Description
Safety Manual Contains safety information for TM Robots.
TMflow Instructions for use of TMflow software.
TMvision Instructions for use of TMvision software.
Table 1: Manual Title & Description

Regular Payload Series-Hardware Installation Manual TM5 Series 10
2. Safety Information
2.1 Overview
The user shall read, understand and abide by the safety information provided in this manual before using the TM
Robot.
2.2 Warning and Caution Symbols
The Table below shows the definitions of the warning and caution levels described in each paragraph of this
Manual. Pay close attention to them when reading each paragraph, and observe them to avoid personal injuries or
equipment damage.
DANGER:
Identifies an imminently hazardous situation which, if not avoided, is likely to result in
serious injury, and might result in death or severe property damage.
WARNING:
Identifies a potentially hazardous situation which, if not avoided, will result in minor or
moderate injury, and might result in serious injury, death, or significant property damage.
CAUTION:
Identifies a potentially hazardous situation which, if not avoided, might result in minor
injury, moderate injury, or property damage.
Table 2: Warning and Caution Symbols
2.3 Safety Precautions
DANGER:
This product can cause serious injury or death, or damage to itself and other equipment, if the
following safety precautions are not observed.
All personnel who install, operate, teach, program, or maintain the system must read the “Hardware
installation Manual”, “Software Manual”, and “Safety Manual” according to the software and hardware
version of this product, and complete a training course for their responsibilities in regard to the robot.
All personnel who design the robot system must read the “Hardware installation Manual”, “Software Manual”,
and “Safety Manual” according to the software and hardware version of this product, and must comply with
Read Manual and Impact Warning Labels

Regular Payload Series-Hardware Installation Manual TM5 Series 11
all local and national safety regulations for the location in which the robot is installed.
The TM Robot shall be used according to its intended use.
Results of the risk assessment may require the use of additional risk reduction measures.
Power to the robot and its power supply must be locked out and tagged out or have means to control
hazardous energy or implement energy isolation before any maintenance is performed.
Dispose of the product in accordance with the relevant rules and regulations of the country or area
where the product is used.
2.4 Validation and Liability
The information contained herein neither includes how to design, install, and operate a complete robotic arm
system, nor involves the peripherals which may affect the safety of the complete system. The integrators of the
robot should understand the safety laws and regulations in their countries and prevent major hazards from
occurring in the complete system.
This includes but is not limited to:
Risk assessment of the whole system
Adding other machines and additional safety mechanisms based on the results of the risk assessment
Building appropriate safety mechanisms in the software
Ensuring the user will not modify any safety-related measures
Ensuring all systems are correctly designed and installed
Clearly labeling user instructions
Clearly marked symbols for installation of the robot arm and the integrator contact details
Collecting all documents into the technology folder, including the risk assessment, and this manual
CAUTION:
This product is a partly complete machin
e. The design and installation of the complete system
must comply with the safety standards and regulations in the country of use. The user and
integrators of the robot should understand the safety laws and regulations in their countries
and prevent major hazards from occurring in the complete system.
2.5 Limitations on Liability
Even if the safety instructions are followed, any safety-related information in the Manual shall not be considered
as a guarantee that the product will not cause any personal injury or damage.
2.6 General Safety Warning
1. The actual noise measured in a factory setting is about 49.3 dB under without production. (Condition: leave
machine body 1m distance and at 1.6m height from the floor and 80% of maximum speed). If the sound

Regular Payload Series-Hardware Installation Manual TM5 Series 12
pressure is over 80 dB(A) while operating, wear proper ear protection.
2. Environmental Conditions:
Ambient air temperature: 0˚C ~ +50˚C
Ambient relative humidity: < 85%
Transportation & Storage condition: -20˚C ~ +60˚C
Transportation & Storage humidity: < 75%
The robot needs to be protected from shock or vibration
Observe ESD precautions when installing or removing robot
2.7 Risk Assessment
Before installing or using this product, the user must first carry out the necessary risk assessment based on the
conditions of use; meanwhile also closely study the potential remaining risk addressed by the Corporation. Refer
to and abide by the relevant chapters in Safety Manual in accordance with its’ software and hardware version.
2.8 Emergency Stop
If any accidents occur during the operation of the robot, the user can stop all movement by pressing the
Emergency Switch. When the robot stops, the user must ensure that all fault conditions are eliminated before
manually restarting the robot. The Emergency Switch is only used in critical conditions. To stop the robot during
normal operations use the Stop Button on the system controller. When the user presses the emergency switch,
the TM Robot product will disconnect the power of robot and activate the brake after the robot motion is stopped.
The indication light ring of the robot will not display light, and the three lights from the robot stick will be constantly
blinking.
Once the risk assessment has been conducted, if an Emergency Switch needs to be installed the selected device
must comply with the requirements of IEC 60204-1. Emergency Stop act, factory reset and any other
circumstances, refer and abide by the relevant chapters in the Safety Manual in accordance with its software and
hardware version.
2.9 Movement without Drive Power
Robot without Drive Power could be found in three circumstances: Emergency stop, when disengaging packaging
posture to initial booting, and power loss. The first two could enter Safe Start up Mode by means of releasing the
Emergency Switch; the latter one is when robot loses external power. Regarding how to operate as well as safety
precautions refer and abide by the relevant chapters in the Safety Manual.
If the robot loses power, and joints need to be moved in order to clear error conditions, you will need to release
the brake for each joint as follows:
1. Remove joint cover screws (M3, Torx-T10) and joint cover.

Regular Payload Series-Hardware Installation Manual TM5 Series 13
2. Release the brake by pushing the pin on the brake solenoid shown in the following figures.
Figure 1: References of Joints by Mode
Base
1
st
Joint
Lower arm
4th Joint
6th Joint
3rd Joint
5thJoint
2
nd
Joint
Upper arm
TM5-700/ TM5M-700
1st Joint
Lower arm
6th Joint
3
rd
Joint
5th Joint
2
nd
Joint
Upper arm
TM5-900/ TM5M-900
Base
4
th
Joint
Upper arm
TM5X-700
1st Joint
Lower arm
4th Joint
6th Joint
5
th
Joint
Base
2
nd
Joint
3rd Joint
1st Joint
Lower arm
4
th
Joint
6
th
Joint
5th Joint
Upper arm
TM5X-900
Base
3
rd
Joint
2
nd
Joint

Regular Payload Series-Hardware Installation Manual TM5 Series 14
Figure 2: Reference of Brake Solenoid by Joints
WARNING:
1. Due to gravity, additional support is recommended when manually releasing the brake.
2. When manually moving each robot joint, the movement angle must be within a range of
+/- 45
。
.
2.10 Labels
The following labels, especially the warning ones, are attached to the locations where specific dangers may occur.
Be sure to comply with description and warnings of the labels when operating to keep the manipulator safely. Do
not tear, damage, or remove the labels. Be very careful if you need to handle the parts where the labels are
attached.
1
st
/2
nd
/3
rd
Joint
4
th
/ 5
th
/6
th
Joint

Regular Payload Series-Hardware Installation Manual TM5 Series 15
A Do not put your hand or fingers close to the moving parts
B
Be careful not to be close to the moving parts and nearby
areas to avoid collision
C
Do not touch any internal electri
c parts to avoid electric
shock
D Product label
Table 3: Denotation of Labels
Figure 3: Locations of Labels
C D
C B A

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3. Transportation and Storage
Transport the TM Robot using its original packing materials. If you will need to transport the TM Robot after
unpacking, store the packing materials in a dry place. Hold both arms of the TM Robot during transportation.
Support the arms while tightening the base screws.
Lift the control box by its handles. Store the cables before transportation.
WARNING:
Pay attention to your posture when moving the arm and control box cartons to avoid back
injury. Omron will not be liable for any injuries caused during transportation.
WARNING:
This product must be shipped and stored in a temperature-controlled environment, within the
range -20°C to 60°C (-4°F to 140°F). The recommended humidity is up to 75 percent,
non-condensing. It should be shipped and stored in the supplied package, which is designed
to prevent damage from normal shock and vibration, You should protect the package from
excessive shock and vibration.
The product must always be stored and shipped in an upright position in a clean, dry area that
is free from condensation. Do not lay the package on its side or any other non-upright position:
this could damage the product.

Regular Payload Series-Hardware Installation Manual TM5 Series 17
4. System Hardware
4.1 Overview
This chapter introduces the mechanical interface of the TM Robot System.
4.2 System Overview
TM Robot is made up of the robot arm and control box (including a robot stick).
Control Box
Robot Stick
Robot arm
Figure 4: System Overview

Regular Payload Series-Hardware Installation Manual TM5 Series 18
4.2.1 Robot Arm
4.2.1.1 Dimension Drawings of Robot
Shown below is the dimension drawing of the robot
Figure 5: Dimension of TM5-700 / TM5M-700
TM5-700 / TM5M-700

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Figure 6: Dimension of TM5-900 / TM5M-900
TM5-900 / TM5M-900

Regular Payload Series-Hardware Installation Manual TM5 Series 20
Figure 7: Dimension of TM5X-700
TM5X-700