Omron TM5 Regular Payload Series Assembly instructions

Collaborative Robot
Hardware Installation Manual
Corresponding models: TM5 Regular Payload Series
Original Instruction
I623-E-02

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) and
shall not be reproduced in whole or in part without prior authorization from the Corporation. No information contained
herein shall be considered an offer or commitment. The information herein is subject to change without notice. The
document is periodically reviewed and revised. The Corporation assumes no responsibility for any errors or omissions
in the documentation.
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
1. Product Description.......................................................................................................................................................7
1.1 Product Description.............................................................................................................................................. 7
1.2 How Can I Get Help? ...........................................................................................................................................7
2. Safety Information .........................................................................................................................................................8
2.1 Overview .............................................................................................................................................................. 8
2.2 Warning and Caution Symbols ............................................................................................................................ 8
2.3 Safety Precautions...............................................................................................................................................9
2.4 Validation and Liability .........................................................................................................................................9
2.5 Limitations on Liability........................................................................................................................................10
2.6 General Safety Warning.....................................................................................................................................10
2.7 Risk Assessment................................................................................................................................................10
2.8 Emergency Stop ................................................................................................................................................ 11
2.9 Movement without Drive Power .........................................................................................................................12
2.10 Labels ..............................................................................................................................................................14
3. Transportation and Storage.........................................................................................................................................15
4. System Hardware........................................................................................................................................................16
4.1 Overview ............................................................................................................................................................16
4.2 System Overview ...............................................................................................................................................16
4.2.1 Robot Arm ...................................................................................................................................................17
4.2.1.1 Dimension Drawings of Robot .............................................................................................................. 17
4.2.1.2 Robot Assembly Diagram .....................................................................................................................19
4.2.1.3 Range of Motion ...................................................................................................................................21
4.2.1.4 Robot Hazard Zone Diagram and Operator Position Diagram.............................................................25
4.2.1.5 Payload................................................................................................................................................. 27
4.2.1.6 Robot Arm Installation ..........................................................................................................................28
4.2.2 Robot End Module....................................................................................................................................... 29
4.2.2.1 End Module Components .....................................................................................................................29
4.2.2.2 End Flange Surface .............................................................................................................................. 30
4.2.2.3 End Mounting Caution ..........................................................................................................................31
4.2.2.4 End Indication Light Ring Table ............................................................................................................31
4.2.3 Control Box..................................................................................................................................................32
4.2.3.1 Robot Stick ........................................................................................................................................... 32
4.3 Operating Position of TM Robot with AGV.........................................................................................................34

Regular Payload Series-Hardware Installation Manual TM5 Series 4
4.4 Working distance and field of view of TM Robot’s EIH camera .........................................................................35
5. Electrical Interface.......................................................................................................................................................36
5.1 Overview ............................................................................................................................................................36
5.2 Electrical Warnings and Cautions ......................................................................................................................36
5.3 Control Box ........................................................................................................................................................37
5.3.1 Safety Connector.........................................................................................................................................38
5.3.2 Power Connector.........................................................................................................................................41
5.3.3 Digital In/Out................................................................................................................................................ 42
5.3.3.1 Digital Input...........................................................................................................................................42
5.3.3.2 Digital Output: .......................................................................................................................................43
5.3.4 Analog In .....................................................................................................................................................46
5.3.5 Analog Out...................................................................................................................................................46
5.3.6 System Remote Power ON/OFF.................................................................................................................47
5.3.7 EtherCAT: For EtherCAT Slave I/O Expansion ...........................................................................................47
5.3.8 USB Port .....................................................................................................................................................47
5.4 Tool End I/O Interface ........................................................................................................................................ 48
5.4.1 I/O Terminals ...............................................................................................................................................48
5.4.2 Connecting Tool End Digital Output ............................................................................................................50
5.4.3 Connecting Tool End Digital Input ...............................................................................................................50
5.4.4 Connecting Tool End Analog Input ..............................................................................................................50
5.5 Control Box Interfaces ....................................................................................................................................... 51
5.6 Control Box Power Interface and Robot Interface .............................................................................................53
5.6.1 Control Box Power Interface .......................................................................................................................53
5.6.2 Robot Interface............................................................................................................................................55
5.6.3 Control Box EMO (Emergency Off ) Interface.............................................................................................55
6. Unboxing & Installation ...............................................................................................................................................56
6.1 Overview ............................................................................................................................................................56
6.2 Inspecting the Equipment ..................................................................................................................................56
6.2.1 Before Unpacking........................................................................................................................................56
6.2.2 Upon Unpacking..........................................................................................................................................56
6.3 Unboxing............................................................................................................................................................57
6.3.1 Carton Types ...............................................................................................................................................57
6.3.2 Contents of Each Carton .............................................................................................................................58
6.4 Installing Your Robot ..........................................................................................................................................61
6.4.1 Remove the Control Box ............................................................................................................................. 61
6.4.2 Verification Before Removal of the Robot Arm............................................................................................63

Regular Payload Series-Hardware Installation Manual TM5 Series 5
6.4.3 Removal of the Robot Arm and Tightening .................................................................................................63
6.4.4 Connect the Robot and Control Box ...........................................................................................................65
7. Maintenance and Repair ............................................................................................................................................. 66
Appendix A. Technical Specifications..............................................................................................................................67

Regular Payload Series-Hardware Installation Manual TM5 Series 6
Revision History Table
Revision Date Revised Content
01 October 2018 Original release
02 December 2018 Updated cover page, minor text fixes

Regular Payload Series-Hardware Installation Manual TM5 Series 7
1. Product Description
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?
Additional information and resources are available at:
www.adept.com/omron-adept-cobot-manuals
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.

Regular Payload Series-Hardware Installation Manual TM5 Series 8
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.

Regular Payload Series-Hardware Installation Manual TM5 Series 9
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
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.
If any local or national electrical regulation requires, 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
Read Manual and Impact Warning Labels

Regular Payload Series-Hardware Installation Manual TM5 Series 10
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 machine. The desig
n 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 49.3dB under without production. (Condition: leave
machine body 1m distance and at 1.6m height from the floor and 8% of maximum speed). If the sound 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 OMRON. Refer to and
abide by the relevant chapters in Safety Manual in accordance with its’ software and hardware version.

Regular Payload Series-Hardware Installation Manual TM5 Series 11
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 ISO 60204-1. Emergency Stop act, factory reset and any other
circumstances, refer and abide by the relevant chapters in Safety Manual in accordance with its’ software and
hardware version.

Regular Payload Series-Hardware Installation Manual TM5 Series 12
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.
2. Release the brake by pushing the pin on the brake solenoid shown in the following three figures.
Base
1st Joint
Lower arm
4th Joint
6th Joint
3rd Joint
5thJoint
2nd Joint
Upper arm
TM5-700/ TM5M-700
1st Joint
Lower arm
6th Joint
3rd Joint
5th Joint
2nd Joint
Upper arm
TM5-900/ TM5M-900
Base
4th Joint

Regular Payload Series-Hardware Installation Manual TM5 Series 13
WARNING:
1. Additional supports may be needed when manually releasing the brake due to gravity.
2. When manually moving each robot joint, the movement angle must be within a range of
+/- 45
。
.
1st/2nd/3rd Joint
4th / 5th /6th Joint

Regular Payload Series-Hardware Installation Manual TM5 Series 14
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.
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 electric parts to avoid electric
shock
D
Product label
C D
C B A

Regular Payload Series-Hardware Installation Manual TM5 Series 15
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 cased 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 16
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

Regular Payload Series-Hardware Installation Manual TM5 Series 17
4.2.1 Robot Arm
4.2.1.1 Dimension Drawings of Robot
Shown below are the three-view dimension drawings of the robot
TM5-700 / TM5M-700

Regular Payload Series-Hardware Installation Manual TM5 Series 18
TM5-900 / TM5M-900

Regular Payload Series-Hardware Installation Manual TM5 Series 19
4.2.1.2 Robot Assembly Diagram
Shown below is an illustration of the robot components. To avoid safety risks, do not attempt to
disassemble any component on your own. Contact your local OMRON support for any service request.
TM5-700 / TM5M-700

Regular Payload Series-Hardware Installation Manual TM5 Series 20
TM5-900 / TM5M-900