Omron Viper 650 User manual

Viper 650 and 850
Robot with EtherCAT
User's Manual
I654-E-01

2 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Copyright Notice
The information contained herein is the property of OMRON, and shall not be reproduced in
whole or in part without prior written approval of OMRON. The information herein is subject
to change without notice and should not be construed as a commitment by OMRON The doc-
umentation is periodically reviewed and revised.
OMRON, assumes no responsibility for any errors or omissions in the documentation.
Copyright  2020 by OMRON Corporation. All rights reserved.
Sysmac and SYSMAC are trademarks or registered trademarks of OMRON Corporation in
Japan and other countries for OMRON factory automation products.
EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Auto-
mation GmbH, Germany.
ODVA, CIP, DeviceNet, and EtherNet/IP are trademarks of ODVA.
Other company names and product names in this document are the trademarks or registered
trademarks of their respective companies.
Created in the United States of America.

Table of Contents
Chapter 1: Introduction 7
Related Manuals 7
1.1 Intended Audience 8
1.2 Robot Overview 8
Robot Amplifier and Controller 8
IP54/65 and Cleanroom Versions 12
Robot Features 12
Robot Links and Joints 13
Robot Connections 13
eCS-ECAT Interface Panel 16
1.3 Robot Options 18
IO Blox 18
T20 Pendant 19
IPC Application Controller 20
Front Panel 20
Optional Cables 22
Chapter 2: Safety 27
2.1 Dangers, Warnings, and Cautions 27
Alert Levels 27
Alert Icons 27
Special Information 28
2.2 Safety Precautions 28
2.3 What To Do In An Emergency 29
Stopping the Robot 29
Fire Response 29
Entrapment and Brake Release Box 29
2.4 Robot Behavior 29
Hardstops 29
Limiting Devices 29
Singularities 30
2.5 Intended Use of the Robot 30
2.6 Additional Safety Information 31
Manufacturer’s Declarations 31
Robot Safety Guide 31
T20 Pendant (Option) 31
2.7 Disposal 31
2.8 How Can I Get Help? 31
Chapter 3: Robot Installation 33
3.1 Robot Installation Overview 33
Basic Installation Steps 33
3.2 Mounting a Viper Robot 33
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 3

Mounting Surface 33
Mounting Surface Preparation 34
Mounting Procedure for Upright Viper 35
Mounting Procedure for Ceiling Mount 36
Robot Mounting Torque 37
3.3 Mounting the eCS-ECAT 37
3.4 Installing the Front Panel 37
Connecting the Front Panel 38
Front Panel Schematic 38
3.5 Air Lines and Signal Wiring 39
3.6 Installing User-Supplied Safety Equipment 41
Contacts on XUSR Connector 41
Contacts on XFP Connector 43
Remote Pendant Signals on the XMCPConnector 43
E-Stop Circuits on XUSR and XFP Connectors 45
Emergency Stop Circuits 46
Remote Manual Mode 48
User Manual/Auto Indication 48
Remote High Power ON / OFF Control 48
Using a User-Supplied Control Panel 50
Remote Pendant Usage 50
3.7 Setting the EtherCATNodeID 50
Setting the EtherCATNode ID UsingHardware Switches 51
3.8 Installing Joint Labels 52
Chapter 4: System Cable Installation 55
4.1 Basic System Cable Layout 55
List of Cables and Parts 56
Cable Installation Steps 58
XBELT IO Belt Encoder Y Adapter Cable 59
4.2 Connecting Digital I/O to the System 62
Optional I/O Products 62
Digital I/O Signal Configuration 62
XIO Connector Signals 70
4.3 Connecting Cable from the eCS-ECAT to the Robot 72
4.4 Connecting the 24 VDC Cable to the eCS-ECAT 73
24 VDC Power Supply Connector 73
Making the 24 VDC Power Supply Cable 74
Connecting the 24 VDC Cable 74
4.5 Connecting 200-240 VAC Power Cable 76
AC Power Diagrams 76
AC Power Supply Connector 77
Making the 200-240 VAC Power Supply Cable 78
Connecting the AC Power Supply Cable 79
4.6 Grounding the Robot System 79
Grounding the Robot Base 79
Ground Point on eCS-ECAT 80
Grounding Robot-Mounted Equipment 80
4 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 5
Chapter 5: Optional Equipment Installation 83
5.1 Installing End-Effectors 83
5.2 Mounting Locations for External Equipment 83
Chapter 6: System Operation 85
6.1 Verifying Installation 85
Mechanical Checks 85
System Cable Checks 85
User-Supplied Safety Equipment Checks 86
Switch Position Checks 87
6.2 Status LED and Display Panel 87
General Robot States 87
6.3 EtherCAT Communications Description 88
SystemBehavior with EtherCATCommunication Errors 89
6.4 Brakes 89
Brake Release Connector 89
Installing and Using the Brake Release Box 90
6.5 Robot Control Modes 91
Manual Mode 91
Automatic Mode 92
Operation Mode 92
Service Mode 92
6.6 Manually Jogging the Robot 93
6.7 Enabling Robot High Power 93
High Power Safety Timeout 93
High Power and Faults 94
High Power Request Methods 94
6.8 Disabling Robot High Power 95
Chapter 7: Maintenance 97
7.1 Periodic Maintenance 97
Periodic Maintenance Schedule 97
Checking Safety Systems 97
Checking Robot Mounting Bolts and CoverPlates 98
Checking Safety and Warning Labels 98
Replacing the Encoder Batteries 99
7.2 Non-Periodic Maintenance 102
Field-Replaceable Parts 103
Replacing the eCS-ECAT Amplifier Chassis 103
Remove and Replace a MicroSD Card 104
Chapter 8: Technical Specifications 107
8.1 Robot Physical Dimension Drawings 107
8.2 General Robot Specifications 112
8.3 Performance Specifications 113
General Performance Information 113
Stopping Distances and Times 114
8.4 Electrical Specifications 121

Solenoid Valve Specifications 121
External Connection Specifications 121
8.5 Environment and Facility Specifications 123
8.6 Other Specifications 124
ConnectorSpecifications 124
Power Consumption Specifications 126
8.7 Tool Flange Dimensions 126
8.8 Front Panel Dimensions 127
8.9 EtherCAT Communications Specifications 128
Chapter 9: IP54/65 Option Considerations 129
9.1 IP54/65 Option Classification 129
9.2 Differences from Standard Robot Model 129
Robot Connector Panel 129
Cable Clearance 130
Replacing Encoder Backup Battery 130
Chapter 10: Cleanroom Option Considerations 131
10.1 Differences from Standard Robot Model 131
10.2 Cleanroom Robot Connections 131
Cleanroom CN22 Cable 132
Air Lines and Signal Wiring 133
10.3 Cleanroom Cover at J6 Flange 135
10.4 Cleanroom Technical Specifications 136
10.5 Cable Clearance 137
10.6 Replacing Encoder Backup Battery 137
Chapter 11: Status Codes 139
11.1 eCS-ECAT Display Panel 139
11.2 Status Codes Table 139
Appendix 145
A.1 Unpacking and Inspecting the Equipment 145
Before Unpacking 145
After Unpacking 145
Inspecting the Equipment 145
A.2 Repacking for Relocation 145
A.3 Transportation and Storage of Robot 145
Transportation and Storage Environment 145
Precautions when Transporting Robot 146
Transport Procedure 147
6 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A

Chapter 1: Introduction
This manual contains information that is necessary to install and use Viper 650 and 850
Robot with EtherCAT. Read this manual and make sure you understand the functionality,
installation, and performance of the robot before attempting to use it.
Related Manuals
Use the following related manuals for reference.
Table 1-1. Related Manuals
Manual Description
Robot Safety Guide (Cat. No. I590) Contains safety information for OMRON
industrial robots.
Sysmac Studio Robot Integrated System
Building Function with Robot Integrated
CPU Unit Operation Manual (Cat. No.
W595)
Describes the operating procedures of the Sys-
mac Studio.
Sysmac Studio Robot Integrated System
Building Function with IPC Application Con-
troller Operation Manual (Cat. No. W621)
Describes the operating procedures of the IPC
ApplicationController.
eV+3 User'sManual (Cat. No. I651) Provides a description of the eV+ pro-
gramming language and functionality.
eV+3 Keyword ReferenceManual (Cat. No.
I652)
Provides reference to eV+ Keyword use and
functionality.
AutomationControl Environment
(ACE)Version 4 User'sManual (Cat. No.
I633)
Describes the installation and use of the ACE
software.
NJ-series Robot Integrated CPU Unit User's
Manual (Cat. No. O037)
Provides information that is necessary to use
the robot control function of the NJ-series CPU
Unit.
IPC Application Controller User’s Manual
(Cat. No. I632)
Provides information that is necessary to use
the robot control function of the IPC Applic-
ation Controller.
T20 Pendant User's Manual (Cat. No. I601) Describes the use of the optional T20 manual
control pendant.
IO Blox User’s Guide (04638-000) Describes the IO Blox product, its connections,
and input/output signals.
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 7

8 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
1.1 Intended Audience
This manual is intended for the following personnel, who must also have knowledge of com-
mon programming practices and robotic control methods.
lPersonnel in charge of introducing factory automation systems.
lPersonnel in charge of designing factory automation systems.
lPersonnel in charge of installing and maintaining factory automation systems.
lPersonnel in charge of managing factory automation systems and facilities.
1.2 Robot Overview
The Viper 650 and Viper 850 robots are high-performance, six-axis articulated robots designed
specifically for assembly applications. The speed and precision of the Viper robots also make
them ideal for material handling, packaging, machine tending, and many other operations
requiring fast and precise automation.
EtherCAT communications allow the robots to operate together with EtherCATnodes, other
Sysmac products, and the Sysmac Studio AutomationSoftware to achieve optimum func-
tionality and ease of operation.
NA-series
PT
Teaching pendant
T20
(with built-in EtherCAT
communications)
Slave
Terminal
Vision sensor
OMRON
robot
Robot Integrated CPU Unit
NJ501-R
I/O control
external devices
1S-series Servo Drives
G5-series Servo Drives
Server Relational database
USB
Camera
FH-series Vision
Systems
Robots controllable by NJ Robotics function
EtherCAT
Application Controller
Sysmac Studio
EtherNet/IP
Front Panel
Safety
devices Encoder,
digital I/O
Figure 1-1. System Topology
These robots are offered with two different arm reaches to provide different working envelopes.
The Viper 650 has a 650 mm radial reach and the Viper 850 has an 850 mm radial reach,
measured from Joint 1 to Joint 5. Refer to Robot Physical Dimension Drawings on page 107
NOTE: The descriptions and instructions in this manual apply to all Viper 650
and 850 Robot with EtherCAT. If there are differences based on type or options,
this manual will provide details in the associated sections.
Robot Amplifier and Controller
The robot's amplifier and controller are contained in the External Control System, or eCS-
ECAT.

Chapter 1: Introduction
The eCS-ECAT is a distributed servo controller and amplifier. It is designed with a dedicated
digital signal processor to communicate, coordinate, and execute servo commands. The eV+
operating system runs on both the eCS-ECAT and the NJ-series Robot Integrated CPU Unit.
The eCS-ECAT contains power amplifiers, safety circuitry, and I/O as well as full trajectory, kin-
ematic, and servo robot control hardware. The robot motors are powered by the eCS-ECAT
amplifiers.
This robot is intended to operate within an EtherCAT network. It receives commands and con-
trol signals from the NJ-series Robot Integrated CPU Unit over an EtherCAT network.
Figure 1-2. Viper 650 Robot
External Control System (eCS-ECAT)
This section is about the eCS-ECAT, which is a distributed servo controller and amplifier used
with Viper robots. The eCS-ECAT has a dedicated microprocessor to communicate, coordinate,
and execute servo commands. The eCS-ECAT unit receives eV+ commands from the NJ-series
Robot Integrated CPU Unit and processes these commands to execute robots motions and other
functions.
The eCS-ECAT contains the interface panel, which provides connections for power supply, peri-
pheral devices such as the front panel, pendant, and user-supplied safety equipment, and
EtherCATnetwork cables. The interface panel also has switches for setting an explicit
EtherCATNode address and operating mode as well as LEDs to indicate operating status.
Additional Information: Refer to eCS-ECAT Interface Panel on page 16 for more
information.
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 9

10 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Figure 1-3. eCS-ECAT
eCS-ECAT Features
The eCS-ECAT unit has the following general features.
lEtherCAT communications, for distributed control by an NJ-series Robot Integrated CPU
Unit.
lIntegrated digital I/O.
lDual 1 GHz Cortex A9 ARM Processors, 1 GB SDRAM.
l8 GB MicroSD card.
lLow EMI for use with noise sensitive equipment.
l8 kHz servo rate to deliver low positional errors and high-performance path following.
lDigital feed-forward control to maximize efficiency, torque, and positioning.
lInternal temperature sensors for hardware protection and troubleshooting.
lPower controller that uses single-phase AC power, 200-240 Volts.
l2-digit alpha-numeric status panel to show operating status and fault codes.
lExpansion Input/Output (EXPIO) port

Chapter 1: Introduction
lBRAKE release port
lSTATUS light
Connectors on eCS-ECAT Interface Panel
Figure 1-4. eCS-ECAT Interface Panel
Name Meaning
XSYSTEM Connects to the eAIB XSYSTEM cable. The mating connector is
provided.
DCIN 24V For user-supplied 24 VDC power. The mating connector is
provided.
GND Ground point for user-supplied 24 VDC cable.
AC 1Ø 200 -
240V
For 200-240 VAC, single-phase, input power. The mating con-
nector is provided.
OUT and IN EtherCAT Ports for connection to the EtherCAT network.
XIO For user I/O signals for peripheral devices. Provides 8 outputs
and 12 inputs. Refer to Connecting Digital I/O to the System on
page 62 for connector pin allocations for inputs and outputs.
That section also contains details on how to access these I/O sig-
nals. (DB-26, high density, female)
XBELTIO Adds two belt encoders, EXPIO, and an RS-232 interface.
ID (x256,
x16, x1)
Used to set the eCS-ECAT node ID. Refer to Setting the
EtherCATNodeID on page 50
ID(RUN,
ERR, FS)
LEDs indicate the status of the EtherCAT connection. Refer to
EtherCAT Communications Description on page 88.
NX/3P,
OP/SV
Switches used to adjust the operating mode of the robot. Refer
to Setting the EtherCATNodeID on page 50 for more inform-
ation.
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 11

12 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Name Meaning
Additional Information: Switch 1 should
remain in the NX / left position. Functionality asso-
ciated with switch 1 in the 3P / right position is
reserved for future use.
IP54/65 and Cleanroom Versions
Viper robots are also available with options for IP54/65 or Class 10 Cleanroom ratings. These
options provide additional protection from dust and fluid.
The following images show the IP54/65 version and the Cleanroom version.
Figure 1-5. IP54/65 Version (left), Cleanroom Version (right)
Robot Features
The following table lists the various features and functionalities that are available.
Feature Available
Vision Support Yes
Local I/O (max. input / output, XIO + IOBlox) 76/72
XIO (max. input / output) 12/8
IOBlox (max. input / output, using 8 IO Blox) 64/64 total per robot1
Conveyor tracking encoder Yes (2 max.)2
T20 Pendant option Yes
IP54/65 option Yes
Cleanroom option Yes
Pass-through, J1 to J4 7 air lines,
10 user electrical contacts

Chapter 1: Introduction
Feature Available
1Requires XBELTIO Cablefor 2nd group of 4 units.
2Requires XBELTIO Cable.
Robot Links and Joints
Figure 1-6. Robot Joints and Links
Robot Connections
This section describes the various external and internal ports and connectors that are available
on the standard Viper robot.
NOTE: Some connections may differ on robots with the IP54/65 or Cleanroom
options. Refer to IP54/65 Option Considerations on page 129 and Cleanroom
Option Considerations on page 131 for more information.
The external connections include:
lPneumatic pass-through ports
lElectrical pass-through connections
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 13

14 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Pneumatic Pass-through Ports
The pneumatic pass-through ports on the back of the robot connector panel are typically used
for end-effector control. Internal air lines are routed through the robot to another set of match-
ing connectors on the top of the outer link (link 2) as shown below.
Additional Information: Refer to Technical Specifications on page 107 for more
information.
CN22
CN20
AIR1
AIR2
Figure 1-7. Robot Air Connections (arrows)

Chapter 1: Introduction
A
B
Figure 1-8. Pneumatic Pass-through Ports from (B)Base to (A)Outer Link
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 15

16 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Electrical Pass-through Connections
A
B
Figure 1-9. Signal Wiring from (B)Robot Base to (A)Outer Link
eCS-ECAT Interface Panel
The eCS-ECAT includes the interface panel. It has connections for power (200-240 VAC, 24
VDC), communications, and other peripheral devices such as a pendant, IOBlox, or a Front
Panel.
Use the information below to understand all connection points for the eCS-ECAT
interfacepanel.

Chapter 1: Introduction
Figure 1-10. eCS-ECAT Interface Panel
Item Meaning
A ACPower Supply Connection
Used for connecting 200-240 VAC, single-phase input power to the eCS-ECAT.
A connector is provided with the robot.
Refer to Connecting 200-240 VAC Power Cable on page 76
B DCPower Supply Connection
Used for connecting the user-supplied 24 VDC power to the eCS-ECAT.
A connector is provided with the robot.
Refer to Connecting the 24 VDC Cable to the eCS-ECAT on page 73 for more
information.
C Ground Terminal
D XSYSTEM Connection
Refer to System Cable Installation on page 55
E EtherCAT Ports
Used for inbound and outbound EtherCAT communications.
FNode ID Switches
Used to set the robot's EtherCATnodeID.
Refer to Setting the EtherCATNodeID on page 50
GLEDs
Indicates the status of the EtherCAT connection.
Refer to EtherCAT Communications Description on page 88 for more inform-
ation.
HTwo 2-Position Mode Switches
Used to adjust the operating mode of the robot.
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 17

18 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Item Meaning
Refer to Robot Control Modes on page 91 for more information.
Additional Information: Switch 1 should remain in the NX / left
position. Functionality associated with switch 1 in the 3P / right
position is reserved for future use.
IXBELTIO Connection
Used to connect up to two external belt encoders and IO Blox external I/O module.
This requires the XBELTIO Adapter cable.
Refer to Basic System Cable Layout on page 55 for more information.
J XIO Connection
Used for user I/O signals for peripheral devices.
Refer to Basic System Cable Layout on page 55 for more information.
1.3 Robot Options
This section describes the various options available for a Viper robot.
!
WARNING: Ensure all optional equipment is installed properly and securely
fastened to the robot before operation. Failure to do so may result in personnel
injury or equipment damage.
IO Blox
The eCS-ECAT provides an interface to addIOBlox expansion I/O modules to a robot.
IO Blox units extend the robot's capabilities by providing expandable I/O capacity.
NOTE: Refer to Connecting Digital I/O to the System on page 62 and the IO Blox
User’s Guide (04638-000) for more information.
You can add up to 8 IO Blox units.

Chapter 1: Introduction
Figure 1-11. IO Blox
T20 Pendant
The T20 pendant is an optional hand held device that allows you to move the robot, teach loc-
ations, and debug programs without a PC. The pendant can also be used to move the robot
before calibration has occurred.
Additional Information: Refer to the T20 Pendant User's Manual (Cat. No. I601)
for more information about operating a robot with the T20 pendant.
IMPORTANT: The T20 pendant can only communicate with the robot it is dir-
ectly connected to.
21861-000 Rev A Viper 650 and 850 Robot with EtherCAT 19

20 Viper 650 and 850 Robot with EtherCAT 21861-000 Rev A
Figure 1-12. T20 Pendant
IPC Application Controller
The IPCApplicationController can be added to your system to execute PackManager and
Robot VisionManager applications.
Refer to the following manuals for more information.
lAutomationControl Environment (ACE)Version 4 User'sManual (Cat. No. I633)
lNJ-series Robot Integrated CPU Unit User's Manual (Cat. No. O037)
lIPC Application Controller User’s Manual (Cat. No. I632)
Figure 1-13. IPC Application Controller
Front Panel
The Front Panel is an optional device that provides the following functions.
lSetting the robot mode to manual or automatic. Refer to Robot Control Modes on page
91 for more information.
lIndicating the robot high power and system power state.
lRobot high power indicator burnout detection (see note below).
lEnabling robot high power. Refer to Enabling Robot High Power on page 93 for more
information.
lEmergency stop / disable robot high power.
Additional Information: Design of the factory-supplied Front Panel E-Stop is in
accordance with the requirements of IEC 60204-1 and ISO 13849.
IMPORTANT: If the Front Panel high power ON / OFF indicator fails, you might
incorrectly assume that High Power is OFF and the robot is safe. To prevent this,
a failed lamp causes an error (-924) *Front panel HIGHPOWERlamp failure*