Omron eCobra 600, eCobra 800 Inverted Robots, eCobra 800 User Manual

eCobra 600, 800 and 800 Inverted Robots

User’s Guide

I593-E-05

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 documentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us in preparation of future documentation. Please submit your comments to: techpubs@adept.com.

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 11

1.1 Product Description

eCobra Robot Models 12 eAIB (Amplifiers in Base) 13

1.2 eCobra Robot Features And Options

SmartController EX 15 ePLC Connect Software 15 IO Blox 15 SmartVision MX 15 T20 Pendant 15 Intelligent Force Sensing 15 ACE PackXpert Process Manager 15

1.3 How Can I Get Help?

Related Manuals 16

Chapter 2: Safety 17

2.1 Dangers, Warnings, and Cautions

Alert Levels 17 Alert Icons 17 Falling Hazards 17 Special Information 18

2.2 What to Do in an Emergency/Abnormal Situation

Releasing the Brakes 18 Releasing an E-Stop 18 Emergency Stop Circuit and Buttons 19 General Hazards 19

2.3 Safety Precautions

User's Responsibilities 19 Qualification of Personnel 20

2.4 Robot Behavior

Hardstops 21 Limiting Devices 21 Singularities 21

2.5 Intended and Non-intended Use

Intended Use 21 Non-Intended Use 22 Robot Modifications 22

2.6 Additional Safety Information

Manufacturer’s Declaration of Incorporation 22

14402-000 Rev. F eCobra User's Guide 3

Table of Contents

Robot Safety Guide 23 T20 Manual Control Pendant (Option) 23 Disposal 23

Chapter 3: Robot Installation 25

3.1 Installation Overview

3.2 Transport and Storage

3.3 Unpacking and Inspecting the Equipment

Before Unpacking 26 Upon Unpacking 26

3.4 Repacking for Relocation

3.5 Environmental and Facility Requirements

3.6 Mounting an Upright eCobra Robot

Mounting Surface 28 Mounting Procedure 29

3.7 Mounting an eCobra 800 Inverted Robot

Mounting Surface 30 Mounting Procedure 30

3.8 Mounting the Front Panel

3.9 Connectors on Robot Interface Panel (eAIB)

Chapter 4: System Installation 35

4.1 System Cables, without SmartController EX

List of Cables and Parts 36 Cable Installation Overview 38

4.2 System Cables, with SmartController EX

Installing a SmartController EX Motion Controller 41 List of Cables and Parts 41 Cable Installation Overview 43

4.3 OptionalCables

XIOBreakout Cable 44 DB9 Splitter Cable 44 eAIB XBELTIOAdapterCable 44 SmartController EX Belt Encoder Y-Adapter Cable 44

4.4 ACE Software

User-supplied PC 49 Installing ACESoftware 49

4.5 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power 50 24 VDC Mating Connector 51 Creating 24 VDC Cable 52 Connecting 24 VDC Cable 52

4 eCobra User's Guide 14402-000 Rev. F

Table of Contents

4.6 Connecting 200-240 VAC Power to Robot

Specifications for AC Power 54 AC Mating Connector 58 Creating the 200-240 VAC Cable 58 Connecting AC Power Cable 59

4.7 Grounding the Robot System

Grounding the Robot Base 59 Grounding Robot-Mounted Equipment 60

4.8 Configuring a PLC

4.9 Installing User-Supplied Safety Equipment

Emergency Stop Circuits 68 Remote Manual Mode 70 User Manual/Auto Indication 70 User High Power On Indication 70 Remote High Power On/Off Control 71 High Power On/Off Lamp 71 Remote Front Panel or User-Supplied Control Panel Usage 71 Remote Pendant Usage 72

Chapter 5: System Operation 73

5.1 Robot Status LED Description

5.2 Status Panel Fault Codes

Status Panel 74

5.3 Brakes

Brake Release Button 80 Remote Brake Release Feature 81

5.4 Front Panel

5.5 Connecting Digital I/O to the System

Optional I/O Products 83 Default Digital I/O Signal Configuration 84 eAIB XIO Connector Signals 86 XIO Input Signals 87 XIO Output Signals 90 XIO Breakout Cable 93

5.6 Starting the System for the First Time

Verifying Installation 95 Turning on Power 96 Starting ACE 96 Enabling High Power 97 Verifying E-Stop Functions 97 Verify Robot Motions 97

5.7 Learning to Program the eCobra Robot

14402-000 Rev. F eCobra User's Guide 5

Table of Contents

Chapter 6: Maintenance 99

6.1 Field-Replaceable Parts

6.2 Periodic Maintenance Schedule

6.3 Warning Labels

6.4 Checking Safety Systems

6.5 Checking Robot Mounting Bolts

6.6 Checking for Oil Leakage

6.7 Lubricating Joint 3

6.8 Replacing the eAIB Chassis

Removing the eAIB Chassis 107 Installing a New eAIB Chassis 109

6.9 Commissioning a System With An eAIB

Safety Commissioning Utilities 110 E-Stop Configuration Utility 112 E-Stop Verification Utility 113 Teach Restrict Configuration Utility 113 Teach Restrict Verification Utility 114

6.10 Replacing a MicroSD Card

Removing a MicroSD Card from an eAIB 115 Installing a MicroSD Card into an eAIB 117

6.11 Replacing the Encoder Battery Pack

Battery Replacement Time Periods 118 Battery Replacement Procedure 118

6.12 Changing the Lamp In the Front Panel High-Power Indicator

100

103

104

107

110

115

117

119

Chapter 7: Optional Equipment Installation 123

7.1 Installing End-Effectors

7.2 Removing and Installing the Tool Flange

Removing the Flange 123 Installing the Flange 124

7.3 User Connections on the Robot

User Air Lines 125 User Electrical Lines 126

7.4 Internal User Connectors

SOLND Connector 127 OP3/4 Connector 128 EOAPWR Connector 129 Internal User Connector Output Specifications 129 ESTOP Connector 130

7.5 Mounting Locations for External Equipment

7.6 Installing the Robot Solenoid Kit

6 eCobra User's Guide 14402-000 Rev. F

123

125

126

132

Table of Contents

Tools Required 133 Signal Setup 133

134 Installation 134 Testing 139

7.7 Installing the Camera Bracket Kit

Tools Required 140 Procedure 141

7.8 Installing Adjustable Hardstops

Joint 1 Adjustable Hardstops 142 Joint 2 Adjustable Hardstops 146

140

142

Chapter 8: Technical Specifications 153

8.1 Dimension Drawings

8.2 Robot Specifications

Physical 166 Performance 167 Stopping Distances and Times 167 Key to Graphs 168 Hardstops and Softstops 174

153

166

Chapter 9: IP65 Option 175

9.1 eCobra 800 Robots IP65 Classification

9.2 Installing Cable Seal Assembly

Cable Seal Identification 176 Installation Procedure 176

9.3 Robot Outer Link Cover Removal and Reinstallation

Cover Removal Procedure 178 Cover Reinstallation Procedure 180

9.4 Customer Requirements

Sealing the Tool Flange 181 Pressurizing the Robot 182

9.5 User Connectors

User Electrical and DeviceNet 183 User Air Lines 184 Robot Solenoid Option 184

9.6 Maintenance

IP65 Bellows Replacement 185

9.7 Dimension Drawing for Cable Seal Assembly

175

176

178

181

183

185

186

Chapter 10: Cleanroom Robots 189

Cleanroom Specifications 189

14402-000 Rev. F eCobra User's Guide 7

Table of Contents

10.1 Connections

10.2 Requirements

10.3 Exclusions and Incompatibilities

10.4 Cleanroom Maintenance

Bellows Replacement 191 Lubrication 192

190

191

8 eCobra User's Guide 14402-000 Rev. F

Revision History

Revision

code

Date Revised Content

01 June,

2016

02 February,

2017

03 August,

2017

04 April,

2018

05 March,

2019

Original release.

l Fixed default signal #s when no SmartController EX is present l Updated Safety chapter, misc. regulatory. l Clarified text about eAIB's RS-232 port when using a SmartCon-

troller EX.

l Clarified the use of "axis" and "joint". l Removed duplicate row in Chapter 8 table. l Minor clarifications to IP65 Option chapter to differentiate

between upright and inverted robots.

l Updated safety chapter and alert levels throughout manual. l Updated recommended power supply part numbers, T20 part

numbers, and XMCPjumper cable part numbers.

l Error reporting and Line E-Stop clarification. l Update ACE software disk to ACEsoftware media. l Corrected "SmartVisionEX" to "SmartVision MX" in system

cable drawing.

l Added WEEE Icon and Disposal section to Safety chapter. l Removed www.adept.com. l Added English condition to www.ia.omron.com. l Revised encoder battery replacement interval. l Updated Safety chapter. l Updated status code table in Chapter 5: Operation. l Updated illustrations with call-outs and tables for translation

compatibility. Other minor illustration improvements applied.

l Removed references to obsolete sDIOunit. l Corrections applied to Chapter 4: System Installation. l Added new figures to illustrate all encoder cable configurations

and pinouts in Chapter 4: System Installation.

l Removed Class 1 cleanroom note in Chapter 10: Cleanroom

Robots.

l Adjusted vacuum flow rates and air supply specifications for reg-

ular and inverted robots in Chapter 10: Cleanroom Robots.

l Adjusted text in Emergency Stop Circuits section in Chapter 4:

System Installation.

l Added a note about typical IO Blox configurations in Chapter 5:

System Operation.

l Dual-Robot Configuration Guide renamed to Single and Multiple

Robot Configuration Guide.

14402-000 Rev. F eCobra User's Guide 9

1.1 Product Description

eCobra robots are four-joint SCARA industrial robots (Selective Compliance Assembly Robot Arm). Joints 1, 2, and 4 are rotational, Joint 3 is translational. See Figure 1-2.

NOTE: The descriptions and instructions in this manual apply to the eCobra 600, eCobra 800, and eCobra 800 Inverted robots. When there are differences, such as in dimensions and work envelopes, the different models will be covered separately.

Chapter 1: Introduction

Figure 1-1. eCobra 800 Robot

By adding a SmartController EX or a PLC, the eCobra series robots replace the previous sCobra and Cobra ePLC series robots, so this manual replaces previous eCobra, sCobra, and Cobra ePLC User Guides.

14402-000 Rev. F eCobra User's Guide 11

1.1 Product Description

Figure 1-2. Robot Joint Motions - eCobra 600 Robot Shown

Table 1-1. Robot Joint Descriptions

Item Description

1 Joint 1

2 Joint 2

3 Joint 3

4 Joint 4

5 Inner Link

6 Outer Link

eCobra Robot Models

There are three tiers of eCobra robots, with 600 and 800 mm upright models and an 800 mm Inverted robot in each tier. In increasing order of performance and features, they are:

eCobra Lite

eCobra Standard

eCobra Pro

12 eCobra User's Guide 14402-000 Rev. F

Chapter 1: Introduction

eCobra robots of any given size and orientation are identical physically for each of the three tiers. The Pro models offer the fastest performance and the most features and connectivity. The Lite models offer the least. All nine models are covered in this manual.

All eCobra robots will typically be connected to a user-supplied PC running the ACE software.

eCobra robots can optionally be used with a SmartController EX motion controller, if more features and connectivity are needed. A SmartVision MX industrial PC can be added for more vision support. The eCobra Standard and eCobra Pro robots can be used with a user-supplied PLC and the ePLCConnect software option.

eAIB (Amplifiers in Base)

eCobra robots use an eAIB amplifier. The robots are programmed and controlled using the eAIB. The eAIB, embedded in the robot's base, contains the amplifiers and full servo control for the eCobra robots. The eAIB also provides the platform for running the eV+ OS and language.

eAIBFeatures

On-board digital I/O

Low EMI for use with noise sensitive equipment

No external fan, for quiet robot operation

l 8 kHz servo rate to deliver low positional errors and superior path following

Sine wave commutation to lower cogging torque and improve path following

Digital feed-forward design to maximize efficiency, torque, and velocity

Temperature sensors on all amplifiers and motors for maximum reliability and easy troubleshooting

Hardware-based E-Stop and Teach Restrict controls

For improved safety relative to European standards implemented in 2012

The eAIB fits all eCobra robots.

Figure 1-3. (1) eAIB Amplifier on eCobra Robot

14402-000 Rev. F eCobra User's Guide 13

1.2 eCobra Robot Features And Options

1.2 eCobra Robot Features And Options

The eAIB controller provides varying levels of vision support and connectivity. Some applications might call for more, in which case you could add a SmartController EX and/or a SmartVision MX industrial PC.

Feature eCobra Lite

eCobra

Standard

eCobra Pro

SmartController

EX Option

Vision - Yes Yes -

on-the-fly - - Yes -

I/O - max

12/8 44/40 76/72 524/520

XIO 12/8 12/8 12/8 eAIB +12/8

IEEE1394 2 2 2 eAIB + 3

IOBlox option - 8/8 x max 4 8/8 x max 8 -

RS-422/485 - - - 1

RS-232 - 1

DeviceNet - - - Option

Conveyors

- - 2

tracked

PLC support - Yes Yes -

ePLCI/O - - Yes -

PackXpert - Yes Yes Yes

Force Sensing - Yes

Yes

T20 Pendant

Yes Yes Yes n/a

option

IP65 option Yes Yes Yes n/a

Cleanroom

Yes Yes Yes n/a

option

Max Robots 1 1 1 4

Dual Robots - - - Yes

Max Joints 4 4 4 16

Pass-through, J1 to J2

Requires eAIB XBELT IO Adapter cable.

More I/Ocan be attained using DeviceNet and combinations of RS- ports, if needed.

5 air

24 user electric

1 DeviceNet

5 air

24 user electric

1 DeviceNet

5 air

24 user electric

1 DeviceNet

14 eCobra User's Guide 14402-000 Rev. F

Chapter 1: Introduction

SmartController EX

The SmartController EX motion controller can coordinate up to 4 robots, increasing the number of robot joints to 16 from the eCobra’s 4. It increases the I/O available, raises the number of serial ports by 3, and provides for tracking up to 4 additional conveyors.

NOTE: Since the eAIB has only one RS-232 port, adding a SmartController EX to the RS-232 port renders the port unusable. If using eV+, "SERIAL:0" will access the eAIB's RS-232 port.

TheSmartController EX supports the DeviceNet option, and allows for the use of third-party vision systems. One RS-485 port is available.

The SmartController EX is covered in the SmartController EX User's Guide.

ePLC Connect Software

The ePLC Connect software allows programming and operation of an eCobra robot directly from a PLC, using the software as an interface between the PLC and the robot. Refer to ePLC Connect 3.0 Software User's Guide.

IO Blox

Up to 8 IO Blox units can be added to increase the available I/O ports by 8 inputs and 8 outputs per unit. The IOBlox does not require a SmartController EX. Refer to the IO Blox User’s Guide.

SmartVision MX

The SmartVision MX is an industrial PC that provides vision-oriented connectivity, as well as extra I/O. It can drive up to 4 Gigabit and 4 USB 3.0 cameras. The Gigabit ports are PoE, so no extra power is needed to the cameras. Refer to the SmartVision MX User's Guide.

T20 Pendant

The T20 pendant provides manual control of an eCobra robot. This is generally used when teaching pick and place locations. Refer to the T20 Pendant User's Guide.

NOTE: Omron Adept Technologies, Inc. does not offer a cableless (wireless) pendant.

Intelligent Force Sensing

The Intelligent Force Sensing system is a hardware and software package that allows eCobra robots to react to sensed forces and moments at the tool flange, reducing force overshoot and stopping time when forces or moments exceed preset thresholds. Refer to the Intelligent Force Sensing System User's Guide.

ACE PackXpert Process Manager

PackXpert provides a point-and-click interface for configuring and programming the workcell. The PackXpert Process Manager is the recommended method for programming most applications. Refer to the ACE User’s Guide.

14402-000 Rev. F eCobra User's Guide 15

1.3 How Can I Get Help?

1.3 How Can I Get Help?

Refer to the corporate website:

http://www.ia.omron.com

Related Manuals

This manual covers the installation, operation, and maintenance of an eCobra robot system. For additional manuals covering programming the system, reconfiguring installed components, and adding optional components, see the following table.

Manual Title Description

Robot Safety Guide Contains safety information for robots.

ACE User’s Guide Instruction for the use of the ACE software.

Table 1-2. Related Manuals

SmartController EX User's Guide

SmartVision MX User's Guide Instructions for use of the optional SmartVision MX indus-

T20 Pendant User's Guide Describes the use of the optional T20 manual control

IO Blox User’s Guide Describes the IO Blox product.

Single and Multiple Robot Configuration Guide

Instructions for use of the optional SmartController EX motion controller.

trial PC.

pendant.

Contains cable diagrams and configuration procedures for a single and multi-robot system.

16 eCobra User's Guide 14402-000 Rev. F

2.1 Dangers, Warnings, and Cautions

Alert Levels

There are three levels of alert notation used in our manuals. In descending order of importance, they are:

DANGER: Identifies an imminently hazardous situation which, if not avoided, is likely to result in serious injury, and might result in fatality 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, fatality, or significant property damage.

CAUTION: Identifies a potentially hazardous situation which, if not avoided, might result in minor injury, moderate injury, or property damage.

Chapter 2: Safety

Alert Icons

The icon that starts each alert can be used to indicate the type of hazard. These will be used with the appropriate signal word - Danger, Warning, or Caution - to indicate the severity of the hazard. The text following the signal word will specify what the risk is, and how to avoid it.

Icon Meaning Icon Meaning

This is a generic alert icon. Any specifics on the risk will be in the text following the signal word.

Falling Hazards

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK If mounted incorrectly, the robot can fall over and cause serious injury to personnel or damage to itself or other equipment.

This identifies a hazardous electrical situation.

14402-000 Rev. F eCobra User's Guide 17

2.2 What to Do in an Emergency/Abnormal Situation

Safety Barriers

To protect personnel from coming in contact with robot unintentionally or objects entering robot’s operation zone, install user-supplied safety barriers in the workcell.

Special Information

There are several types of notation used to call out special information.

IMPORTANT: Information to ensure safe use of the product.

NOTE: Information for more effective use of the product.

Additional Information: Offers helpful tips, recommendations, and best prac-

tices.

Version Information: Information on differences in specifications for different versions of hardware or software.

2.2 What to Do in an Emergency/Abnormal Situation

Press any E-Stop button (a red push-button on a yellow background) and then follow the internal procedures of your company or organization for an emergency situation. If a fire occurs, use a type D extinguisher: foam, dry chemical, or CO2.

Releasing the Brakes

In case of entrapment of a person by the robot, or any other emergency of abnormal situation, the robot can be manually moved to a safe state without high voltage electric power. However only qualified personnel who have read and understood this manual and the Robot Safety Guide should manually move the robot. See Brake Release Button on page 80.

WARNING: PERSONALINJURYRISK eCobras are not collaborative robots. They require a dedicated work area that will prevent personnel from coming into contact with them during operation.

Releasing an E-Stop

CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK If the robot’s E-Stop is triggered, ensure that the cause of the E-Stop is resolved, and all surrounding areas are clear before releasing the E-Stop.

After the E-Stop button has been manually released, the robot will wait until the motors are manually enabled.

There are two ways to enable the motors:

Enable power through ACE software installed on your PC.

Press the ROBOTPOWER button on the Pendant.

18 eCobra User's Guide 14402-000 Rev. F

Chapter 2: Safety

Once the motors are enabled, the robot will wait two seconds and then resume commanded motion, if there is adequate space to maneuver.

Emergency Stop Circuit and Buttons

The E-Stop provided complies with ISO 10218-1 (Clause 5.5.2), with stop category 1 (per IEC

60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d per ISO 13849.

If you design your own front panel, it must meet the requirements of ISO13849, and be at least PL-d. The E-Stop button must comply with IEC 60204-1 and ISO13850, Clause 5.5.2.

If you choose to use your own E-Stop buttons, they must meet the requirements of IEC 60204-1 and ISO 13850, Clause 5.5.2.

General Hazards

IMPORTANT: The following situations could result in injury or damage to the equipment.

Do not place objects on the robot.

Do not exceed the maximum payload capacity.

Do not exceed the maximum recommended moment of Inertia, speed, and rotation limits. See Technical Specifications on page 153.

Do not drop the robot, put weights on it or otherwise operate it irresponsibly.

Do not use unauthorized parts.

2.3 Safety Precautions

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK An eCobra robot can cause serious injury or death, or damage to itself and other equipment, if the safety precautions in this manual are not observed.

WARNING: ELECTROCUTIONRISK During maintenance, disconnect AC power from the robot, and install a lockout tag-out to prevent anyone from reconnecting power.

User's Responsibilities

Safe use of the eCobra robot is your responsibility. To ensure compliance with safety rules and regulations:

All personnel who install, operate, teach, program, or maintain an eCobra robot system must read this guide, read the Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot.

14402-000 Rev. F eCobra User's Guide 19

2.3 Safety Precautions

All personnel who design an eCobra robot system must read this guide, read the Robot Safety Guide, and must comply with all local and national safety regulations for the location in which the robot is installed.

Figure 2-1. Read Manual and Impact Warning Labels

The eCobra robot system must not be used for purposes other than described in Intended Use on page 21. Contact Omron Adept Technologies, Inc. if you are not sure of the suitability for your application.

l The environment must be suitable for safe operation of the robot.

The user is responsible for providing safety barriers around the robot to prevent anyone from accidentally coming into contact with the robot when it is in motion.

Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed.

The eCobra Robots must be well maintained, so that their control and safety functions continue to work properly.

Qualification of Personnel

It is the end-user’s responsibility to ensure that all personnel who will work with or around robots have attended an appropriate Omron training course and have a working knowledge of the system. The user must provide the necessary additional training for all personnel who will be working with the system.

As noted in this and the Robot Safety Guide, certain procedures should be performed only by skilled or instructed persons. For a description of the level of qualification, we use the standard terms:

Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers, electrical and/or mechanical

Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers, electrical and/or mechanical

All personnel must observe industry-prescribed safety practices during the installation, operation, and testing of all electrically-powered equipment.

IMPORTANT: Before working with the robot, every entrusted person must confirm that they:

Have the necessary qualifications

Have received the guides (both this user’s guide, and the Robot Safety Guide)

20 eCobra User's Guide 14402-000 Rev. F

Have read the guides

Understand the guides

Will work in the manner specified by the guides

2.4 Robot Behavior

Hardstops

If the eCobra Robot runs into one of its hardstops, the robot`s motion will stop completely, an envelope error will be generated, and power will be cut to the robot motors. The robot cannot continue to move after hitting a hardstop until the error has been cleared.

The eCobra’s hardstops are capable of completely stopping the robot at any speed, load, and maximum or minimum extension.

Limiting Devices

There are no dynamic or electro-mechanical limiting devices provided by Omron Adept Technologies, Inc. The robot does not have safety-rated soft axis or space limiting.

Chapter 2: Safety

However, the user can install their own safety rated (category 0 or 1) dynamic limiting devices if needed, that comply with ISO10218-1, Clause 5.12.2.

Singularities

No singularities exist that cause a hazardous situation with an eCobra robot.

2.5 Intended and Non-intended Use

Intended Use

The normal and intended use of these robots does not create hazards. The eCobra robots have been designed and constructed in accordance with the relevant requirements of IEC60204-1.

The eCobra robots are intended for use in parts assembly and material handling for payloads less than 5.5 kg (12.1 lb). See Robot Specifications on page 166 for complete information on the robot specifications. Refer to the Robot Safety Guide for details on the intended use of eCobra robots.

WARNING: PERSONALINJURYRISK eCobra robots are not collaborative robots. They require a dedicated work area that will prevent personnel from coming into contact with them during operation.

Guidelines for safe use:

Clean, dry mounting surfaces — surfaces that are routinely kept free of debris and liquids.

14402-000 Rev. F eCobra User's Guide 21

2.6 Additional Safety Information

Temperature — 5 to 40°C (41 to 104°F), with a recommended humidity range of 5% to 90%, non-condensing.

Non-Intended Use

The eCobra robots are not intended for use in any of the following situations:

Use in the presence of ionizing or non-ionizing radiation

Use in potentially explosive atmospheres

Use in medical or life saving applications

Use in a residential setting. They are for industrial use only

Use before performing a risk assessment

Where the equipment will be subject to extremes of heat or humidity

IMPORTANT: The instructions for operation, installation, and maintenance given in this guide and Robot Safety Guide must be strictly observed.

Non-intended use of eCobra robots can:

Cause injury to personnel

Damage itself or other equipment

Reduce system reliability and performance

If there is any doubt concerning the application, ask your your local Omron support to determine if it is an intended use or not.

Robot Modifications

If the user or integrator makes any changes to the robot, it is their responsibility to ensure that there are no sharp edges, corners, or protrusions.

Note that any change to the robot can lead to loss in safety or functionality. The user or integrator must ensure that all safety features are operational after modifications.

2.6 Additional Safety Information

Contact your local Omron support for other sources of safety information:

Manufacturer’s Declaration of Incorporation

This lists all standards with which the robot complies. The Manufacturer’s Declarations for the eCobra robot and other products are in the Manufacturer's Declarations.

22 eCobra User's Guide 14402-000 Rev. F

Chapter 2: Safety

Robot Safety Guide

The Robot Safety Guide, which ships with every robot system, provides detailed information on safety for Omron Adept Technologies, Inc. robots. It also gives resources for information on relevant standards.

T20 Manual Control Pendant (Option)

The protective stop category for the pendant enable switch is category 1, which complies with the requirements of ISO 10218-1. The pendant is designed in accordance with the requirements of IEC 60204-1 and ISO 13849. The E-Stop button is ISO 13850 compliant.

NOTE: Omron Adept Technologies, Inc. does not offer a cableless (wireless)pendant.

The manual control pendant can only move one robot at a time, even if multiple robots are connected to a SmartController EX, and the pendant is connected to the SmartController EX.

Disposal

Dispose of in accordance with applicable regulations.

Customers can contribute to resource conservation and protecting the environment by the proper disposal of WEEE (Waste Electronics and Electrical Equipment). All electrical and electronic products should be disposed of separately from the municipal waste system via designation collection facilities. For information about disposal of your old equipment, contact your local Omron support.

14402-000 Rev. F eCobra User's Guide 23

3.1 Installation Overview

The system installation process is summarized in the following table.

NOTE: For multi-robot installations, see the Single and Multiple Robot Con- figuration Guide.

Task to be Performed Reference Location

Mount the robot to a flat, secure mounting surface. See Mounting an Upright eCobra

Chapter 3: Robot Installation

Table 3-1. Installation Overview

Robot on page 27 or Mounting an eCobra 800 Inverted Robot on page 30.

Install the Front Panel, pendant, and ACE software. The pendant is an option.

Create a 24 VDC cable and connect it between the robot and the user-supplied 24 VDC power supply.

Create a 200-240 VAC cable and connect it between the robot and the facility AC power source.

Install user-supplied safety barriers in the workcell. See Installing User-Supplied Safety

Learn about connecting digital I/O through the XIO connector on the eAIB.

Learn about starting the system for the first time. See Starting the System for the First

Learn about installing optional equipment, including end-effectors, user air and electrical lines, external equipment, solenoids, etc.

3.2 Transport and Storage

This equipment must be shipped and stored in a temperature-controlled environment, within the range –25 to +60° C (-13 to +140° F). The recommended humidity range is 5% to 90%, noncondensing. It should be shipped and stored in the supplied crate, which is designed to prevent damage from normal shock and vibration. You should protect the crate from excessive shock and vibration.

See System Installation on page 35.

See Connecting 24 VDC Power to Robot on page 50.

See Connecting 200-240 VAC Power to Robot on page 54.

Equipment on page 62.

See eAIB XIO Connector Signals on page 86.

Time on page 94.

See Optional Equipment Installation on page 123.

Use a forklift or pallet jack to transport the packaged equipment. See Figure 3-1.

14402-000 Rev. F eCobra User's Guide 25

3.3 Unpacking and Inspecting the Equipment

The robots must always be stored and shipped in an upright position in a clean, dry area that is free from condensation. Do not lay the crate on its side or any other non-upright position; this could damage the robot.

The eCobra 600 robot weighs 41 kg (90 lb), the eCobra 800 robot weighs 43 kg (95 lb), and the eCobra 800 Inverted weighs 51 kg (112 lb), all with no options installed.

3.3 Unpacking and Inspecting the Equipment

Before Unpacking

Carefully inspect all shipping crates for evidence of damage during transit. Pay special attention to any tilt and shock indication labels on the exteriors of the containers. If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked.

Upon Unpacking

Before signing the carrier’s delivery sheet, please compare the actual items received (not just the packing slip) with your equipment purchase order and verify that all items are present and that the shipment is correct and free of visible damage.

If the items received do not match the packing slip, or are damaged, do not sign the receipt. Contact Omron Adept Technologies, Inc. as soon as possible.

If the items received do not match your order, please contact Omron Adept Technologies, Inc. immediately.

Inspect each item for external damage as it is removed from its container. If any damage is evident, contact Omron Adept Technologies, Inc.. See How Can I Get Help? on page 16.

Retain all containers and packaging materials. These items may be necessary to settle claims or, at a later date, to relocate equipment.

3.4 Repacking for Relocation

If the robot or other equipment needs to be relocated, reverse the steps in the installation procedures that follow. Reuse all original packing containers and materials and follow all safety notes used for installation. Improper packaging for shipment will void your warranty. Specify this to the carrier if the robot is to be shipped.

CAUTION: PROPERTYDAMAGERISK Before unbolting the robot from the mounting surface, fold the outer arm against the Joint 2 hardstops to help centralize the center of gravity. The robot must always be shipped in an upright orientation.

26 eCobra User's Guide 14402-000 Rev. F

3.5 Environmental and Facility Requirements

The robot system installation must meet the operating environment requirements shown in the following table.

Table 3-2. Robot System Operating Environment Requirements

Ambient temperature 5 to 40° C (41 to 104° F)

Shipping/storage temperature –25 to 55° C (-13 to 131° F)

Humidity 5% to 90%, non-condensing

Altitude up to 2000 m (6500 ft)

Pollution degree 2

Robot protection class IP20 (NEMA Type 1)

IP65 Versions IP65

Cleanroom rating, cleanroom models only ISO 4, Fed Reg Class 10

Chapter 3: Robot Installation

NOTE: For robot dimensions, see Dimension Drawings on page 153.

3.6 Mounting an Upright eCobra Robot

This section applies to the eCobra 600 and eCobra 800 robots, but not the eCobra 800 Inverted robot.

Figure 3-1. eCobra 800 Robot on a Transportation Pallet

14402-000 Rev. F eCobra User's Guide 27

3.6 Mounting an Upright eCobra Robot

+0.015

2x R4

160

200

+0.015

Ø 8

Ø 14 THRU

234

338

Table 3-3. Lifting Points for Robot while on a Transportation Pallet

Item Description

1 Eyebolt for lifting robot after robot has been unbolted from the transportation pallet.

2 Place for forklift or pallet-jack here.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK Only qualified service personnel may install or service the robot system.

Mounting Surface

The upright eCobra robots are designed to be mounted on a smooth, flat, level surface. The mounting structure must be rigid enough to prevent vibration and flexing during robot operation. We recommend a 25 mm (1 in.) thick steel plate mounted to a rigid tube frame. Excessive vibration or mounting flexure will degrade robot performance. The following figure shows the mounting hole pattern for the eCobra robots.

NOTE: On the under side of the base there is a hole and a slot that can be used as locating points for user-installed dowel pins in the mounting surface; see the following figure. Using locating pins will improve the ability to remove and reinstall the robot in the same position.

Figure 3-2. Mounting Hole Pattern for Upright eCobra Robots (Units in mm)

28 eCobra User's Guide 14402-000 Rev. F

Mounting Procedure

Using the dimensions shown in the previous figure, drill and tap the mounting surface for four M12 - 1.75 x 36 mm (or 7/16 - 14 UNC x 1.50 in.) machine bolts (mounting hardware is user-supplied).

If you are using dowel pins for locating the robot, insert those in the mounting surface.

While the robot is still bolted to the transportation pallet, connect a hydraulic lift to the eyebolt at the top of the inner link. See Figure 3-1.

Remove the four bolts securing the robot base to the pallet.

Retain these bolts for possible later relocation of the equipment.

Chapter 3: Robot Installation

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK Do not attempt to lift the robot at any points other than the eyebolt provided. Do not attempt to extend the inner or outer links of the robot until the robot has been secured in position. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage.

Lift the robot and position it directly over the mounting surface.

Slowly lower the robot while aligning the base and the tapped holes in the mounting surface.

NOTE: The base casting of the robot is aluminum and can easily be dented if bumped against a harder surface.

Verify that the robot is mounted squarely (cannot rock back and forth) before tightening the mounting bolts.

Install the user-supplied mounting bolts and washers. Tighten bolts to the torque specified in the following table.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK The center of mass of the robot may cause the robot to fall over if the robot is not secured with the mounting bolts.

NOTE: Check the tightness of the mounting bolts one week after initial installation, and then recheck every 6 months. See Maintenance on page 99 for periodic maintenance.

Table 3-4. Mounting Bolt Torque Specifications

Standard Size Specification Torque

Metric M12 x 1.75 ISO Property Class 8.8 85 N·m

SAE 7/16-14 UNC SAE J429 Grade 5 or

ASTM A449

14402-000 Rev. F eCobra User's Guide 29

65 ft-lb

3.7 Mounting an eCobra 800 Inverted Robot

107

160

205

160

189

4X Ø 14 Thru

Ø 8

2X R 4

+ 0.015

0.000

+ 0.015

0.000

3.7 Mounting an eCobra 800 Inverted Robot

Mounting Surface

The eCobra 800 Inverted robot is designed to be mounted in an inverted position. When designing the mounting structure, you must account for both load and stiffness. The mounting structure must be rigid enough to prevent vibration and flexing during robot operation. Excessive vibration or mounting flexure will degrade robot performance. The mounting structure should be stiff enough so that the first vibration mode is greater than 70 Hz.

The following figure shows the mounting hole pattern.

Figure 3-3. Robot Mounting Dimensions for eCobra Inverted Robot (Units in mm)

NOTE: On the robot mounting surface, there is a hole and a slot that can be used as locating points for user-installed dowel pins in the mounting surface. Using locating pins can improve the ability to remove and reinstall the robot in the same position.

Mounting Procedure

Always use at least two people, and preferably three, to mount the robot.

The robot should be in the folded position when lifting. See the following figure.

30 eCobra User's Guide 14402-000 Rev. F

Chapter 3: Robot Installation

183.2

278

500

778

Figure 3-4. Robot in Folded Position (Units in mm)

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK Do not attempt to extend the inner or outer links of the robot until the robot has been secured in position. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage.

Using the dimensions shown in Figure 3-3. , drill and tap the mounting surface for four M12 - 1.75 x 36 mm (or 7/16 - 14 UNC x 1.50 in.) machine bolts (mounting hardware is user-supplied).

If you are using dowel pins for locating the robot, insert those in the mounting surface.

Remove the four screws on top of the wooden robot base protection box. See Figure 3-5.

Remove the robot base protection box.

Retain the four screws and box for possible later relocation of the equipment.

Figure 3-5. Pallet Lifting Device (1) Insertion Point

14402-000 Rev. F eCobra User's Guide 31

3.8 Mounting the Front Panel

While the robot is still bolted to the transportation pallet, use a forklift or other mechanical lifting device to lift the robot and position it directly under the mounting surface. Make sure that one person watches the robot carefully as it is lifted and transported, to ensure it does slip or become unbalanced.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK The center of mass of the robot may cause the robot to fall over if the robot is not secured to the pallet.

Slowly lift the robot while aligning the base and the tapped mounting holes in the mounting surface.

Install, but do not tighten, the user-supplied mounting bolts and washers.

CAUTION: PROPERTYDAMAGERISK The base casting of the robot is aluminum and can easily be dented if bumped against a harder surface.

NOTE: Verify that the robot is mounted squarely (will not rock back and forth) before tightening the mounting bolts.

Remove the bolts securing the robot to the pallet.

Retain these bolts for possible later relocation of the equipment.

Move the pallet out of the way.

Tighten the mounting bolts to the torque specified.

Table 3-5. Mounting Bolt Torque Specifications

Standard Size Specification Torque

Metric M12 x 1.75 ISO Property Class 8.8

SAE 7/16-14 UNC SAE J429 Grade 5 or

NOTE: Check the tightness of the mounting bolts one week after installation, and then recheck every 6 months. See Maintenance on page 99 for periodic maintenance.

3.8 Mounting the Front Panel

The Front Panel must be installed outside of the workspace.

85 N·m

65 ft-lbf

ASTM A449

NOTE: European standards require that the remote High Power push-button be located outside of the workspace of the robot.

32 eCobra User's Guide 14402-000 Rev. F

3.9 Connectors on Robot Interface Panel (eAIB)

GND

C 1Ø

200-240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

24 VDC—for connecting user-supplied 24 VDC power to the robot. The mating connector is provided.

Ground Point—for connecting cable shield from user-supplied 24 VDC cable.

200/240 VAC — for connecting 200-240 VAC, single-phase, input power to the robot. The mat-

ing connector is provided. The cable is user-supplied.

XIO (DB26, high density, female) — for user I/O signals for peripheral devices. This connector provides 8 outputs and 12 inputs. For connector pin allocations for inputs and outputs, see eAIB XIO Connector Signals on page 86. That section also contains signal numbers to access these I/O signals via eV+.

XBELTIO — (this is not supported on eCobra Lite robots) adds two belt encoders (Pro only), an RS-232 interface, and either Intelligent Force Sensing or IO Blox support. This requires the eAIB XBELT IO Adapter cable.

SmartServo x2 (IEEE1394) — for connecting the IEEE 1394 cable from an optional controller to the robot. The servo connectors can also be used to connect to a second robot or another 1394based motion axis.

Chapter 3: Robot Installation

XSYSTEM — The Front Panel, optional T20 pendant, and XUSR cable connect here. This uses the eAIB XSYSTEM cable. See System Cables, without SmartController EX on page 35.

If you are using an optional SmartController EX, it uses the eAIB XSYS cable, instead of this cable, and the Front Panel and T20 pendant connect to the SmartController EX.

ENET — Two Ethernet ports are available. One will be needed to connect to a PC running ACE software or a user-supplied PLC.

Figure 3-6. Robot Interface Panel

14402-000 Rev. F eCobra User's Guide 33

Chapter 4: System Installation

DC IN 24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

XMCP

XFP

XUSR

200 - 240 VAC

eCobra Robot

SmartVision MX

DC IN 24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

This chapter does not cover I/O. Refer to Connecting Digital I/O to the System on page 83.

4.1 System Cables, without SmartController EX

The letters in the following figure correspond to the letters in Table 4-1. Cables and Parts Description (without SmartController EX). The numbers in the following figure correspond to the numbers in Table 4-2. Connections Installation Steps.

Figure 4-1. System Cable Diagram for eCobra Robots, Pendant and Vision Shown

14402-000 Rev. F eCobra User's Guide 35

4.1 System Cables, without SmartController EX

The figure above includes the optional T20 pendant, optional SmartVision MX industrial PC, and optional PLC. These items may not be present in your system.

NOTE: For additional system grounding information, see Connecting 24 VDC Cable on page 52.

List of Cables and Parts

Open the Accessory box and locate the eAIB XSYSTEM cable. Connect the cables and peripherals as shown in the preceding figure. Installation steps are covered in Cable Installation Overview on page 38.

Table 4-1. Cables and Parts Description (without SmartController EX)

Item Description Part #

A eAIB XSYSTEM Cable

Assembly

B User E-Stop, Safety

Gate

C XUSR Jumper Plug 04736-

D Front Panel 90356-

E Front Panel Cable 10356-

F Front Panel Jumper

Plug

13323000

n/a X

000

10358

10500

10053000

Standard Option

X Required if no

X X Front Panel (D)

X X

X Front Panel (D)

User-

supplied

Notes

E-stop, safety gate or muted safety gate used.

or Front Panel Jumper Plug (F) must be used.

G XMCP Jumper Plug 10052-

000

H T20 Pendant Bypass

Plug

10048000

X XMCPJumper

Plug (G), T20 Pendant Bypass Plug (H), or T20 Pendant Assembly (W)must be used.

X XMCPJumper

Plug (G), T20 Pendant

36 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Item Description Part #

I T20 Pendant Adapter

Cable

The following three items are available, as an option, in the power supply/cable kit 90565-010

J VAC Power Cable 04118-

K 24 VDC Power Cable 04120-

L 24 VDC, 6 A Power

Supply

M Ethernet Cable -

switch -> eAIB

N Ethernet Cable -

switch -> SmartVisionMX

10051003

000

04536000

n/a X

Standard Option

X X 200-240 VAC,

X X

X X 85-264 VAC

User-

supplied

Notes

Bypass Plug (H), or T20 Pendant Assembly (W) must be used.

single phase

universal input

O Ethernet switch n/a X

P Camera and cable n/a X X

Q Ethernet Cable -

switch - > PLC (only while programming PLC)

R Robot Interface Panel n/a X

S User-supplied ground

wire

T PCrunning

ACESoftware

U Ethernet Cable - PC->

ethernet switch

V PLC(optional) X

W T20 Pendant

Assembly

n/a X

10054010

X X

X Optional T20

Pendant Kit (10046- 010) includes items W, H, and I.

14402-000 Rev. F eCobra User's Guide 37

4.1 System Cables, without SmartController EX

The XUSR, XMCP, and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup.

WARNING: PERSONALINJURYRISK Under no circumstances should you run an eCobra system, in production mode, with all three jumpers installed. This would leave the system with no EStops.

Cable Installation Overview

Table 4-2. Connections Installation Steps

Step Connection Description Item

1 Connect eAIB XSYSTEM cable to XSYSTEM on eMB-40R. A, R

2 Connect a user E-Stop or Muted Safety Gate to the eAIB XSYSTEM cable

XUSR connector or verify XUSR jumper plug (2a) is installed in eAIB XSYSTEM cable XUSR connector.

Refer to Installing User-Supplied Safety Equipment on page 62 for more information.

3 Connect Front Panel cable to Front Panel and eAIB XSYSTEM cable XFP con-

nector.

If no Front Panel is used, install FP jumper (3a) on eAIB XSYSTEM cable XFP connector. See NOTE after table.

4 Connect T20 adapter cable and the T20 Pendant to eAIB XSYSTEM cable

XMCP connector.

If no T20 Pendant, install XMCP jumper (4a) or T20 Adapter Cable with T20 bypass plug (4b).

5 Connect user-supplied ground.

Refer to Grounding the Robot System on page 59 for more information.

6 Connect Ethernet cable from PLCto switch, if a PLCis used.

Refer to Configuring a PLC on page 60 for more information.

7 Connect 200-240 VAC to VAC Input on eAIB Interface Panel; secure with

clamp.

B, C

D, E, F

G or H, I, T20 Pendant

J, R

Refer to System Installation on page 35 for more information.

8 Connect 24 VDC to DC Input on Interface Panel.

Connect 24 VDC and shield ground to SmartVision MX, if used (8a). See SmartVision MX user's guide for location.

Refer to Connecting 24 VDC Power to Robot on page 50 for more information.

9 Connect Ethernet cable from switch to eAIB. M, O, R

K, L, R

38 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Step Connection Description Item

10 Connect Ethernet cable from switch to SmartVision MX, if used. N, O

11 Connect optional camera and cable to SmartVision MX, if used. P

12 Connect Ethernet cable from PC to switch if used. T, U

NOTE: A front panel ships with each eCobra robot system, but you can choose not to use it if you replace its functionality with equivalent circuits. That is beyond the scope of this guide.

14402-000 Rev. F eCobra User's Guide 39

4.2 System Cables, with SmartController EX

SmartController EX

COM1

COM2

MOUSE KEYBD

DVI

VGA

LAN1 USB

LAN2 USB

LOUT

LIN

MIC

POWER

HDD SYS

24VCD 6A

SmartVision EX

SmartVision MX

eCobra Robot

200-240 VAC 10 A

DC IN 24V

GND

200 -

240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

DC IN 24 V

GND

200 240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

4.2 System Cables, with SmartController EX

The letters in the following figure correspond to the letters in Table 4-3. Cables and Parts Description (with SmartController EX). The numbers in the following figure correspond to the numbers in Table 4-4. Connections Installation Steps(with SmartController EX).

When the optional SmartController EX is included in the system, the Pendant, Front Panel, and XUSR connections must connect to the SmartController EX.

Figure 4-2. System Cable Diagram with SmartController EX

40 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Installing a SmartController EX Motion Controller

Refer to the SmartController EX User’s Guide for complete information on installing the optional SmartController EX. This list summarizes the main steps.

Mount the SmartController EX and Front Panel.

Connect the Front Panel to the SmartController EX.

Connect the pendant (if purchased) to the SmartController EX.

Connect a jumper plug, if no pendant is being used.

Connect user-supplied 24 VDC power to the controller.

Instructions for creating the 24 VDC cable, and power specification, are covered in the SmartController EX User’s Guide.

Install a user-supplied ground wire between the SmartController EX and ground.

List of Cables and Parts

Table 4-3. Cables and Parts Description (with SmartController EX)

Part Cable and Parts

List

A eAIB XSYS Cable 13323-

B User E-Stop, Safety

Gate

C XUSR Jumper Plug 04736-

D Front Panel 90356-

E Front Panel Cable 10356-

F Front Panel Jumper

Plug

Part # Standard Option

000

n/a X

000

10358

10500

10053-

000

User-

supplied

X Required if no E-

X X Front Panel (D) or

X X

X Front Panel (D) or

Notes

stop, safety gate or muted safety gate used.

Front Panel Jumper Plug (F) must be used.

G XMCP Jumper Plug 10052-

000

X XMCP Jumper Plug

(G), T20 Pendant

14402-000 Rev. F eCobra User's Guide 41

4.2 System Cables, with SmartController EX

Part Cable and Parts

List

H T20 Pendant Bypass

Plug

I T20 Pendant Adapter

Cable

The following three items are available, as an option, in the power supply/cable kit 90565-010

J VAC Power Cable 04118-

K 24 VDC Power Cable 04120-

L 24 VDC, 6 A Power

Supply

M Ethernet Cable,

Switch (if used) -> SmartController EX

Part # Standard Option

10048-

000

10051-

003

000

04536-

000

n/a X

X XMCP Jumper Plug

X X 200-240 VAC,

X X

X X 85 - 264

User-

supplied

Notes

Bypass Plug (H), or T20 Pendant (W) must be used.

(G), T20 Pendant Bypass Plug (H), or T20 Pendant (W) must be used.

single phase

VACuniversal input

N Ethernet Cable,

Switch (if used) -> SmartVision MX, if used

O IEEE 1394 cable 13632-

P Camera and cable n/a X X

Q Robot Interface Panel n/a X

R User-supplied ground

wire

S PCrunning ACE Soft-

ware

T Ethernet Switch n/a X

U Ethernet Cable - PC -

> ethernet switch

V PLC (optional) X X

W T20 Pendant

Assembly

n/a X

045

n/a X

10054-

010

X Optional T20 Pend-

ant Kit (10046-

010) includes items W, H, and I.

42 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

The XUSR, XMCP, and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup.

WARNING: PERSONALINJURYRISK Under no circumstances should you run an eCobra system, in production mode, with all three jumpers installed. This would leave the system with no EStops.

Cable Installation Overview

Power requirements for the SmartVision MX industrial PCare covered in that user guide. For 24 VDC, both the eCobra robot and a SmartVision MX can usually be powered by the same power supply.

Table 4-4. Connections Installation Steps(with SmartController EX)

Step Connection Part

1 Connect eAIB XSYS cable to XSYSTEM on eAIB. A

2 Connect a user E-Stop or Muted Safety Gate to the XUSR connector

or verify XUSR jumper plug is installed in XUSR connector (2a).

Refer to Installing User-Supplied Safety Equipment on page 1 for more information.

3 Connect Front Panel cable to Front Panel and XFP connector or if no

Front Panel, install FP jumper on XFP connector (3a).

4 Connect Pendant adapter cable to XMCP connector and T20 Pendant.

If no Pendant, install XMCP jumper (4a) or bypass plug (4b).

5 Connect user-supplied ground to robot, SmartController EX, and

Smart Vision MX. See user's guides for locations.

Refer to Grounding the Robot System on page 59 for more information.

6 Connect 200-240 VAC to VAC Input on eAIB Interface Panel; secure

with clamp.

Refer to Connecting 200-240 VAC Power to Robot on page 54 for more information.

7 Connect 24 VDC to DC Input on Interface Panel.

Connect 24 VDC and shield ground to SmartVision MX, if used (8a). See SmartVision MX user's guide for location.

B, C

D, E, F

H, I, G, T20 Pendant

J, Q

Q, K, L

Connect 24 VDC to SmartController EX, if used (8b).

Refer to Connecting 24 VDC Power to Robot on page 50 for more information.

8 Connect Ethernet cable to SmartController EX, if used. M,T

9 Connect Ethernet cable to SmartVision MX, if used. N, T

14402-000 Rev. F eCobra User's Guide 43

4.3 OptionalCables

Step Connection Part

10 Connect IEEE1394 cable between SmartController EXand eAIB

SmartServo.

11 Connect optional camera and cable to SmartVision MX, if used. P

12 Connect Ethernet cable from PC to switch if used. S, T, U

13 Connect optional PLC to switch, if used.

Refer to Configuring a PLC on page 60 for more information.

4.3 OptionalCables

XIOBreakout Cable

The XIO Breakout cable is for using the I/O on the eAIB. See Optional XIO Breakout Cable on page 93. This cable provides access to 12 inputs and 8 outputs (5 m).

DB9 Splitter Cable

An optional Y cable attaches at the SmartController EX XSYS connector and splits it into two XSYS connectors. This is part number 00411-000. See the Single and Multiple Robot Con- figuration Guide.

eAIB XBELTIOAdapterCable

O, Q

T, V

The optional eAIBXBELT IO Adapter cable split the eAIB XBELTIO port into a belt encoder lead, an Intelligent Force Sensor or IOBlox lead, and an RS-232 lead. If the system has a SmartController EX, this is only needed for Intelligent Force Sensing.

Find the pin connection diagrams in the figures below.

SmartController EX Belt Encoder Y-Adapter Cable

The optional SmartController EX Belt Encoder Y-Adapter cable split the SmartController EX BELTENCODER port into two belt encoder leads for encoders 1 and 2 and encoders 3 and 4.

Find the pin connection diagrams in the figures below.

44 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

600 ± 25

3000 ± 50

500 ± 25

XBELT IO

13463-000

BELT

ENCODER

FORCE/

EXPIO

RS232

BELT ENC.

09443-000

BELT ENC.

09443-000

BELT ENC.

09443-000

BELT ENC.

09550-000

BELT ENC.

#1 AND #2

BELT ENC.

#3 AND #4

SmartController EX

Figure 4-3. System Cable Diagram with Belt Encoders (Units in mm)

14402-000 Rev. F eCobra User's Guide 45

4.3 OptionalCables

Table 4-5. Conveyor Belt Encoder Cables Description

Item Description Part # Standard Option

A Robot InterfacePanel n/a X

B eAIBXBELTIOAdapterCable

Connector

C Belt Branch Connector DB 15 Male

D Force / EXPIOBranch Con-

nector

E RS232 Branch Connector DB9 Male

F Belt Y Splitter Cable Con-

nector

G Belt Encoder 1 Connector M12 Female,

H Belt Encoder 2 Connector M12 Female,

I SmartController EX

(optional)

J SmartController EX Belt

Encoder Y Adapter Cable Connector

13463000

09443000

19300000

09550000

X X HDB26

X X DB15

X X HDB26

User-

supplied

Notes

Female

DB9 Male

Female

8-pin

Female

K Belt Branch Connector,

Encoder 1 and 2

L Belt Branch Connector,

Encoder 3 and 4

DB15 Male

46 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

PIN 15 PIN 7 PIN 14 PIN 6 PIN 13 PIN 5 PIN 11 PIN 3 PIN 10 PIN 2 PIN 9 PIN 1 PIN 4 PIN 12

PIN 2 (ENC1_A+) PIN 3 (ENC1_A-) PIN 11 (ENC1_B+) PIN 12 (ENC1_B-) PIN 19 (ENC1_Z+) PIN 20 (ENC1_Z-) PIN 4 (ENC2_A+) PIN 5 (ENC2_A-) PIN 13 (ENC2_B+) PIN 14 (ENC2_B-) PIN 21 (ENC2_Z+) PIN 22 (ENC2_Z-) PIN 1 (5V) PIN 10 (GND)

PIN 8 PIN 1

PIN 15 PIN 9

PIN 1

PIN 10

PIN 19

PIN 9

PIN 18

PIN 26

SHIELD

PIN 5 PIN 4 PIN 6 PIN 1 PIN 3 PIN 2

PIN 7 (CLK +) PIN 8 (CLK -) PIN 6 (EXPIO 5V) PIN 15 (GND) PIN 16 (DATA +) PIN 17 (DATA -)

PIN 1 PIN 5

PIN 6

PIN 1

PIN 10

PIN 19

PIN 9

PIN 18

PIN 26

PIN 9

SHIELD

PIN 3 PIN 2 PIN 5

PIN 25 (TXD) PIN 26 (RXD) PIN 18 (GND)

PIN 1

PIN 10

PIN 19

PIN 9

PIN 18

PIN 26

PIN 1 PIN 5

PIN 6

PIN 9

SHIELD

Figure 4-4. eAIBXBELTIOAdapterCable Pinout - Encoder 1 and 2 Connections

NOTE: Cable shields connected to DSUBshell.

Figure 4-5. eAIBXBELTIOAdapterCable Pinout - Force / EXPIO Connections

NOTE: Cable shields connected to DSUBshell.

14402-000 Rev. F eCobra User's Guide 47

Figure 4-6. eAIBXBELTIOAdapterCable Pinout - RS232 Connections

NOTE: Cable shields connected to DSUBshell.

4.3 OptionalCables

PIN 1 PIN 15 (ENC1_A+)

SHIELD

PIN 3

PIN 7 (ENC1_A-)

PIN 4

PIN 14 (ENC1_B+)

PIN 5

PIN 6 (ENC1_B-)

PIN 6

PIN 13 (ENC1_I+)

PIN 8

PIN 5 (ENC1_I-)

PIN 2

PIN 4 (5V)

PIN 7

PIN 12 (GND)

PIN 11 (ENC2_A+) PIN 3 (ENC2_A-) PIN 10 (ENC2_B+) PIN 2 (ENC2_B-) PIN 9 (ENC2_I+) PIN 1 (ENC2_I-) PIN 4 (5V) PIN 12 (GND)

PIN 1 PIN 3 PIN 4 PIN 5 PIN 6 PIN 8 PIN 2 PIN 7

PIN 1

PIN 8

PIN 2

PIN 3

PIN 4

PIN 5

PIN 6

PIN 7

PIN 1

PIN 8

PIN 2

PIN 3

PIN 4

PIN 5

PIN 6

PIN 7

SHIELD

SHIELDSHIELD

PIN 8

PIN 1

PIN 15PIN 9

Figure 4-7. Belt YSplitter Cable Pinout - 2 Encoder Connections

NOTE: Cable shields connected to DSUBshell.

48 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

PIN 15 PIN 2 (ENC1_A+)

SHIELD

PIN 7

PIN 3 (ENC1_A-)

PIN 14

PIN 11 (ENC1_B+) PIN 6 PIN 12 (ENC1_B-) PIN 13 PIN 19 (ENC1_Z+) PIN 5

PIN 20 (ENC1_Z-) PIN 11

PIN 1 (5V)

PIN 3

PIN 10 (GND)

SHIELD

PIN 10 PIN 2 PIN 9 PIN 1

PIN 12

PIN 4

PIN 4 (ENC2_A+)

PIN 5 (ENC2_A-)

PIN 13 (ENC2_B+)

PIN 14 (ENC2_B-)

PIN 21 (ENC2_Z+)

PIN 22 (ENC2_Z-)

PIN 6 (ENC3_A+)

PIN 7 (ENC3_A-)

PIN 15 (ENC3_B+)

PIN 16 (ENC3_B-)

PIN 23 (ENC3_Z+)

PIN 24 (ENC3_Z-)

PIN 1 (5V)

PIN 10 (GND)

SHIELD

PIN 8 (ENC4_A+)

PIN 9 (ENC4_A-)

PIN 17 (ENC4_B+)

PIN 18 (ENC4_B-)

PIN 25 (ENC4_Z+)

PIN 26 (ENC4_Z-)

PIN 15

SHIELD

PIN 7 PIN 14 PIN 6 PIN 13 PIN 5 PIN 11 PIN 3

PIN 10 PIN 2 PIN 9 PIN 1

PIN 12

PIN 4

PIN 8 PIN 1

PIN 15 PIN 9

PIN 8 PIN 1

PIN 15 PIN 9

PIN 1

PIN 10

PIN 19

PIN 9

PIN 18

PIN 26

4.4 ACE Software

14402-000 Rev. F eCobra User's Guide 49

User-supplied PC

The user loads the ACE software onto the PC and connects it to the eAIB via an Ethernet cable. Depending on the other equipment in the system, there may be an Ethernet switch between the two.

Installing ACESoftware

The ACE software media will display a ReadMe file when inserted in your PC. This contains hardware and software requirements for running ACE software.

You install ACE from the software media. ACE needs Microsoft .NET Framework. The ACE Setup Wizard scans your PC for .NET, and installs it automatically if it is not already installed.

Figure 4-8. SmartController EX Belt Encoder Y Adapter Cable Connections

NOTE: Cable shields connected to DSUBshell.

4.5 Connecting 24 VDC Power to Robot

Insert the ACEsoftware media into your PC.

If Autoplay is enabled, the menu is displayed. If Autoplay is disabled, you will need to manually access the mediacontent.

NOTE: The online document that describes the installation process opens in the background when you select one of software installation steps below.

Especially if you are upgrading your ACE software installation: from the ACE software menu, click Read Important Information.

From the ACE software menu, select:

Install the ACE Software

The ACE Setup wizard opens.

Follow the online instructions as you step through the installation process.

When the installation is complete, click Finish.

After closing the ACE Setup wizard, click Exit on the menu to close the menu.

NOTE: You will have to restart the PC after installing ACE software.

4.5 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power

Table 4-6. Specifications for 24 VDC User-Supplied Power Supply

User-Supplied Power Supply 24 VDC (± 10%), 150 W (6 A)

Circuit Protection

Power Cabling 1.5 – 1.85 mm² (16-14 AWG)

Shield Termination Braided shield connected to frame ground

User-supplied 24 V power supply must incorporate overload protection to limit peak power to less than 300 W, or 8 A in-line circuit protection must be added to the 24 V power source. (In case of multiple units on a common 24 V supply, each unit must be protected individually.)

(21.6 V < Vin< 26.4 V)

Output must be less than 300 W peak

8 Amp in-line circuit protection

terminal at both ends of cable. See Figure 4-9.

NOTE: Fuse information is located on the eAIB electronics.

The power requirements for the user-supplied power supply will vary depending on the configuration of the robot and connected devices. We recommend a 24 V, 6 A power supply to

50 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

A B

allow for startup current draw and load from connected user devices, such as solenoids and digital I/O loads. If multiple robots are sharing a 24 V power supply, increase the supply capacity by 3 A for each additional robot.

Single eCobra robot, no other units:6 A

Additional eCobra robots:add 3 A per robot

SmartVision MX:add 4 to 7 A, depending on camera load

SmartController EX:add 2 to 5 A, depending on I/O load

NOTE: Make sure you select a 24 VDC power supply that meets the specifications in the previous table. Using an under-rated supply can cause system problems and prevent your equipment from operating correctly. See the following table for a recommended power supply.

Table 4-7. Recommended 24 VDC Power Supply

Vendor Name Model Ratings

Mount

OMRON S8FS-G15024C 24 VDC, 6.5 A, 150 W Front Mount

OMRON S8FS-G15024CD 24 VDC, 6.5 A, 150 W DIN-Rail Mount

24 VDC Mating Connector

The 24 VDC mating connector and two pins are supplied with each system. They are shipped in the cable/accessories box.

Table 4-8. 24 VDC Mating Connector Specs

Connector Details

Connector receptacle, 2 position, type: Molex Saber, 18 A, 2-Pin

Molex P/N 44441-2002

Digi-Key P/N WM18463-ND

A: 24 VReturn

B:24 VDC

Pin Details Molex connector crimp terminal,

female, 14-18 AWG

Molex P/N 43375-0001

Digi-Key P/N WM18493-ND

Recommended crimping tool, Molex Hand Crimpers

Molex P/N 63811-0400

Digi-Key P/N WM9907-ND

14402-000 Rev. F eCobra User's Guide 51

4.5 Connecting 24 VDC Power to Robot

NOTE: The 24 VDC cable is not supplied with the system, but is available in the optional Power Cable kit. See List of Cables and Parts on page 41.

Creating 24 VDC Cable

Locate the connector and pins shown in Table 4-8.

Use 14-16 AWG wire to create the 24 VDC cable. Select the wire length to safely reach from the user-supplied 24 VDC power supply to the robot base.

Crimp the pins onto the wires using the crimping tool.

Insert the pins into the connector. Confirm that the 24 V and 24 V return wires are in the correct terminals in the plug.

Prepare the opposite end of the cable for connection to the user-supplied 24 VDC power supply.

NOTE: If you are using the optional SmartController EX motion controller, you also must create a separate 24 VDC cable for it. That cable uses a different style of connector. See the SmartController EX User's Guide.

Connecting 24 VDC Cable

Connect one end of the shielded 24 VDC cable to your user-supplied 24 VDC power supply. The cable shield should be connected to frame ground on the power supply. Do not turn on the 24 VDC power until instructed to do so in Turning on Power on page 96. See the following figure.

Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the back of the robot. The cable shield should be connected to the ground point on the interface panel.

52 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

–

eCobra Robot

SmartController EX

–

GND

SmartVision MX

Figure 4-9. User-Supplied 24 VDC Cable, Power Supply

Table 4-9. User-Supplied 24 VDCCable, Power Supply Description

Item Description

1 User-suppliedPower Supply, 24 VDC

2 Optional Equipment

3 User-supplied, Shielded PowerCable

4 Circuit Protection, 8 Amax.

5 Shield - attach from user-supplied cable to ground screw on eCobra robot interface

6 Shield - attach from user-supplied cable to frame ground on power supply.

7 Shield - attach from user-supplied cable to left wire slot of SmartVision MX.

8 Shield - attach from user-supplied cable to side of SmartController EX using star

panel.

washer and M3 x 6 screw.

14402-000 Rev. F eCobra User's Guide 53

4.6 Connecting 200-240 VAC Power to Robot

CAUTION: PROPERTYDAMAGERISK The 24 VDCoutput must be less than 300 W peak or 8 Amp (max) in-line circuit protection must be provided, separately, for each connected robot, SmartController EX, and SmartVision MX.

NOTE: In order to maintain compliance with standards, we recommend that DC power be delivered over a shielded cable, with the shield connected to frame ground at both ends of the cable.

4.6 Connecting 200-240 VAC Power to Robot

WARNING: ELECTROCUTIONRISK Appropriately sized Branch Circuit Protection and Lockout / Tagout Capability must be provided in accordance with the National Electrical Code and any local codes. Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system.

WARNING: ELECTROCUTIONRISK During installation, user-supplied fail-safe lockout measures must be used to prevent, unauthorized third parties from turning on power. This is mandated by Clause 5.2.4 of ISO 10218-1.

During any maintenance-related activities, care must be taken involving AC power lockout. It is the user’s responsibility to make sure adequate measures are taken to

l lockout/ tagout power to the robot and related equipment.

l make sure that the robot cannot be energized during maintenance, as

mandated by Clause 5.2.4 of ISO 10218-1.

Specifications for AC Power

Table 4-10. Specifications for 200/240 VAC User-Supplied Power Supply

Auto-Ranging

Nominal

Voltage

200 V to 240 V 180 V 264 V 50/60 Hz

Minimum

Operating

Voltage

Maximum

Operating

Voltage

Frequency/

Phasing

External Circuit

Breaker,

User-Supplied

10 Amps

1-phase

Specifications are established at nominal line voltage. Low line voltage can affect robot

performance.

54 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Table 4-11. Typical Robot Power Consumption

eCobra Robot

Move

600 No load—Adept cycle

5.5 kg—Adept cycle

Average

Power (W)

344 1.56 1559

494 2.25 2061

5.5 kg—all joints move 880 4.00 2667

800 No load—Adept cycle

5.5 kg—Adept cycle

377 1.71 1406

531 2.41 1955

5.5 kg—all joints move 794 3.61 2110

For short durations (100 ms).

For details on Adept cycle, see Robot Specifications on page 166.

NOTE: The eCobra robot system is intended to be installed as a piece of equipment in a permanently-installed system.

WARNING: ELECTROCUTIONRISK eCobra robot systems require an isolating transformer for connection to mains systems that are asymmetrical or use an isolated (impedant) neutral. Many parts of Europe use an impedant neutral.

RMS Current

(A)

Peak Power

(W)

WARNING: ELECTROCUTIONRISK AC power installation must be performed by a skilled and instructed person— refer to the Robot Safety Guide. During installation fail-safe lockout measures must be used to prevent, unauthorized third parties from turning on power. This is mandated by Clause 5.2.4 of the ISO 10218-1.

Failure to use appropriate power (less than or more than the rated voltage range of 200-240 VAC) can lead to malfunction or failures of the robot or hazardous situations.

Facility overvoltages Protection

The user must protect the robot from excessive overvoltages and voltage spikes. If the country of installation requires a CE-certified installation, or compliance with IEC1131-2, the following information may be helpful: IEC 1131-2 requires that the installation must ensure that CategoryII overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltages CategoryII, i.e., not higher than the impulse voltage corresponding to the rated voltage for the basic insulation. The user-supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient.

14402-000 Rev. F eCobra User's Guide 55

4.6 Connecting 200-240 VAC Power to Robot

EENNL

eCobra Robots

1Ø 200–240

VAC

In the industrial environment, nonperiodic overvoltage peaks may appear on mains power supply lines as a result of power interruptions to high-energy equipment (such as a blown fuse on one branch in a 3-phase system). This will cause high current pulses at relatively low voltage levels. The user shall take the necessary steps to prevent damage to the robot system (such as by interposing a transformer). See IEC 1131-4 for additional information.

AC Power Diagrams

Figure 4-10. Typical AC Power Installation with Single-Phase Supply

Table 4-12. Single-Phase Power Supply Description

Item Description

1 1 Ø, 200-240 VAC @ 20A

L = Line

N = Neutral

E = Earth Ground

2 User- supplied ACPower Cable

3 User- supplied fuse, slow blow, 10A

56 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

EENL3L

eCobra Robots

1Ø 200–240 VAC

Figure 4-11. Single-Phase Load across L1 and L2 of a Three-Phase Supply

Table 4-13. Three-phase Power Supply Description

Item Description

1 3 Ø, 200-240 VAC

2 200 -240 VAC

3 User-supplied fuses, slow blow, 10 A

4 User-supplied ACPower Cable

5 L = Line 1

N = Line 2

E = Earth Ground

NOTE: If a three-phase power source is used, it must be symmetrically-earthed (with grounded neutral). Connections called out as single-phase can be wired Line-to-Neutral or Line-to-Line.

14402-000 Rev. F eCobra User's Guide 57

4.6 Connecting 200-240 VAC Power to Robot

AC Mating Connector

The AC mating connector is supplied with each system. It is shipped in the cable/accessories box. The supplied plug is internally labeled for the AC power connections (L, E, N).

Table 4-14. AC Mating Connector Details

AC Connector details AC in-line power plug,

straight, female, screw terminal, 10 A, 250 VAC

Qualtek P/N 709-00/00

Digi-Key P/N Q217-ND

NOTE: The AC power cable is not supplied with the system.

Creating the 200-240 VAC Cable

Locate the AC mating connector shown in the previous table.

Open the connector by unscrewing the screw on the shell and removing the cover.

Loosen the two screws on the cable clamp. See Figure 4-12.

Use 18 AWG wire to create the AC power cable. Select the wire length to safely reach from the user-supplied AC power source to the robot base.

Strip approximately 18 to 24 mm insulation from each of the three wires.

Insert the wires into the connector through the removable bushing.

Connect each wire to the correct terminal screw, and tighten the screw firmly.

Tighten the screws on the cable clamp.

Reinstall the cover and tighten the screw to seal the connector.

10.

Prepare the opposite end of the cable for connection to the facility AC power source.

58 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Figure 4-12. AC Power Mating Connector

Table 4-15. AC Power Mating Connector Description

Item Description

1 Earth

2 Neutral

3 Removable Bushing

4 Cable Clamp

5 Line

Connecting AC Power Cable

Connect the unterminated end of the AC power cable to your facility AC power source. See AC Power Diagrams on page 56. Do not turn on AC power at this time.

Plug the AC connector into the AC power connector on the interface panel on the robot.

Secure the AC connector with the locking latch.

4.7 Grounding the Robot System

Proper grounding is essential for safe and reliable robot operation. Follow these recommendations to properly ground your robot system.

Grounding the Robot Base

The user can install a ground wire at the robot base to ground the robot. See the following figure. The robot ships with an M8 x 12 stainless steel, hex-head screw, and M8 split and flat

14402-000 Rev. F eCobra User's Guide 59

4.8 Configuring a PLC

washers installed in the grounding hole. The user is responsible for supplying the ground wire to connect to earth ground.

Figure 4-13. (1) Ground Point on Robot Base and (2) Ground Label

NOTE: The resistance of the earth ground conductor must be ≤ 10 Ω.

Grounding Robot-Mounted Equipment

The following two parts of an eCobra robot are not grounded to protective earth: the Joint 3 quill and the tool flange. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment or tooling to the ground point on the robot base. Hazardous voltages can be considered anything in excess of 30 VAC (42.4 VAC peak) or 60VDC.

Also, for the grounding point on the tool flange, see Figure 8-6.

WARNING: ELECTROCUTIONRISK Failing to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end-effector when an electrical fault condition exists.

4.8 Configuring a PLC

A PLC is user-supplied. This section describes how to configure your PLC for automatic startup when the system boots.

Start the ACE software.

Open the Controller object.

In the Configure tab, select Configure Controller, then click Finish.

60 eCobra User's Guide 14402-000 Rev. F

Select SYSTEM_SECTION >eplc_autostart.

Chapter 4: System Installation

Click Edit (or double-click the selection).

Check the eplc_autostart box. It defaults to unchecked.

14402-000 Rev. F eCobra User's Guide 61

4.9 Installing User-Supplied Safety Equipment

Save the configuration by clicking Accept and then Yes.

4.9 Installing User-Supplied Safety Equipment

The user is responsible for installing safety barriers to protect personnel from coming in contact with the robot unintentionally. Depending on the design of the workcell, safety gates, light curtains, and emergency stop devices can be used to create a safe environment. Read the Robot Safety Guide for a discussion of safety issues.

The user-supplied safety and power-control equipment connects to the system through the XUSR and XFP connectors on the eAIB XSYSTEM cable. The XUSR connector (25-pin) and XFP (15-pin) connector are both female D-sub connectors. Refer to the following table for the XUSR pin-out descriptions. See "Contacts Provided by the XFP Connector" for the XFP pin-out descriptions. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 66 for the XUSR wiring diagram.

62 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Table 4-16. Contacts Provided by the XUSR Connector

Pin Pairs

Description Comments

Voltage-Free Contacts Provided by Customer

1, 14 User E-Stop CH 1 (mushroom

N/C contacts, Shorted if NOT Used

push-button, safety gates, etc.)

2, 15 User E-Stop CH 2 (same as pins

N/C contacts, Shorted if NOT Used

1, 14)

3, 16 Line E-Stop (used for other robot or

N/C contacts, Shorted if NOT Used assembly line E-Stop interconnection. Does not affect E-Stop indication (pins 7, 20))

4, 17 Line E-Stop (same as pins 3, 16) N/C contacts, Shorted if NOT Used

5, 18 Muted safety gate CH 1 (causes E-

N/C contacts, Shorted if NOT Used Stop in Automatic mode only)

6, 19 Muted Safety Gate CH 2 (same as

N/C contacts, Shorted if NOT Used pins 5, 18)

Voltage-Free Contacts provided by eCobra

7, 20 E-Stop indication CH 1 Contacts are closed when Front Panel,

pendant, and customer E-Stops are not

tripped

8, 21 E-Stop indication CH 2 (same as

pins 7, 20)

Contacts are closed when Front Panel,

pendant, and customer E-Stops are not

tripped

9, 22 Manual/Automatic indication CH 1 Contacts are closed in Automatic mode

10, 23 Manual/Automatic indication CH 2 Contacts are closed in Automatic mode

11, 12,

No connection

13, 24, 25

14402-000 Rev. F eCobra User's Guide 63

4.9 Installing User-Supplied Safety Equipment

Table 4-17. Contacts Provided by the XFP Connector

Pin Pairs

Description Requirements for User-

Supplied Front Panel

Voltage-Free Contacts Provided by Customer

1, 9 Front Panel E-Stop CH 1 User must supply N/C con-

tacts

2, 10 Front Panel E-Stop CH 2 User must supply N/C con-

tacts

3, 11 Remote Manual/Automatic switch CH 1.

Manual = Open Automatic = Closed

4, 12 Remote Manual/Automatic switch CH 2.

Manual = Open Automatic = Closed

Optional - jumper closed for Auto Mode-only operation

6, 14 Remote High Power on/off momentary push-button User must supply moment-

ary push-button to enable High Power to system

Non-voltage-Free Contacts

5, 13 System-Supplied 5 VDC and GND for High Power

On/Off Switch Lamp

User must supply lamp, or use 1 W, 47 ohm resistor system will not operate if not present

7, 15

Controller system 5 V power on LED, 5 V, 20mA Optional - indicator only

8 No connection

See the figure Front Panel Schematic on page 68 for a schematic diagram of the Front Panel.

Users must exercise caution to avoid inadvertently connecting 24 V signals to these pins,

because this will damage the electronics.

NOTE: The system was evaluated by Underwriters Laboratory with a Front Panel. Using a substitute front panel could void UL compliance.

64 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Table 4-18. Remote Pendant Connections on the XMCP Connector

Pin XMCP (15-Pin D-Sub)

Description

1, 9 Pendant E-Stop Push-button CH 1

2, 10 Pendant E-Stop Push-button CH 2

3, 11 Pendant Enable CH 1 (Hold-to-run)

4, 12 Pendant Enable CH 2 (Hold-to-run)

13 Serial GND/Logic GND

7 Pendant TXD: “eV+to Pendant TXD”

8 Pendant RXD: “eV+to Pendant RXD”

14 No connection

15 No connection

Shield Shield GND

6 24 V

5 No connection

The following figure shows an E-Stop diagram for the system. See Emergency Stop Circuits on page 68 for a description of the functionality of this circuit.

14402-000 Rev. F eCobra User's Guide 65

4.9 Installing User-Supplied Safety Equipment

ES1

ES2

XSYSTEM-31

(XFP-1)

XSYSTEM-20

(XFP-9)

(XPND-7)

XSYSTEM-24

(XPND-24)

(XUSR-1)

(XUSR-14)

XSYSTEM-13

(XUSR-3)

(XPND-9)

XSYSTEM-8

(XPND-26)

XSYSTEM-32 (XFP-2)

(XFP-10)

(XPND-6)

(XPND-23)

(XUSR-2)

(XUSR-15)

XSYSTEM-43 (XUSR-4)

XSYSTEM-39 (XUSR-17)

XSYSTEM-9 (XUSR-16)

(XPND-8)

XSYSTEM-38 (XPND-25)

XSYSTEM-29 (XUSR-18)

XSYSTEM-44 (XUSR-19)

ES1

ES2

SR1 SR2

AM2 AM1

XSYSTEM-14

(XUSR-5)

XSYSTEM-30 (XUSR-6)

XSYSTEM-33 (XFP-13)

XSYSTEM-3 (XFP-5)

XSYSTEM-31 (XFP-6)

XSYSTEM-34 (XFP-14)

XSYSTEM-5

(XFP-4)(XFP-3)

XSYSTEM-19 (XFP-12)

XSYSTEM-4

(XFP-11)

AM2

Coil

AM1 Coil

XSYSTEM-12 (XUSR-9)

XSYSTEM-28 (XUSR-10)

AM2

AM1

XSYSTEM-42 (XUSR-23)

XSYSTEM-27 (XUSR-22)

XSYSTEM-26 (XUSR-8)

XSYSTEM-10 (XUSR-7)

XSYSTEM-25 (XUSR-20)

XSYSTEM-40 (XUSR-21)

Figure 4-14. E-Stop Circuit on XUSR and XFP Connectors

66 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

Table 4-19. E-Stop Circuit on XUSR and XFPConnectors Description

Item Description

1 ESTOP 24 VSource

2 ESTOPGround

3 Front Panel ESTOPPushbutton

4 T20 ESTOPPushbutton

5 User E-Stop and Gate Interlock (jumper closed when not used, must open both chan-

nels independently if used)

6 LINEE-Stop (external user E-Stop system)

7 T20 Pendant Enable

8 Muted Safety Gate - Active in auto mode only (jumper closed when not used)

9 Manual Mode Path

10 Auto Mode Path

11 Force-Guided Relay Cyclic Check Control Circuit

12 Single-Phase AC Input, 200-240 VAC

13 High Power to Amplifiers (internal connections)

14 Front Panel High Power ON / OFF (6 V, 1.2 W bulb)

15 ESTOP24VSource

16 Front Panel Auto / Manuals Keyswitch

17 Auto / Manual Output

18 User ESTOP Output

14402-000 Rev. F eCobra User's Guide 67

4.9 Installing User-Supplied Safety Equipment

ESTOPSRC

24 VS

5 VD

SYSPWRLT 7

2 3

11 12 13 14 15

XFP

15PDSUBM

MANUALSRC1

HIPWRREQ

MANUALRLY2

MANUALRLY1

HIPWRLT

ESTOPFP2

ESTOPFP1

HPLT5V

MANUALSRC2

MANUALSRC1

SW1

MANUALRLY2 MANUALRLY1

MANUALSRC2

24 VS

SWL1

HIPWRREQ

HPLT5 V

HIPWRLT

ESTOPSRC

SW2

ESTOPFP2 ESTOPFP1

5 VD

2-PIN_MINI

SYSPWRLT

2 4

Figure 4-15. Front Panel Schematic

Table 4-20. Front Panel Schematic Description

Item Description

1 System Power LED

2 Manual / Auto

3 High Power ON / OFF

4 Emergency Stop

Emergency Stop Circuits

The eAIB XSYSTEM cable provides connections for Emergency Stop (E-Stop) circuits on the XUSR and XFP connectors. This gives the controller system the ability to duplicate E-Stop functionality from a remote location using voltage-free contacts. See Figure 4-14.

The XUSR connector provides external two-channel E-Stop input on pin pairs 1, 14 and 2, 15. The XFP connector provides two-channel E-Stop input on pin pairs 1, 9 and 2, 10.

NOTE: These pin pairs must be shorted if not used. Both channels must open independently if used. The controller will flag an error state if one channel is jumpered closed and the other channel is opened, although an Emergency Stop will still occur. It will also flag an error state if the independent channels are crossed, meaning one line from each channel is accidentally connected to the other channel.

68 eCobra User's Guide 14402-000 Rev. F

Chapter 4: System Installation

User E-Stop Indication Contacts - Remote Sensing of E-Stop

These contacts provide a method to indicate the status of the ESTOP chain, inclusive of the Front Panel Emergency Stop push-button, the pendant Emergency Stop push-button, and the User Emergency Stop Contacts.

NOTE: These contacts do not indicate the status of any connections below the User E-Stop contacts. Thus, they will NOT indicate the status of the Line E-Stop, MCP ENABLE, or the Muted Safety gate. If you have a specific need in this area, contact your local Omron support for information on alternate indicating modes.

Two pairs of pins on the XUSR connector (pins 7, 20 and 8, 21) provide voltage-free contacts, one for each channel, to indicate whether the E-Stop chain, as described above, on that channel is closed. Both switches are closed on each of the redundant circuits in normal operation (no E-Stop). The user may use these contacts to generate an E-Stop for other equipment in the workcell. The load on the contacts must not exceed 40 VDC or 30VAC at a maximum of 1 A.

These voltage-free contacts are provided by a redundant, cyclically-checked, positive-drive, safety relay circuit for Category 3 PL-d per ISO 13849 operation (see Figure 4-14. and the table Contacts Provided by the XFP Connector on page 64 for the customer E-Stop circuitry).

Line E-Stop Input

The XUSR connector on the controller contains a two-channel Line E-Stop input for workcell, production line, or other equipment emergency-stop inputs. Generally, the customer E-Stop Indication contact outputs are used to generate an emergency stop in such external equipment. Thus, if one were to wire the same equipment’s outputs into the customer E-Stop input (that is, in series with the local robot’s E-Stop push-buttons), a lock-up situation could occur.

The Line E-Stop input comes into the circuit at a point where it cannot affect the customer EStop indication relays and will not cause such a lock-up situation. For any situation where two systems should be cross-coupled, for example, the customer E-Stop indication of one controller is to be connected to the input of another controller, the Line E-Stop input is the point to bring in the other controller’s output contacts. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 66 for more information.

Do not use the Line E-Stop for such devices as local E-Stop push-buttons, since their status should be reported to the outside on the local user E-Stop indication output contact while the Line E-Stop inputs will not.

Muted Safety Gate E-Stop Circuitry

Two pairs of pins on the XUSR connector (pins 5, 18 and 6, 19) provide connections for a safety gate designed to yield an E-Stop allowing access to the workspace of the robot in Manual mode only, not in Automatic mode. It is up to the customer to determine if teaching the robot in Manual Mode, by a skilled programmer (See Qualification of Personnel in the Robot Safety Guide), wearing safety equipment and carrying a pendant, is allowable under local regulations. The E-Stop is said to be “muted” in Manual mode (for the customer E-Stop circuitry, see the figures and tables at the beginning of this section).

The muted capability is useful for a situation where a shutdown must occur if the cell gate is opened in Automatic mode, but you need to open the gate in Manual mode. If the mute gate is opened in Automatic mode, the robot defaults to Manual mode operation when power is reenabled. In muted mode, the gate can be left open for personnel to work in the robot cell. However, safety is maintained because of the speed restriction.

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4.9 Installing User-Supplied Safety Equipment

WARNING: PERSONALINJURYRISK If you want the cell gate to always cause a robot shutdown, wire the gate switch contacts in series with the user E-Stop inputs. Do not wire the gate switch into the muted safety gate inputs.

Remote Manual Mode

The Front Panel provides for a Manual Mode circuit. See Remote High Power On/Off Control on page 71 for further details about the customer Remote Manual Mode circuitry.

The Front Panel, or the user-supplied panel, must be incorporated into the robot workcell to provide a “Single Point of Control” (the pendant) when the controller is placed in Manual mode. Certain workcell devices, such as PLCs or conveyors, may need to be turned off when the operating mode switch is set to Manual mode. This is to ensure that the robot controller does not receive commands from devices other than from the pendant, the single point of control.

If the user needs to control the Manual/Automatic mode selection from other control equipment, then a custom splitter cable or complete replacement of the Front Panel may be required. See Front Panel Schematic on page 68. In this situation, a pair of contacts should be wired in series with the Front Panel Manual/Automatic mode contacts. Thus, both the Front Panel and the customer contacts need to be closed to allow Automatic mode.

WARNING: PERSONALINJURYRISK Do not wire user-supplied Manual/Automatic contacts in parallel with the Front Panel switch contact. This would violate the “Single Point of Control” principle and might allow Automatic (high-speed) mode to be selected while an operator is in the cell.

User Manual/Auto Indication

Two pairs of pins on the XUSR connector (pins 9, 22 and 10, 23) provide a voltage-free contact to indicate whether the Front Panel and/or remote Manual/Automatic switches are closed. The user may use these contacts to control other mechanisms (for example, conveyor, linear modules, etc.) when Manual mode is selected. The load on the contacts should not exceed 40 VDC or 30 VAC at a maximum of 1 A.

WARNING: PERSONALINJURYRISK Return any suspended safeguards to full functionality prior to selecting Automatic Mode.

User High Power On Indication

In the optional SmartController EX, eV+ controls a normally-open relay contact on the XDIO connector (pins 45, 46, see the table XDIO Digital I/O Connector Pin Assignments in the SmartController EX manual), that will close when high power has been enabled. The user can use this feature to power an indicator lamp or other device, that signals High Power is On. The limit on these contacts is 1 A at 30 VDC or 30 VAC.

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Chapter 4: System Installation

Remote High Power On/Off Control

The easiest and most effective way to provide the high power on/off control in a remote location is to mount the Front Panel in the desired location with an extension cable.

However, if the user needs to control high power on/off from other control equipment or from a location other than the Front Panel, then a custom splitter cable will be required. See the Front Panel schematic (Front Panel Schematic on page 68) for details of the Front Panel’s wiring. In this situation, a second momentary contact for high power on/off would be placed in parallel with the Front Panel push-button contact. This second contact should be suppressed when in Manual mode (see the note on “Single Point of Control” below).

This method allows relocating the push-button switch to a more convenient location. Implementation of this method must conform to EN standard recommendations.

NOTE: European standards require that the remote High Power push-button be located outside of the workspace of the robot.

Pins 6, 14 and 5, 13 of the XFP connector provide this remote capability. Pins 5, 13 provide power for the lamp, +5 VDC and ground, respectively. Pins 6, 14 are inputs for voltage-free normally-open contacts from a user-supplied momentary push-button switch.

WARNING: PERSONALINJURYRISK To fulfill the “Single Point of Control” requirement, do not place the Manual/Automatic and High Power On controls in multiple locations. After putting the robot into Manual mode, the operator should remove the key for safety purposes. The system should not be wired so that a PLC or another operator can put the system back into Automatic mode.

High Power On/Off Lamp

The Front Panel High Power On/Off Lamp (p/n: 27400-29006) will cause an error, from eV+, if the lamp burns out. This error prevents High Power from being turned on. This safety feature prevents a user from not realizing that High Power is enabled because the High Power indicator is burned out. See Changing the Lamp In the Front Panel High-Power Indicator on page 119 for information on changing this lamp.

Remote Front Panel or User-Supplied Control Panel Usage

Users can mount the Front Panel remotely by using an extension cable or by wiring a user-supplied Front Panel (control panel) to the controller using the 15-pin XFP connector. The Front Panel contains no active components, only switches and lights. Customers should be able to adapt the Front Panel’s functionality into their own Front Panel design. To automatically control the Front Panel’s signals, use relay contacts instead of switches. See the figure Front Panel Schematic on page 68 for a schematic drawing of the Front Panel, and see the table System Installation on page 35 for a summary of connections and pin numbers.

NOTE: The system was evaluated by Underwriters Laboratory with our Front Panel. If you provide a substitute front panel, the system may no longer be UL compliant.

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4.9 Installing User-Supplied Safety Equipment

Customers can build an extension cable to place the Front Panel in a remote location. The extension cable must conform to the following specifications:

Wire Size: must be larger than 26 AWG.

Connectors: must be 15-pin, standard D-sub male and female.

Maximum cable length is 10 meters.

NOTE: The XMCP and XFP connectors can be interchanged without electrical damage. However, neither the Front Panel nor the pendant will work properly unless they are plugged into the correct connector.

Remote Pendant Usage

Customers can build an extension cable to place the pendant in a remote location. The extension cable must conform to the following specifications:

Wire Size: must be larger than 26 AWG.

Connectors: must be 15-pin, standard D-sub male and female.

Maximum cable length is 10 meters.

IMPORTANT: Do not modify the cable that is attached to the pendant. This could cause unpredictable behavior from the robot system.

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Chapter 5: System Operation

5.1 Robot Status LED Description

The robot Status LED indicator is located on the top of the upright robots, and at the top of the status panel for the eCobra Inverted robot. The blinking pattern indicates the status of the robot.

The eCobra robots support the UL standard. The LED on these robots is amber. See the following figure and table.

Figure 5-1. (1) Robot Status LED Indicator Location, Upright Model Shown

Table 5-1. Status LED Definitions on UL-Certified Robots

LED Status 2-Digit Status Panel Display Description

Off Off 24 VDC not present

Off OK High Power Disabled

Amber, Solid ON High Power Enabled

Amber, Slow Blink OK Selected Configuration Node

Amber, Fast Blink Fault Code(s) Fault, see the next section

Amber, Solid Fault Code(s) Fault, see the next section

5.2 Status Panel Fault Codes

The status panel, shown in the following figure, displays alpha-numeric codes that indicate the operating status of the robot, including fault codes. The following table gives meanings of the fault codes, which provide information for isolating problems during troubleshooting.

14402-000 Rev. F eCobra User's Guide 73

5.2 Status Panel Fault Codes

The displayed fault code will continue to be displayed even after the fault is corrected or additional faults are recorded. All displayed faults will be cleared from the display, and reset to a no-fault condition, upon successfully enabling high power to the robot, or power cycling the 24 V supply to the robot.

Figure 5-2. (1) Status Panel for Displaying Fault Codes, (2) ZBrake Release Button - Upright Model

Shown.

Status Panel

The status panel, shown in Figure 5-2. displays alpha-numeric codes that indicate the operating status of the robot. The following table gives definitions of the fault codes. These codes provide details for quickly isolating problems during troubleshooting.

In the Status Panel Codes table, the '#' in the LED column represents a single digit. The digits will be displayed as one of the following:

0 1 2 3 4 5 6 7 8 9

Table 5-2. Status Panel Codes

LED

Status

Code

OK None N/A STATUS message-High

V+

Error

Message

V+ Error Code

Explanation User Action

None

Power OFF.

ON None N/A STATUS message-High

Power ON.

MA None N/A STATUS message-Robot

24 *RSC power fail-

ure*

is in Manual Mode.

-670 The 24 VDC input voltage is out of bounds

None

Check connections and voltage level

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Chapter 5: System Operation

LED

Status

Code

A# *Motor Amplifier

Fault*

AC *RSC Power Fail-

ure*

V+

Error

Message

V+

Error

Code

-1018 A power amplifier fault is

-670 A loss of AC power was

Explanation User Action

(too high or low). from the user-sup-

indicated on axis #.

detected.

plied 24 VDC power supply.

Check user motor power connections for shorts or opens. Turn high power back on and restart the program. If the error persists, contact your local Omron support.

Check user AC power connections for shorts or opens. Turn high power back on and restart the program. If the error persists, contact your local Omron support.

B# None N/A IO-Blox communications

error with IO-Blox (#).

BA None N/A The encoder backup bat-

tery is low.

D# *Duty-cycle

exceeded* Mtr #

-1021 The indicated motor (#) has been driven hard for too long a period of time. The servo system has disabled power to protect the robot hardware.

Check user IOBlox connections for shorts or opens. Check IOBlox address switches for proper configuration. Cycle power to the control system. If the error persists, contact your local Omron support.

Replace the encoder backup battery.

Turn high power back on; reduce the speed and/or acceleration for the motion that was in progress or for motions that preceded that motion. Repeat the motion that failed.

E# *Encoder Fault* -1025 The servo system has User actions vary by

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5.2 Status Panel Fault Codes

LED

Status

Code

ES *E-STOP detected

by robot*

F1 *E-STOP detected

by robot*

FM None N/A Firmware version mis-

FW *1394 com-

munications timeout*

V+

Error

Message

V+ Error Code

-643 An E-STOP condition has

-643 The End-Of-Arm Break-

-927 The IEEE 1394 com-

Explanation User Action

detected an encoder fault.

been detected by the robot.

away Sensor has tripped (open circuit). Reporting of this error can be enabled / disabled via ACE.

match.

munications system has failed to initialize or has lost communications with the SmartController EX.

product. Please reference individual robot manuals for appropriate actions.

This is a normal response to many ESTOP conditions. Remove the source of the ESTOP and reenable high power.

Re-close the breakaway circuit and reenable high power.

Contact your local Omron support.

This will occur normally if the SmartController EX is powered down separately from the robot systems. If it occurs unexpectedly, check the connections and integrity of the 1394 cabling.

h# *Robot over-

heated*

H# *Motor over-

heating* Mtr #

-606 The temperature sensor on the embedded processor board has reached its temperature limit. It may be necessary to slow the motion or insert pauses to reduce overall heating.

-1016 The motor encoder temperature sensor indicates an overtemperature.

Check for excessive ambient temperature, inadequate ventilation, and proper function of any cooling fans.

Reduce the speed, acceleration and/or deceleration of the robot motions, or introduce delays in the application cycle to give the motor an opportunity to cool.

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Chapter 5: System Operation

LED

Status

Code

hV *RSC power fail-

ure*

I# None N/A Servo initialization

M# *Motor stalled*

Mtr #

V+

Error

Message

V+

Error

Code

-670 The high-voltage DC bus

-1007 A motor stall occurs

Explanation User Action

for the amplifiers is out of bounds (too high or low).

stages. These steps normally sequence (I0, I1, …) on the display during normal system boot.

when the maximum allowed torque for a given motor was applied for longer than the defined timeout period. This typically occurs when an obstacle is encountered.

This may occur when AC power is unexpectedly removed. Check AC connections and reenable high power. If the error persists, contact your local Omron support.

None, unless an initialization code persists longer than 30 seconds. This may indicate servo initialization has failed. Contact your local Omron support.

Check for obstacles and free movement of all joints. Turn high power back on and repeat the motion that failed.

P0 *Power system

failure* Code 0

P1 *Power system

failure* Code 1

P2 *Power system

failure* Code 2

P3 *Power system -1115 The regenerative energy Contact your local

-1115 The dual-channel brake circuit has reported a cyclic check error.

-1115 The power system has unexpectedly turned off power.

-1115 The high-voltage DC bus to the regenerative energy dump circuit has experienced an overvoltage.

Contact your local Omron support.

On PA-4 chassis, further information may be indicated on the PA-4 status lights. Refer to Adept PA-4 Power Chassis User's Guide for details. Contact your local Omron support if the error persists.

Contact your local Omron support.

14402-000 Rev. F eCobra User's Guide 77

5.2 Status Panel Fault Codes

LED

Status

Code

failure* Code 3 dump circuit has

P4 *Power system

failure* Code 4

P5 *Power system

failure* Code 5

PR None N/A A servo task has overrun

V+

Error

Message

V+ Error Code

-1115 The high-voltage DC bus

-1115 An inrush error was

Explanation User Action

exceeded its max shortterm dump rating.

did not discharge its voltage when expected. (Note: This error is only relevant to legacy Cobra AIB systems.)

detected by the power sequencer. This means the high-voltage DC bus failed to rise at the expected rate when power was enabled.

its allotted execution window.

Omron support.

Contact your local Omron support.

This can occur if AC power is abruptly removed during the high-power enable sequence. If it occurs unexpectedly, contact your local Omron support.

If the problem persists, contact your local Omron support.

RC *RSC com-

munications failure*

S0 *Safety System

Fault* Code 0

S1 *Safety System

Fault* Code 1

S2 *Safety System

Fault* Code 2

-651 There is a failure to communicate with the Robot Signature Card.

-1109* The robot hardware did not detect that the front-panel high-power button was pressed prior to the servo system attempting to enable power.

-1109* The SmartController EX has signaled a power off condition to the robot via the HIPWR_DIS line on the XSYS interface. This fault indication typically accompanies other fault conditions that cause "fatal error" on the SmartController EX error (such as a loss in IEEE1394 communication).

-1109* The safety system exper- If the problem per-

Contact your local Omron support.

Check for other messages on the SmartController EX that may indicate a fatal error. If the error source can be eliminated, reenable power.

sists, contact your

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Chapter 5: System Operation

LED

Status

Code

S3 *Safety System

Fault* Code 3

S4 *Safety System

Fault* Code 4

V+

Error

Message

V+

Error

Code

-1109* The safety system exper-

-1109* The internal E-STOP

Explanation User Action

ienced a failure on channel 1 during the cyclic check of dual-channel power system. This may indicate a welded relay contact or other hardware failure.

ienced a failure on channel 2 during the cyclic check of dual-channel power system. This may indicate a welded relay contact or other hardware failure.

delay timer timed out and power has been turned off. Under normal circumstances, software sequences the shutdown prior to the timeout, averting this message.

local Omron support.

If the problem persists, contact your local Omron support.

S5 *Safety System

Fault* Code 5

S6 *Safety System

Fault* Code 6

S9 *Safety System

Fault* Code 9

SE *Safety System -648 The E-Stop Delay has Commission and

-1109* The power system was not properly unlocked by software during a power sequence while in manual mode.

-1109* The CAT-3 hardware safety system detected an encoder OVERSPEED and power has been turned off. This circuitry is active in manual mode only, on select robots which have the CAT-3 teach mode option installed.

-1109* A watchdog circuit that cross-checks the clocks for the dual-channel safety system is reporting an error.

Contact your local Omron support.

This fault is triggered on purpose during specific commissioning tests for the CAT-3 system. If the fault occurs during normal operation, contact your local Omron support.

Contact your local Omron support.

14402-000 Rev. F eCobra User's Guide 79

5.3 Brakes

LED

Status

Code

Not Commissioned*

SW None N/A Software watchdog

T0 *Safety System

Fault* Code 10

TR *Safety System

Not Commissioned*

V# *Hard envelope

error* Mtr #

V+

Error

Message

V+ Error Code

-1109 An error was detected

-648 The Teach Restrict fea-

-1027 The indicated motor was

Explanation User Action

not been commissioned and verified.

timer timeout. On some products it is normal for this to occur momentarily during a servo reset.

during a software self test of a secondary safety and monitoring circuit (SRV_DIRECT / SRV_STAT).

ture has not been commissioned and verified.

not tracking the commanded position with sufficient accuracy as set by ACE.

verify the E-Stop Delay.

If the problem persists, contact your local Omron support.

Contact your local Omron support.

Commission and verify the Teach Restrict feature.

Turn on high power and try to perform the motion at a slower speed. Make sure that nothing is obstructing the robot's motion. If the error recurs, contact your local Omron support.

NOTE: For more information on status codes, refer to the Status Codes for Embedded Products document.

5.3 Brakes

The robot has a braking system that decelerates the robot in an emergency or abnormal situation, such as when the emergency stop circuit is open or a robot joint passes its softstop.

The braking system will not prevent you from moving the robot manually once the robot has stopped (and high power has been removed).

In addition, Joint 3 has an electromechanical brake. The brake is released when high power is enabled. When high power is turned off, the brake engages and holds the position of Joint 3.

Brake Release Button

Under some circumstances you may want to manually position Joint 3 on the Z-Axis without turning on high power. For such instances, a ‘Z’ Brake Release button is located above the

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Chapter 5: System Operation

robot status panel, as shown in Figure 5-2. When system power is on, pressing this button releases the brake, which allows movement of Joint 3.

NOTE: 24 Volt robot power must be on to release the brake.

If this button is pressed while high power is on, high power will automatically shut off.

CAUTION: PROPERTYDAMAGERISK Pressing the Brake Release button may cause the quill and tool flange to fall. When the Brake Release button is pressed, Joint 3 may drop to the bottom of its travel. To prevent possible damage to the equipment, make sure that Joint 3 is supported while releasing the brake and verify that the end-effector or other installed tooling is clear of all obstructions.

Remote Brake Release Feature

You can also configure the XIO Input 6.2 (pin 18) to act as an alternate hardware brake release input. The setting is available on the Robot page in the ACE software. The parameter is Remote Brake Release Input. When enabled (True), activating XIO Input 6.2 is identical to pressing the brake button on the status display. The input status will still reflect in the IO register.

If an alternate (user-supplied)brake release button is used, ensure that the brake release button displays a warning similar to the preceding WARNING. This is to comply with ISO 10218-1, Clause 5.13.

5.4 Front Panel

NOTE: The factory-supplied Front Panel E-Stop is designed in accordance with the requirements of IEC 60204-1 and ISO 13849.

IMPORTANT: Any user-supplied front panel E-Stop must be designed in accordance with the requirements of IEC 60204-1 and ISO 13849. The push button of the E-Stop must comply with ISO 13850 (Clause 5.5.2).

14402-000 Rev. F eCobra User's Guide 81

Figure 5-3. Front Panel

5.4 Front Panel

XFP connector

Connects to the XFP connector on the eAIB XSYSTEM cable (or the optional SmartController EX, if one is being used).

System 5 V Power-On LED

Indicates whether or not power is connected to the robot.

Manual / Automatic Mode Switch

Switches between Manual ( ) and Automatic ( ) mode. In Automatic mode, executing programs control the robot, and the robot can run at full speed. In Manual

mode, the system limits robot speed and torque so that an operator can safely work in the cell. Manual mode initiates hardware and software restrictions on robot speed, commanding no more than 250 mm/sec.

There is no high speed mode in manual mode.

WARNING: PERSONALINJURYRISK If an operator is going to be in the work cell in manual mode, it is strongly recommended that the operator carry an enabling device. The Enable button on the manual control pendant is such a device.

WARNING: PERSONALINJURYRISK Whenever possible, manual mode operations should be performed with all personnel outside the workspace.

High Power On / Off Switch and Lamp

Controls high power, which is the flow of current to the robot motors. Enabling high power is a two-step process. An “Enable Power” request must be sent from the user-supplied PC, an executing program, or a pendant. Once this request has been made and the High Power On/Off lamp/button is blinking, the operator must press and release this button, and high power will be enabled.

NOTE: The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step.

IMPORTANT: Disabling the High Power button violates IEC 60204-1. It is strongly recommended that you not alter the use of the High Power button.

NOTE: If enabled, the Front Panel button must be pressed while blinking (default time-out is 10 seconds). If the button stops blinking, you must enable power again.

Emergency Stop Switch

The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements. Pressing this button turns off high power to the robot motors.

NOTE: The Front Panel must be installed to be able to Enable Power to the robot. To operate without a Front Panel, the user must supply the equivalent circuits.

82 eCobra User's Guide 14402-000 Rev. F

5.5 Connecting Digital I/O to the System

You can connect digital I/O to the system in several different ways. See the following table and figure.

NOTE: A typical IOBlox configuration is shown in Figure 5-4. Other configurations may be possible. Contact your local Omron support for more information.

Table 5-3. Digital I/O Connection Options

Product I/O Capacity For more details

Chapter 5: System Operation

XIO Connector on robot 12 inputs

8 outputs

Optional IO Blox Device, connects to robot

8 inputs, 8 outputs per device; up to eight IO Blox devices per

see eAIB XIO Connector Signals on page 86

see IO Blox User’s Guide. Not available with eCobra Lite.

robot

The following I/Oconnector and module require the optional SmartController EX motion controller

XDIO Connector on SmartController EX

12 inputs 8 outputs

SmartController EX User's Guide

Optional I/O Products

These optional products are also available for use with digital I/O:

XIO Breakout Cable For information, see XIO Breakout Cable on page 93. This cable is not compatible with the XIO Termination Block.

XIO Termination Block, with terminals for user wiring, plus input and output status LEDs. Connects to the XIO connector with 6 foot cable. See the XIO Termination Block Installation Guide for details.

14402-000 Rev. F eCobra User's Guide 83

5.5 Connecting Digital I/O to the System

24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

SmartController EX

eCobra Robot

Default Digital I/O Signal Configuration

Figure 5-4. Connecting Digital I/O to the System

Table 5-4. Default Digital I/O Signal Configuration, Single Robot, no SmartController EX

Item Location Type Signal Range

Robot 1 XIO connector

On eAIB panel.

IO Blox 1 Inputs 1033–1040

a

Inputs 1001–1012

Outputs 0001–0008

Outputs 0033–0040

IO Blox 2 Inputs 1041–1048

Outputs 0041–0048

IO Blox 3 Inputs 1049–1056

Outputs 0049–0056

IO Blox 4 Inputs 1057–1064

Outputs 0057–0064

IO Blox 5 Inputs 1065–1072

Outputs 0065–0072

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Chapter 5: System Operation

Item Location Type Signal Range

IO Blox 6 Inputs 1073–1080

Outputs 0073–0080

IO Blox 7 Inputs 1081–1088

Outputs 0081–0088

IO Blox 8 Inputs 1089–1096

Outputs 0089–0096

For Multi-Robot systems, see Single and Multiple Robot Configuration Guide.

Table 5-5. Default Digital I/O Signal Configuration, Single Robot, with SmartController EX

Item Location Type Signal Range

SmartController EX (optional) XDIO connector

Robot 1 XIO connector

a

On eAIB panel.

IO Blox 1 Inputs 1113–1120

Inputs 1001–1012

Outputs 0001–0008

Inputs 1097–1108

Outputs 0097–0104

Outputs 0105–0112

IO Blox 2 Inputs 1121–1128

Outputs 0113–0120

IO Blox 3 Inputs 1129–1136

Outputs 0121–0128

IO Blox 4 Inputs 1137–1144

Outputs 0129–0136

NOTE: The signal number sequence at this point jumps ahead it is not contiguous from IO Blox 4 to IO Blox 5.

IO Blox 5 Inputs 1289–1296

Outputs 0257–0264

IO Blox 6 Inputs 1297–1304

Outputs 0265–0272

IO Blox 7 Inputs 1305–1312

Outputs 0273–0280

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5.5 Connecting Digital I/O to the System

Item Location Type Signal Range

IO Blox 8 Inputs 1313–1320

Outputs 0281–0288

For Multi-Robot systems, see Single and Multiple Robot Configuration Guide.

eAIB XIO Connector Signals

The XIO connector on the robot interface panel offers access to digital I/O, 12 inputs and 8 outputs. These signals can be used by eV+ to perform various functions in the workcell. See the following table for the XIO signal designations.

12 Inputs, signals 1097 to 1108

8 Outputs, signals 0097 to 0104

Table 5-6. XIO Signal Designations

Pin No. Designation

Signal

Bank

eV+ Signal

Number

1 GND

2 24 VDC

3 Common 1 1

4 Input 1.1 1 1097

5 Input 2.1 1 1098

6 Input 3.1 1 1099

7 Input 4.1 1 1100

8 Input 5.1 1 1101

9 Input 6.1 1 1102

10 GND

11 24 VDC

12 Common 2 2

13 Input 1.2 2 1103

14 Input 2.2 2 1104

15 Input 3.2 2 1105

16 Input 4.2 2 1106

17 Input 5.2 2 1107

18 Input 6.2 2 1108

19 Output 1 0097

86 eCobra User's Guide 14402-000 Rev. F

Chapter 5: System Operation

Pin 1Pin 9 Pin 10

Pin 18 Pin 26 Pin 19

Pin No. Designation

Signal

Bank

eV+ Signal

Number

20 Output 2 0098

21 Output 3 0099

22 Output 4 0100

23 Output 5 0101

24 Output 6 0102

25 Output 7 0103

26 Output 8 0104

XIO Input Signals

The 12 input channels are arranged in two banks of six. Each bank is electrically isolated from the other bank and is optically isolated from the robot’s ground. The six inputs within each bank share a common source/sink line.

The inputs are accessed through direct connection to the XIO connector (see the previous table), or through the optional XIO Termination Block. See the documentation supplied with the termination block for details.

For REACTI programming, high-speed interrupts, or vision triggers:

With a SmartController EX, you can only use the EXXDIO inputs.

Without a SmartController EX, you can only use the XIO inputs.

See the eV+ Language User’s Guide for information on digital I/O programming.

14402-000 Rev. F eCobra User's Guide 87

5.5 Connecting Digital I/O to the System

XIO Input Specifications

Table 5-7. XIO Input Specifications

Operational voltage range 0 to 30 VDC

OFF state voltage range 0 to 3 VDC

ON state voltage range 10 to 30 VDC

Typical threshold voltage Vin= 8 VDC

Operational current range 0 to 7.5 mA

OFF state current range 0 to 0.5 mA

ON state current range 2.5 to 7.5 mA

Typical threshold current 2.0 mA

Impedance (Vin/I

Current at Vin= +24 VDC I

Turn on response time (hardware)

Software scan rate/response time

) 3.9 K Ω minimum

≤ 6 mA

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

Turn off response time (hardware)

Software scan rate/response time

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

NOTE: The input current specifications are provided for reference. Voltage sources are typically used to drive the inputs.

88 eCobra User's Guide 14402-000 Rev. F

Typical Input Wiring Example

1097

1098

1099

1100

1101

1102

+24V

GND

9 3 2 1

1103

1104

1105

1106

1107

1108

18 12

GND

+24V

Chapter 5: System Operation

14402-000 Rev. F eCobra User's Guide 89

NOTE: All input signals can be used for either sinking or sourcing configurations.

Figure 5-5. Typical User Wiring for XIO Input Signals

5.5 Connecting Digital I/O to the System

Table 5-8. Typical User Wiring for XIOInput Signal Description

Item Description

1 Supplied Equipment

3 Equivalent Circuit

4 Wiring Terminal Block

5 Typical User Input Signals (part present sensor, feeder empty sensor, part jammed

6 Bank 1 configured for Sinking (NPN) inputs

7 Bank 2 configured for Sourcing (PNP)inputs

8 Input Bank 1

9 Input Bank 2

10 Bank 1 Common

11 Bank 2 Common

User-suppliedEquipment

sensor, sealant ready sensor, etc.)

NOTE: The OFF state current range exceeds the leakage current of XIO outputs. This guarantees that the inputs will not be turned on by the leakage current from the outputs. This is useful in situations where the outputs are looped-back to the inputs for monitoring purposes.

XIO Output Signals

The eight digital outputs share a common, high side (sourcing) driver IC. The driver is designed to supply any kind of load with one side connected to ground. It is designed for a range of user-provided voltages from 10 to 24 VDC and each channel is capable of up to 0.7 A of current. This driver has overtemperature protection, shorted load protection, and is current limiting. In the event of an output short or other overcurrent situation, the affected output of the driver IC turns off and back on automatically to reduce the temperature of the IC. The driver draws power from the primary 24 VDC input to the robot through a self-resetting polyfuse.

The outputs are accessed through direct connection to the XIO connector. See Table 5-6. Optionally, use the XIO Termination Block. See the documentation supplied with the termination block for details.

90 eCobra User's Guide 14402-000 Rev. F

XIO Output Specifications

Parameter Value

Power supply voltage range See Specifications for 24 VDC

Chapter 5: System Operation

Table 5-9. XIO Output Circuit Specifications

Power on page 50.

Operational current range, per chan-

≤ 700 mA

out

nel

Total Current Limitation, all chan-

≤ 1.0 A @ 50° C ambient

total

nels on.

≤ 1.5 A @ 25° C ambient

total

On state resistance (I

Output leakage current I

out

= 0.5 A)

≤ 0.32 Ω @ 85° C

≤ 25 µA

out

Turn-on response time 125 µsec max., 80 µsec typical

(hardware only)

Turn-off response time 60 µsec max., 28 µsec typical

(hardware only)

Output voltage at inductive load turnoff (I

= 0.5A, Load = 1 mH)

out

DC short circuit current limit 0.7A ≤ I

(+V - 65) ≤V

LIM

demag

≤ 2.5 A

≤ (+V - 45)

Peak short circuit current I

ovpk

≤ 4 A

14402-000 Rev. F eCobra User's Guide 91

5.5 Connecting Digital I/O to the System

+24 VDC

0097

0098

0099

0100

0101

0102

0103

0104

GND GND

1 10

Typical Output Wiring Example

Figure 5-6. Typical User Wiring for XIO Output Signals

Table 5-10. Typical User Wiring for XIOOutput Signal Description

Item Description

1 Supplied Equipment

3 Wiring Terminal Block

4 Typical User Loads

5 Equivalent Circuit

6 Outputs 1 - 8

7 XIOConnector (26-Pin Female D-Sub)

8 Customer ACPower Supply

User-supplied Equipment

92 eCobra User's Guide 14402-000 Rev. F

Chapter 5: System Operation

XIO Breakout Cable

The XIO Breakout cable is available as an option—see the following figure. This cable connects to the XIO connector on the eAIB, and provides flying leads on the user’s end, for connecting input and output signals in the workcell. The cable length is 5 M (16.4 ft).

For the wire chart on the cable, see the following table.

NOTE: This cable is not compatible with the XIO Termination Block.

Figure 5-7. Optional XIO Breakout Cable

Table 5-11. XIO Breakout Cable Wire Chart

Signal

Pin No.

Designation Wire Color

1 GND White

2 24 VDC White/Black

3 Common 1 Red

4 Input 1.1 Red/Black

5 Input 2.1 Yellow

6 Input 3.1 Yellow/Black

7 Input 4.1 Green

8 Input 5.1 Green/Black

9 Input 6.1 Blue

10 GND Blue/White

11 24 VDC Brown

12 Common 2 Brown/White

14402-000 Rev. F eCobra User's Guide 93

5.6 Starting the System for the First Time

Pin 9Pin 1 Pin 18Pin 10

Pin 19

Pin 26

Pin No.

Designation Wire Color

13 Input 1.2 Orange

14 Input 2.2 Orange/Black

15 Input 3.2 Gray

16 Input 4.2 Gray/Black

17 Input 5.2 Violet

18 Input 6.2 Violet/White

19 Output 1 Pink

20 Output 2 Pink/Black

21 Output 3 Light Blue

22 Output 4 Light Blue/Black

23 Output 5 Light Green

24 Output 6 Light Green/Black

Signal

25 Output 7 White/Red

26 Output 8 White/Blue

Shell Shield

5.6 Starting the System for the First Time

Follow the steps in this section to safely bring up your robot system. The steps include:

Verifying installation, to confirm all tasks have been performed correctly

Starting up the system by turning on power for the first time

Verifying all E-Stops in the system function correctly

Moving each joint of the robot (generally with the pendant) to confirm it moves in the proper directions

94 eCobra User's Guide 14402-000 Rev. F

Chapter 5: System Operation

Verifying Installation

Verifying that the system is correctly installed and that all safety equipment is working correctly is an important process. Before using the robot, make the following checks to ensure that the robot system has been properly installed.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK After installing the robot, you must test it before you use it for the first time. Failure to do this could cause death, or serious injury or equipment damage.

Mechanical Checks

Verify that:

The robot is mounted level and that all fasteners are properly installed and tightened.

Any end-of-arm tooling is properly installed.

All other peripheral equipment is properly installed and in a state where it is safe to turn on power to the robot system.

System Cable Checks

Verify the following connections:

NOTE: The first three connections are made via the eAIB XSYSTEM cable if you are not using an optional SmartController EX motion controller.

Front Panel to the XSYSTEM on the eAIB.

Pendant to the XSYSTEM on the eAIB.

XUSR to the XSYSTEM on the eAIB.

User-supplied 200/240 VAC power to the robot 200/240 VAC connector.

User-supplied 24 VDC power to the robot 24 VDC connector.

If you are using an optional SmartController EX, you should check the following:

eAIBXSYScable between the robot interface panel XSYSTEM connector and XSYS connector on the SmartController EX, and the latching screws tightened.

Front Panel to the SmartController EX.

Pendant to the SmartController EX, via the pendant adapter cable.

User-supplied 24 VDC power to the controller.

User-supplied ground wire between the SmartController EX and ground.

One end of the IEEE 1394 cable into the SmartServo connector on the SmartController EX, and the other end into a SmartServo connector on the robot interface panel.

14402-000 Rev. F eCobra User's Guide 95

5.6 Starting the System for the First Time

User-Supplied Safety Equipment Checks

Verify that all user-supplied safety equipment and E-Stop circuits are installed correctly.

Turning on Power

After the system installation has been verified, you are ready to turn on AC and DC power to the system and start up ACE.

Manually move the robot joints away from the folded shipping position.

See Transport and Storage on page 25.

Turn on the 200/240 VAC power.

WARNING: ELECTROCUTIONRISK Make sure personnel are skilled and instructed—refer to the Robot Safety Guide.

Turn on the 24 VDC power to the robot.

The Status Panel will display OK.

The Robot Status LED will be off.

Verify the Auto/Manual switch on the Front Panel is set to Auto Mode.

Starting ACE

The robot should be on, and the status panel should display OK before proceeding.

Turn on the user-supplied PC and start ACE.

Double-click the ACE icon on your Windows desktop,

From the Windows Start menu bar, select:

Start > Programs > Omron > ACE x.y

where x is the ACE major version, and y is the ACEminor version. For example, for ACE3.6, it would be:

Start > Programs > Omron > ACE 3.6

On the ACE Getting Started screen:

Select Connect To Controller.

Select Create New Workspace for Selected Controller to make the connection to the controller.

Select the IP address of the controller you wish to connect to, or manually type in the IP address.

Click OK. You will see the message “Working ... please wait”.

96 eCobra User's Guide 14402-000 Rev. F

Chapter 5: System Operation

Enabling High Power

After you have started ACE and connected to the controller, enable high power to the robot motors.

Using ACE to Enable High Power

From the ACE main menu, click the Enable High Power icon.

Press and release the blinking High Power button on the Front Panel within 10 seconds.

The Front Panel is shown in Figure 5-3. (If the button stops blinking, you must Enable Power again.)

NOTE: The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step.

IMPORTANT: Disabling the High Power button violates IEC 60204-1. It is strongly recommended that you not alter the use of the High Power button.

This step turns on high power to the robot motors and calibrates the robot.

The Robot Status LED glows amber.

The code on the Robot Status Panel displays ON. See Status Panel Fault Codes on page 73.

Verifying E-Stop Functions

Verify that all E-Stop devices are functional (pendant, Front Panel, and user-supplied). Test each mushroom button, safety gate, light curtain, etc., by enabling high power and then opening the safety device. The High Power push button/light on the Front Panel should go out for each.

Verify Robot Motions

Use the pendant (if purchased) to verify that the robot moves correctly. Refer to your pendant user's guide for complete instructions on using the pendant.

If the optional pendant is not installed in the system, you can move the robot using the Robot Jog Control in the ACE software. For details, see the ACE User’s Guide.

Verify that the Teach Restrict speed limitation is working correctly by running the Teach Restrict verification procedure. Refer to the Teach Restrict Verification Utility on page 114.

5.7 Learning to Program the eCobra Robot

To learn how to use and program the robot, see the ACE User’s Guide, which provides information on robot configuration, control and programming through the ACE software “point and click” user interface.

For eV+ programming information, refer to the eV+ user and reference guides.

14402-000 Rev. F eCobra User's Guide 97

6.1 Field-Replaceable Parts

WARNING: ELECTROCUTIONRISK Only qualified service personnel may install or service the robot system. All maintenance work must be performed by a skilled and instructed personnel refer to the Robot Safety Guide.

WARNING: ELECTROCUTIONRISK During maintenance, user-supplied fail-safe lockout measures must be used to prevent, unauthorized third parties from turning on power. This is mandated by Clause 5.2.4 of ISO 10218-1.

During any maintenance-related activities, care must be taken involving AC power lockout. It is the user’s responsibility to make sure adequate measures are taken to

l lockout/ tagout power to the robot and related equipment.

l make sure that the robot cannot be energized during maintenance, as

mandated by Clause 5.2.4 of ISO 10218-1.

Chapter 6: Maintenance

The following parts are the only field-replaceable parts:

Table 6-1. Field-replaceable Parts

Part Omron Adept Technologies, Inc. Part Number

Encoder battery 09977-000 (3.6 V, 6.8 Ah)

(This has replaced part number 02704-000)

eCobra 600 eCobra 800

eAIB (Amp-In-Base)

MicroSD card 12053-000

These parts must only be replaced with the parts listed in the preceding table.

19800-600 19800-800

6.2 Periodic Maintenance Schedule

The following table gives a summary of the preventive maintenance procedures and guidelines on frequency.

See also Cleanroom Maintenance on page 191 and Customer Requirements on page 181.

14402-000 Rev. F eCobra User's Guide 99

6.3 Warning Labels

Table 6-2. Inspection and Maintenance

Item Period Reference

Safety Labels 1 week

Check E-Stop, enable and key

6 months Warning Labels on page 100

switches, and barrier interlocks

Check robot mounting bolts 6 months Checking Robot Mounting Bolts on page 103

Check for signs of oil around

3 months Checking for Oil Leakage on page 103.

Harmonic Drive®area.

Lubricate Joint 3 ball

3 months Lubricating Joint 3 on page 104

screw

Replace encoder battery 2 to 4

Replacing the Encoder Battery Pack on page 117

years

NOTE: The frequency of these procedures will depend on the particular system, its operating environment, and amount of usage. Use the times in this table as guidelines and modify the schedule as needed.

WARNING: ELECTROCUTIONRISK Lockout and tagout power before servicing.

WARNING: ELECTROCUTIONRISK The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons, as defined in the Robot Safety Guide. The access covers on the robot are not interlocked – turn off and disconnect power if covers or the eAIB will be removed.

6.3 Warning Labels

NOTE: Labels giving instructions for lifting or installing are not considered warning labels. They may be removed by the user, and do not need to be checked.

All warning labels on the eCobra robot should be checked on a weekly basis for being present and legible. If any of the labels are missing or illegible, they should be replaced. The labels, with part numbers, are:

Read User’s Guide, Impact Warning Label, 18241-000

These labels instruct the user to read the user’s guide before using the robot, and to be aware of the potential of impact by the robot.

100 eCobra User's Guide 14402-000 Rev. F

Omron eCobra 600, eCobra 800 Inverted Robots, eCobra 800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Product Description

Chapter 1: Introduction

eCobra Robot Models

eAIB (Amplifiers in Base)

1.2 eCobra Robot Features And Options

SmartController EX

ePLC Connect Software

IO Blox

SmartVision MX

T20 Pendant

Intelligent Force Sensing

ACE PackXpert Process Manager

1.3 How Can I Get Help?

Related Manuals

2.1 Dangers, Warnings, and Cautions

Alert Levels

Chapter 2: Safety

Alert Icons

Falling Hazards

Special Information

2.2 What to Do in an Emergency/Abnormal Situation

Releasing the Brakes

Releasing an E-Stop

Emergency Stop Circuit and Buttons

General Hazards

2.3 Safety Precautions

User's Responsibilities

Qualification of Personnel

2.4 Robot Behavior

Hardstops

Limiting Devices

Singularities

2.5 Intended and Non-intended Use

Intended Use

Non-Intended Use

Robot Modifications

2.6 Additional Safety Information

Manufacturer’s Declaration of Incorporation

Robot Safety Guide

T20 Manual Control Pendant (Option)

Disposal

3.1 Installation Overview

Chapter 3: Robot Installation

3.2 Transport and Storage

3.3 Unpacking and Inspecting the Equipment

Before Unpacking

Upon Unpacking

3.4 Repacking for Relocation

3.5 Environmental and Facility Requirements

3.6 Mounting an Upright eCobra Robot

Mounting Surface

Mounting Procedure

3.7 Mounting an eCobra 800 Inverted Robot

Mounting Surface

Mounting Procedure

3.8 Mounting the Front Panel

3.9 Connectors on Robot Interface Panel (eAIB)

Chapter 4: System Installation

4.1 System Cables, without SmartController EX

List of Cables and Parts

Cable Installation Overview

4.2 System Cables, with SmartController EX

Installing a SmartController EX Motion Controller

List of Cables and Parts

Cable Installation Overview

DB9 Splitter Cable

SmartController EX Belt Encoder Y-Adapter Cable

4.4 ACE Software

User-supplied PC

4.5 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power

24 VDC Mating Connector

Creating 24 VDC Cable

Connecting 24 VDC Cable

4.6 Connecting 200-240 VAC Power to Robot

Specifications for AC Power