Omron Quattro 650H, Quattro 650HS, Quattro 800H, Quattro 800HS User Manual

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Quattro 650H/650HS/800H/800HS

User’s Guide

I597-E-05

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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

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Table of Contents

Chapter 1: Introduction 13

1.1 Quattro Robots, Product Description

Controllers 13 Sizes and Materials 13 Major Differences between Quattro H and HS Robots 13 eAIB 15 Quattro Robot Base 16 Inner Arms 16 Ball Joints, Outer Arms 16 Platforms 17 SmartController EX 20

1.2 Installation Overview

1.3 How Can I Get Help?

Related Manuals 22

Chapter 2: Safety 23

2.1 What to Do in an Emergency / Abnormal Situation

Releasing the Brakes 23 General Hazards 23 Releasing an E-Stop 23

2.2 Dangers, Warnings, and Cautions

Alert Levels 24 Alert Icons 24 Special Information 25

2.3 User's Responsibilities

Electrical Hazards 25 Pinch Hazard 25 Qualification of Personnel 25

2.4 Robot Behavior

Hardstops 26

2.5 Intended and Non-intended Use

Intended Use 26 Non-Intended Use 27 Robot Modifications 27

2.6 Additional Safety Information

Robot Safety Guide 28 T20 Manual Control Pendant (Option) 28 Disposal 28

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Table of Contents

Chapter 3: Robot Installation - H 29

3.1 Transport and Storage

3.2 Unpacking and Inspecting the Equipment

Before Unpacking 29 Upon Unpacking 29 Unpacking 29

3.3 Repacking for Relocation

3.4 Environmental and Facility Requirements

3.5 Mounting Frame

Frame Orientation 33 Frame Construction 33 Robot-to-Frame Considerations 33 Mounting 34 Gussets 34

3.6 Mounting the Robot Base

Robot Orientation 34 Mounting Surfaces 35 Mounting Options 35 Mounting Procedure from Above the Frame 35 Mounting Procedure from Below the Frame 37 Install Mounting Hardware 37

3.7 Attaching the Outer Arms and Platform

Clocking the Platform to the Base 40 Attaching the Outer Arms 41

3.8 Mounting the Front Panel

Chapter 4: Robot Installation - HS 45

4.1 Transport and Storage

4.2 Unpacking and Inspecting the Quattro Equipment

Before Unpacking 45 Upon Unpacking 45 Unpacking 45

4.3 Repacking for Relocation

4.4 Environmental and Facility Requirements

4.5 Mounting Frame

Frame Mounting Tabs 48 Robot-to-Frame Considerations 49 Mounting 49 Gussets 49

4.6 Cable Inlet Box

Assembling Cable Inlet Box 50 Connecting the Cables 54

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Installing the Cable Inlet Box 55

4.7 Mounting the Robot Base

Robot Orientation 56 Mounting Surfaces 56 Mounting Options 56 Mounting Procedure from Above the Frame 57 Mounting Procedure from Below the Frame 58 Install Mounting Hardware 59

4.8 Attaching the Outer Arms and Platform

Clocking the Platform to the Base 61 Attaching the Outer Arms 62

4.9 Mounting the Front Panel

4.10 Attaching the Cable Tray

Chapter 5: System Installation 71

5.1 System Cable Diagram

5.2 Installing the SmartController EX

List of Cables and Parts 72 Cable Installation Overview 74

5.3 Optional Cables

XIOBreakout Cable 75 DB9 Splitter Cable 75 eAIB XBELTIOAdapterCable 75 SmartController Belt Encoder Y-Adapter Cable 75

5.4 Connecting User-Supplied PC to Robot

PC Requirements 80

5.5 Installing ACE Software

5.6 Description of Connectors on Robot Interface Panel

5.7 Cable Connections from Robot to SmartController

5.8 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Robot and Controller Power 83 Details for 24 VDC Mating Connector 84 Procedure for Creating 24 VDC Cable 84 Installing 24 VDC Robot Cable 85

5.9 Connecting 200-240 VAC Power to Robot

Specifications for AC Power 86 Details for AC Mating Connector 89 Procedure for Creating 200-240 VAC Cable 89 Installing AC Power Cable to Robot 90

5.10 Grounding the Quattro Robot System

Quattro Robot Base 90 Quattro HS Robot Base 91

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Robot-Mounted Equipment 91 Configuration 92

5.11 Installing User-Supplied Safety Equipment

Emergency Stop Circuits 99 Remote Manual Mode 100 User Manual/Auto Indication 101 User High Power On Indication 101 Remote High Power On/Off Control 101 High Power On/Off Lamp 102 Remote Front Panel or User-Supplied Control Panel Usage 102 Remote Pendant Usage 103

Chapter 6: System Operation 105

6.1 Robot Status Display Panel

6.2 Status Panel Fault Codes

6.3 Using the Brake-Release Button

Brakes 107 Brake-Release Button 107

6.4 Front Panel

6.5 Connecting Digital I/O to the System

6.6 Using Digital I/O on Robot XIO Connector

Optional I/O Products 114 XIO Input Signals 114 XIO Output Signals 116 XIO Breakout Cable 119

6.7 Starting the System for the First Time

Verifying Installation 121 Turning on Power and Starting ACE 122 Enabling High Power 123 Verifying E-Stop Functions 123 Verify Robot Motions 123

6.8 Quattro Motions

Straight-line Motion 124 Containment Obstacles 124 Tool Flange Rotation Extremes 124

6.9 Learning to Program the Quattro Robot

105

106

107

109

110

112

121

124

128

Chapter 7: Optional Equipment Installation 129

7.1 End-Effectors

Attaching 129 Aligning 129 Grounding 129 Accessing Vacuum 129

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7.2 Routing End-effector Lines

7.3 Ball Stud Locks

Installing a Ball Stud Lock 132 Removing a Ball Stud Lock 133

130

131

Chapter 8: Technical Specifications 135

8.1 Dimension Drawings

8.2 Internal Connections

8.3 XSYS/XSYSTEM Connector

8.4 Robot Specifications

8.5 Payload Specifications

Torque and Rotation Limits 147 Payload Mass vs. Acceleration 147 Payload Inertia vs. Acceleration 149

8.6 Stopping Times and Distances

8.7 Robot Mounting Frame, Quattro 650H Robot

135

144

145

147

150

158

Chapter 9: Maintenance - H 165

9.1 Periodic Maintenance Schedule

9.2 Warning Labels

9.3 Checking Safety Systems

9.4 Checking Robot Mounting Bolts

9.5 Checking Robot Gear Drives

9.6 Checking Fan Operation

9.7 Replacing the eAIB Chassis

Removing the eAIB Chassis 170 Installing a New eAIB Chassis 173

9.8 Commissioning a System with aneAIB

Safety Commissioning Utilities 175 E-Stop Configuration Utility 176 E-Stop Verification Utility 177 Teach Restrict Configuration Utility 177 Teach Restrict Verification Utility 178

9.9 Replacing the Encoder Battery Pack

Battery Replacement Interval 179 Battery Replacement Procedure 180

9.10 Replacing a Platform

Replacement 182

9.11 Configuration

9.12 Replacing a Ball Joint Insert

165

168

169

170

174

179

182

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9.13 Replacing Outer Arm Spring Assemblies

Removing Outer Arm Spring Assemblies 183 Installing Outer Arm Spring Assemblies 184

9.14 Changing the Lamp in the Front Panel High-Power Indicator

182

186

Chapter 10: Maintenance - HS 189

10.1 Cleaning

Water Shedding 189 Wash-Down 189 Chemical Compatibility 190

10.2 Warning Labels

10.3 Periodic Maintenance

10.4 Checking Safety Systems

10.5 Checking Robot Mounting Bolts

10.6 Checking Robot Gear Drives

10.7 Checking Fan Operation

10.8 Removing and Installing the Cable Inlet Box

Removing the Cable Inlet Box 197 Installing the Cable Inlet Box 198

10.9 Replacing the eAIB Chassis

Removing the eAIB Chassis 199 Installing a New eAIBChassis 201

10.10 Commissioning a System with aneAIB

Safety Commissioning Utilities 203 E-Stop Configuration Utility 204 E-Stop Verification Utility 205 Teach Restrict Configuration Utility 205 Teach Restrict Verification Utility 206

10.11 Replacing the Encoder Battery Pack

Battery Replacement Interval 207 Battery Replacement Procedure 208

10.12 Replacing a Platform

Replacement 211 Configuration 212

10.13 Replacing a Ball Joint Insert

10.14 Replacing Outer Arm Spring Assemblies

Removing Outer Arm Spring Assemblies 213 Installing Outer Arm Spring Assemblies 214

10.15 Replacing the Front Panel

189

190

191

195

196

197

199

202

207

211

212

213

216

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Chapter 11: Robot Cleaning/ Environmental Concerns- H 217

11.1 Ambient Environment

Humidity 217 Temperature 217

11.2 Cleaning

Caustic Compatibility 218 Water Shedding 218 Wipe-Down 218

11.3 Cleanroom Classification

11.4 Design Factors

Robot Base and Components 218 Inner Arms 219 Ball Joints 219 Outer Arms 219 Springs 219 Platforms 219

11.5 Installing Cable Seal Kit

Overview 220 Installation Procedure 221

217

218

220

Chapter 12: Environmental Concerns - HS 227

12.1 Ambient Environment

Humidity 227 Temperature 227

12.2 Cleanroom Classification

12.3 Design Factors

Robot Base and Components 228 Inner Arms 228 Ball Joints 228 Outer Arms 228 Spring Assemblies 229 Platforms 229

227

228

Chapter 13: Status Codes 231

13.1 Status Panel Display

13.2 Status Codes

231

232

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Revision History

Revision

Code

01 June,

Date Revised Content

Original release.

2016

02 May, 2017 Regulatory updates.

03 November,

2017

l Added the Quattro 800HS to USDA approved list. l Clarified that Line E-Stop Input can be used for pro-

duction lines.

l Clarified note on emergency stop circuits. l Clarified that the ball joint inserts are made of special

acetal material.

04 April, 2018 l Updated safety chapter format and alert levels through-

out user guide.

l Clarified that USDA approved platforms are stainless

steel.

l Updated unpacking instructions with new crate con-

figuration.

l Updated recommended power supply model numbers. l Updated images of platform to show Omron Adept logo. l Changed ACE software disk to ACEsoftware media. l Updated pictures to show painted inner arms. l Add note to firmly hold end of arm tooling when attach-

ing to the flange to prevent damage to platform belt.

l Minor updates to fix broken links and incorrect ref-

erences.

05 March,

2019

l Updated copyright for 2019. l Added WEEEdisposal information. l Removed www.adept.com from Chapter 1: Introduction. l Updated safety chapter format and added fire and ESD

alert icons.

l Added addition information regarding intended and non-

intended use of Quattro robots.

l Made a note that Hardstops have been moved to the

base.

l Added Max Allowable Center of Gravity (CG) table in

chapter 8.

l Graphics improved and modified for translation and

added call-out tables.

l Added Status Codes chapter. l Added Platform configuration procedure to System

Installation chapter and removed configuration procedure from Maintenance chapters.

l Revised encoder battery replacement interval. l Revised Ball Stud Lock section with new part number for

individual locks.

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Revision

Code

Date Revised Content

l Many changes to Chapter 5: System Installation includ-

ing new and improved figures, content removal and additions.

l Operating temperature range, changed to 1 to 40°C

from previously noted 5 to 40°C.

l Added red CADversion of status codes to Status Panel

Fault Codes section in chapter 5.

l Dual robot configuration renamed to single and multiple

robot configuration.

l Removed references to obsolete sDIO module. l Added IOBlox device to Table 6-3. Digital I/O Connection

Options

l Added a note about typical IOBlox configurations in

Chapter 6: System Operation.

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Chapter 1: Introduction

1.1 Quattro Robots, Product Description

The Quattro robot is a four-axis parallel robot. The four identical axis motors control movement of the robot tool in X, Y, and Z directions, as well as Theta rotation.

Controllers

The Quattro robot requires a SmartController EX motion controller for control. That controller can be combined with a user-supplied PLC, for programming.

The robot servo code runs on an SmartServo distributed-motion control platform embedded in the robot base as part of the power amplifiers.

Sizes and Materials

There are two sizes of Quattro robots, each available with anodized aluminum or stainless steel platforms:

Quattro 650H (AnodizedAluminum & SS) and Quattro 650HS (SS)

and

Quattro 800H (Anodized Aluminum &SS) and Quattro 800HS (SS)

The Quattro 650H and 800H areavailable with anodized aluminum or stainless steel (SS) platforms, and anodized aluminum outer arm spoons. The eAIB and cable box used with the two H models are anodized aluminum.

The Quattro 650HS and 800HS are USDAAccepted, and therefore only available with stainless steel platforms and stainless steel outer arm spoons. The eAIB and cable box used with the two HS models are electroless nickel (EN).

In most aspects, the robots are similar enough that they will be covered together. In areas where there are significant differences, the Quattro H and Quattro HS robots will be presented in two chapters, using titles such as Robot Installation—H for the 650H and 800H robots, and Robot Installation—HS for the 650HS and 800HS robots.

Major Differences between Quattro H and HS Robots

Note that either anodized aluminum or stainless steel platforms can be used on the Quattro 650H and 800H robots.

The Quattro 650HS and 800HS are only available with stainless steel platforms.

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1.1 Quattro Robots, Product Description

Table 1-1. Quattro H/HS Differences

Standard (650H/800H) HS (650HS/800HS)

USDA Accepted

No Yes

(Meat and Poultry)

IP rating IP65, Option IP66, Standard

P30 Platform, no rotation Hard-anodized or Stainless Steel

Stainless Steel (SS)

(SS)

P31 Platform, 46.25° Hard-anodized or SS SS

P32 Platform, 92.5° Hard-anodized or SS SS

P34 Platform, 185° Hard-anodized or SS SS

Outer Arm Spoons Hard-Anodized Stainless Steel

Base Mounting Pad Holes M16-2.0, through-hole M16-2.0, blind, 40 mm

bolt

Base Coating material White polyurethane

powder

eAIB Black Anodized, Single-bolt

White ETFE, USDA approved

EN, 6-bolt installation

installation

Cable Inlet box Hard-Anodized, Option EN, Standard

Cable Tray Not required Required (for USDA)

Status Display Half-height Full-height, to shield

labels

Protective Earth Ground On base-mounting pad In cable inlet box

Motor covers White Solid white, no label

Exposed bolts and screws all

No Yes

gasketed

Similarities Between the Quattro Robots

All models use the same motors

All models share the same base casting, although the H and HS have some machining and coating differences. Platform coatings/materials differ for HS robots, but dimensions do not.

The mounting hole pattern for the bases is the same.

All share the same inner arm design.

All have an eAIB.

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Chapter 1: Introduction

Figure 1-1. Major Robot Components, Isometric View (650HS shown)

Callout Description Callout Description

A Mounting Pads F Motor Cover

B eAIB G Outer Arms

C Cable Inlet Box H Platform

D Base J Ball Joints (Spring Assemblies not shown)

E Inner Arm

eAIB

The power amplifiers for the Quattro robot are embedded in the base of the robot. This amplifier section is known as the Amplifiers in Base (eAIB)distributed motion control platform, and provides closed-loop servo control of the robot amplifiers, as well as robot I/O. The eAIB is available in either an anodized or electroless nickel finish.

The eAIB features:

On-board digital I/O: 12 inputs, 8 outputs

Low EMI for use with noise-sensitive equipment

No external fan for quiet operation

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1.1 Quattro Robots, Product Description

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

These are for improved safety relative to European standards implemented in 2012.

NOTE: The H and HSamplifiers and their cable inlet boxes are not interchangeable.

Quattro Robot Base

The Quattro robot base is an aluminum casting that houses the four drive motors, and supports the power amplifiers. It provides four mounting pads for attaching the base to a rigid support frame. The Status Display Panel is mounted on the side of the robot base.

Inner Arms

The four robot motors attach directly to the inner arms through a high-performance gear reducer. Other than optional, user-supplied hardware mounted on the platform, these are the only drive motors in the Quattro robot. The following figure shows an inner arm from a Quattro robot. RIA-compliant hard stops limit the inner arm motion to -52° and +124°.

Figure 1-2. Inner Arm

Ball Joints, Outer Arms

The inner arm motion is transmitted to the platform through the outer arms, which are connected between the inner arms and platform with precision ball joints. The outer arms are carbon fiber epoxied assemblies with identical ball joint sockets at each end. A bearing insert in

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Chapter 1: Introduction

each socket accepts the ball joint studs on the inner arms and platform, and allows for approximately ± 60° of relative motion. No ball joint lubrication is required.

Platforms

Figure 1-3. Quattro Ball Joint Assembly, Quattro HS Robot shown

Callout Description Callout Description

A Ball Joint Stud E Ball Joint Socket Insert

B Inner Arm F Outer Arm Springs

C Ball Joint Socket G Spring Horseshoe

D Pressed Pin H Outer Arms

Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints. The outer arms can be installed and removed without tools.

The platform converts the motion of the four Quattro motors into Cartesian motion and, for all but the fixed platform, Theta rotation of the robot tool.

The Quattro robot currently supports four models of platforms, depending on the amount of Theta rotation and inertia needed.

NOTE: The four models of platforms require different robot parameters.

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1.1 Quattro Robots, Product Description

The suffix on the part numbers that follow indicates the finish or material of the platform. Refer to Materials and Finishes on page 20.

P31 Platform (P/N 09503-xxx)

The P31 platform has a rotation range of ±46.25°. The tool flange is machined into one of the pivot links. It does not rotate in relation to the pivot link, so there are no gears or belts involved. See P31 Platform on page 18.

P30 Platform (P/N 09730-xxx)

The P30 platform is a fixed platform that provides no Theta rotation. The tool flange is machined into the one-piece platform. See P30 Platform on page 19.

P32 Platform (P/N 09732-xxx)

The P32 platform has a rotation range of ±92.5°. The tool flange is mounted on one of the pivot links. See P32 Platform on page 19.

P34 Platform (P/N 09734-xxx)

The P34 platform has a rotation range of ±185°. The tool flange is mounted on one of the pivot links.

Figure 1-4. P31 Platform

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Figure 1-5. P30 Platform

Chapter 1: Introduction

Figure 1-6. P32 Platform

NOTE: The only visible difference between the P32 and P34 platforms is the model number, and the two or four dots immediately below that number. Two dots designate a P32 platform.

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1.1 Quattro Robots, Product Description

Materials and Finishes

Platforms are available in:

Aluminum with hard-anodized finish

Stainless steel

The following table shows which materials and finishes are compatible with which robots:

650H 650HS 800H 800HS Part Number

Hard

Yes No Yes No XXXXX-000

Anodized

Stainless

Yes Yes Yes Yes XXXXX-200

Steel

Platform Clocking

Rotational platforms are constructed such that the clocking, or rotational alignment, of the platform relative to the robot base is critical. This is detailed in Clocking the Platform to the Base on page 40.

Platform Shipping

The platform and outer arms are removed.

The platform is shipped pre-assembled as a unit. You will need to connect the outer arms between the inner arms and the platform to reassemble the robot. The outer-arm assemblies are interchangeable.

Any end-effectors and their air lines and wiring are user-supplied.

SmartController EX

The SmartController motion controller is the foundation of our family of high-performance, distributed motion controllers. The SmartController EX is designed for use with:

Quattro robots

eCobra 600/800 robots

Viper robots

The controller supports a conveyor tracking option, as well as other options. The SmartController EX uses the eV+ operating system. It offers scalability and support for IEEE 1394-based digital I/O and general motion expansion modules. The IEEE 1394 interface is the backbone of SmartServo, our distributed controls architecture supporting our products. The SmartController EX also includes Fast Ethernet and DeviceNet.

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Refer to the SmartController EX User’s Guide for SmartController specifications.

1.2 Installation Overview

The system installation process is summarized in the following table. Also, refer to System Installation on page 71.

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

Chapter 1: Introduction

Figure 1-7. SmartController EX

Table 1-2. Installation Overview

Task to be Performed Reference Location

Mount the cable box (Quattro HS robot or Quattro H robot with IP65 option).

Mount the robot to a level, stable mounting frame. Mounting the Robot Base on page

Attach the robot outer arms and platform. Attaching the Outer Arms and Plat-

Install the SmartController, Front Panel, Pendant (if purchased), and ACE software.

Install the IEEE 1394 and XSYS cables between the robot and SmartController.

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

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.

Cable Inlet Box on page 50 and Installing Cable Seal Kit on page

220.

34.

form on page 39.

Installing the SmartController EX on page 72.

Cable Connections from Robot to SmartController on page 82.

Installing the SmartController EX on page 72.

Connecting 24 VDC Power to Robot on page 83.

Connecting 200-240 VAC Power to Robot on page 86.

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

Equipment on page 94.

Connect digital I/O through the robot XIO connector. Using Digital I/O on Robot XIO Con-

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1.3 How Can I Get Help?

Task to be Performed Reference Location

nector on page 112.

Start the system, including system start-up and testing operation.

Install optional equipment, including end-effectors, user air and electrical lines, external equipment, etc.

1.3 How Can I Get Help?

For support or service, contact your local Omron support.

Refer to additional information sources on our corporate website:

http://www.ia.omron.com

Related Manuals

This manual covers the installation, operation, and maintenance of an Quattro robot system. There are additional manuals that cover programming the system, reconfiguring installed components, and adding optional components. See the following table. These manuals are available on the software media shipped with each system.

Manual Title Description

Starting the System for the First Time on page 121.

End-Effectors on page 129.

Table 1-3. Related Manuals

Robot Safety Guide Contains safety information for our robots.

SmartController EX User’s Guide

ePLC Connect 3 User’s Guide Describes the installation and use of the ePLC Connect 3 soft-

ACE User’s Guide Describes the installation and use of ACE software.

Single and Multiple Robot Configuration Guide

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

Contains complete information on the installation and operation of the SmartController EX.

ware, for using a user-supplied PLC as controller.

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

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Chapter 2: Safety

2.1 What to Do in an Emergency / Abnormal Situation

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

Releasing the Brakes

In case of an emergency or abnormal situation, the platform can be manually moved without electric power. However, only qualified personnel who have read and understood this manual and the Robot Safety Guide should manually move the platform to a safe state. The brakes can be released with the brake release button on Status Display Panel, see Robot Status Display Panel on page 105. This requires 24 V power, and an E-Stop must be pressed on the robot. All robot axes are held by brakes, which can be released with the brake release button. Remote brake release feature is also available via XIO Input 6.2 (Pin 18) configuration, see Remote Brake Release Feature on page 108.

General Hazards

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

Do not place objects on the Platform or Base of the robot.

Do not exceed the maximum payload capacity.

Do not exceed the maximum recommended limits given in technical specifications. See Technical Specifications on page 135.

Rotational speed becomes more significant when the payload’s center of gravity is farther away (vertically and/ or horizontally) from the platform’s center of gravity.

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

Do not use unauthorized parts.

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, 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 three ways to enable the motors:

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2.2 Dangers, Warnings, and Cautions

Enable power through ACE software installed on your PC

Press the green ROBOT POWER button on the Front Panel

Press the ROBOTPOWER button on the Pendant

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

2.2 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.

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.

This identifies a hazardous electrical situation.

This identifies a hazardous ESD situation.

This identifies a hazardous burnrelated situation.

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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.

2.3 User's Responsibilities

Safe use of the Quattro robot is your responsibility. Safe use includes:

Reading the installation and operation instructions, as well as the Robot Safety Guide, before using the equipment.

Chapter 2: Safety

Ensuring that the environment is suitable for safe operation of the robot.

Ensuring that anyone working with or near a robot has been adequately trained, and is following this guide and the Robot Safety Guide for safe robot operation.

Maintaining the robots so that their control and safety functions continue to work properly.

Electrical Hazards

WARNING: ELECTROCUTIONRISK Quattro robots use 200-240 VAC power. Thus, appropriately-sized branch circuit protection and lockout/ tagout capability must be provided in accordance with National Electrical Code and any local codes.

Pinch Hazard

Robots' Arm Spring Assemblies

CAUTION: PINCHRISK Ball joints are spring-loaded. Be careful not to pinch your fingers.

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.

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2.4 Robot Behavior

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)

Have read the guides

Understand the guides

Will work in the manner specified by the guides

2.4 Robot Behavior

Hardstops

The robot’s hardstops are located at the base. If the robot runs into one of its hardstops, the robot’s motion will stop completely, the system will generate an envelope error, and power will be cut to the robot motors.

The robot cannot continue to move after hitting a hardstop until you clear the error.

The robot’s hardstops can stop the robot at any speed, load, and maximum or minimum extension.

2.5 Intended and Non-intended Use

Intended Use

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

The Quattro robot is intended for use in parts assembly and material handling for payloads up to 6.0 kg (13.2 lb), for anodized platforms, and payloads up to 3 kg (6.6 lb) for stainless steel platforms. See Technical Specifications on page 135 for complete information on the robot specifications. Refer to the Robot Safety Guide for details on the intended use of our robots.

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

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Guidelines for safe use:

Clean, dry surfaces— The Quattro robot is designed to be compatible with standard cleaning and operational needs for secondary food packaging, as well as less stringent requirements. The platform and the arms, are IP67 rated. The base of the Quattro H robot, is IP65 rated, and for the Quattro HS robot, the rating is IP66.

IMPORTANT: For standard Quattro H robot, the topside of the base is IP20 rated, and therefore must not be exposed to liquid.

Temperature — 1 to 40°C (34 to 104°F), with a recommended humidity range of 5% to 90%, non-condensing.

Non-Intended Use

The Quattro 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

Chapter 2: Safety

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

Non-intended use of Quattro 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 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:

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2.6 Additional Safety Information

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's design is in accordance with the requirements of IEC 60204-1 and ISO 13849. The E-Stop button complies with ISO 13850.

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

The manual control pendant can only move one robot at a time, even if your network contains multiple robots.

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.

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Chapter 3: Robot Installation - H

3.1 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%, non-condensing. 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.

Use a forklift, pallet jack, or similar device to transport and store the packaged equipment.

The robot 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 Quattro robot weighs 118 to 123 kg (260 to 271 lb) with no options installed.

3.2 Unpacking and Inspecting the Equipment

Before Unpacking

Before unpacking, carefully inspect all shipping crates for evidence of damage during transit. 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, compare the actual items received (not just the packing slip) with your equipment purchase order. 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 your local Omron support as soon as possible (see How Can I Get Help? on page 22).

If the items received do not match your order, please contact your local Omron support immediately.

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

Unpacking

The Quattro robot is shipped in a wooden crate that holds the robot base, outer arms, platform, controller, miscellaneous hardware, and any accessories ordered.

The top of the crate should be removed first.

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3.2 Unpacking and Inspecting the Equipment

Figure 3-1. Robot Base in Crate, (A) Outer Arms

The robot base is shipped with the inner arms attached. The outer arms are assembled in pairs, packed in a cardboard box at the bottom of the crate. The platform is shipped fully assembled, but separate from the robot base and outer arms.

1. Remove the ancillary items (controller, outer arms, platform, etc.) that are in cardboard boxes and attached to the crate bottom.

Figure 3-2. Outer Arms

The robot base is secured to the crate with four machine bolts, one in each crate post.

Place a protective pad over the eAIB to protect it from damage from tools during the removal of the bolts.

Remove the bolt from each crate post.

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3.3 Repacking for Relocation

Chapter 3: Robot Installation - H

Figure 3-3. Removal ofBolt

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

CAUTION: PROPERTYDAMAGERISK The robot must always be shipped in an upright orientation.

3.4 Environmental and Facility Requirements

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

Table 3-1. Robot System Operating Environment Requirements

Ambient temperature 1 to 40°C (34 to 104°F)

Humidity 5% to 90%, non-condensing

Altitude up to 2000 m (6500 ft)

Pollution degree 2

Protection class: robot base IP65 (with optional cable sealing kit)

Protection class: arms, platform IP67

Note: For robot dimensions, see Technical Specifications on page 135.

Note: For power requirements, see Connecting 24 VDC Power to Robot on page 83 and Con-

necting 200-240 VAC Power to Robot on page 86.

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3.5 Mounting Frame

20x

1800.0

2000.0

Note: The SmartController must be installed inside a NEMA-1 rated enclosure. The controller must not come into contact with liquids.

3.5 Mounting Frame

The Quattro robot is designed to be mounted above the work area suspended on a user-supplied frame. The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace.

While we do not offer robot frames for purchase, and the frame design is the responsibility of the user, we provide here some general guidelines as a service to our users. We make no representation or warranty with respect to these guidelines, or the rigidity and longevity of the structure designed and built by the user or for the user by a third party using these guidelines. In addition, when the robot is mounted on the structure based on these guidelines, We do not guarantee that the robot will perform to the specifications given in this product documentation, due to user’s frame or user’s production environmental factors.

As an example, a sample frame design is presented and discussed. For generalized application performance, frames built to the specifications of this sample should experience no degradation in robot performance due to frame motions. Applications requiring higher than 6 kg * 10 g forces across the belt and/or 6 kg * 3 g along the belt may require a stiffer frame design.

Figure 3-4. Sample Quattro Mounting Frame, (A) See Detail 1, (B) See Detail 2

NOTE: More specifications for the sample frame are provided in Robot Mounting Frame, Quattro 650H Robot on page 158.

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Chapter 3: Robot Installation - H

Any robot’s ability to settle to a fixed point in space is governed by the forces, masses, and accelerations of the robot. Since “every action has an equal and opposite reaction”, these forces are transmitted to the robot frame and cause the frame and base of the robot to move and possibly vibrate in space. As the robot system works to position the tool flange relative to the base of the robot, any frame or base motion will be “unobservable” to the robot system, and will be transmitted to the tool flange. This transmitted base motion will result in inertial movement of the tool flange mass, and will cause disturbance forces to be introduced into the robot control system. These disturbance forces cause “work” to be done by the robot servo control system which may result in longer settling times for robot operations.

It is important to note that, even after the system reports the robot to be fully settled, the tool flange will still be moving by any amount of motion that the suspended base of the robot may be experiencing.

Frame Orientation

The sample robot frame design is stiffer in one direction than the other. This is to accommodate conveyor belt applications where the robot is moving with much more acceleration across a conveyor belt than along it. The conveyor should generally be aligned so that the belt travel is along the robot World Y-axis, and the mid-height frame members cross the belt at a 90° angle. The across-the-belt dimension of the frame should be minimized to get the best performance of the robot in that direction. While this frame design assumes a 1.8 m across-thebelt frame dimension, a 1.5 m dimension would offer increased stiffness and possibly increased robot performance at high accelerations and payloads. The mid-height horizontal members are important to the frame stiffness, and should be located as close to the belt as possible.

For applications requiring high accelerations along the direction of belt travel, consideration should be given to strengthening the frame in that direction.

Frame Construction

Typically, the frame is constructed of welded steel members. Hygiene-sensitive applications may call for stainless steel fabrication, with care taken to seal up all possible voids and grind smooth all weld joints. For other applications, it may be suitable to manufacture the frame of carbon steel and paint the resulting assembly. The frame design presented here is based on a stainless steel construction using 10 mm thick members. It may be reasonable to use a reduced thickness for carbon steel assemblies. Some customers may choose to use tubular members, or turn horizontal members at 45° angles to facilitate water runoff from the flat frame surfaces.

Robot-to-Frame Considerations

The Quattro has a moderately-complex mounting requirement due to the nature of the parallelarm kinematics and the need to minimize the robot size and mass. Arm Travel Volume (650 shown) (units in mm) on page 143 shows the inner arm travel and how it may encroach on the robot mounting points. As a starting point, for a frame that is 2 meters in each direction, (allowing use of the full range of the Quattro 650 robots), you should attempt to attain a frame frequency of 25 Hz.

For specialized applications, such as heavy payloads and/or aggressive moves, you may want to attain a frame frequency of 40 Hz.

In general, a smaller frame will yield a higher frequency. If you aren’t going to use the entire work envelope, you can increase the frequency simply by using a smaller frame.

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3.6 Mounting the Robot Base

A lower frequency frame, more aggressive robot moves, and heavier payloads will all contribute to longer settling times.

Mounting

The robot mounts in four locations, as detailed in the drawings. The holes are tapped for an M16 x 2.0 bolt. The Quattro robot may be mounted from the top or bottom of the frame. A crane or forklift should be used to position the robot. If lifted from above, the robot must be lifted by user-supplied eyebolts and slings.

Mounting Hole Dimensions, Quattro H Robots, (A) Detail A, (B) Detail B (units in mm) on page 136 shows the mounting hole pattern for the Quattro robot. Note the hole location and mounting pad tolerances for position and flatness.

Deviation from this flatness specification will, over time, cause a possible loss of robot calibration. If the frame does not meet this flatness specification, use shims to achieve it.

NOTE: We suggest welding the robot mounting tabs as a last step in the frame fabrication, using a flat surface as a datum surface during the tack welding operation.

Gussets

The triangular gussets are an integral part of the frame stiffness. The vibrational strength of a structural assembly is strongly governed by controlling the shear forces between members. The 250 mm gussets, shown in Sample Quattro Mounting Frame, (A) See Detail 1, (B) See Detail 2 on page 32, are nominally sufficient for transferring the load from the vertical members into the horizontal cross pieces. Preferably, gussets should be placed at the edges of the frame members to transfer the loading into the walls of the members, instead of the faces, and enable easier cleaning. Some frame designs may benefit from extending these gussets to 500 mm in the vertical direction, as the design intent of the gussets is mainly to secure the long vertical members from rotating out of position. For this reason, the gussets to the across-the-belt horizontal member should be at the bottom of the member, as shown in Sample Quattro Mounting Frame, (A) See Detail 1, (B) See Detail 2 on page 32, and as close to the vertical midplane of the frame as feasible (15 mm thickness is adequate for most situations).

3.6 Mounting the Robot Base

NOTE: All mounting hardware is user-supplied.

CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK

Remove all ancillary components (controller, outer arms, platform, etc.) from the shipping crate before lifting the robot base.

Robot Orientation

We recommend mounting the Quattro robot so that the Status Display Panel faces away from the conveyor belt. Although the work envelope of the robot is symmetrical, this orientation gives better access to the status display, status LED, and Brake-Release button. It also balances the arm loading for aggressive moves across the belt.

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Chapter 3: Robot Installation - H

This orientation places the robot World Y-axis along the conveyor belt, and the X-axis across the belt.

Mounting Surfaces

Mounting surfaces for the robot mounting flanges must be within 0.75 mm of a flat plane. If the surfaces do not meet this tolerance, use shims to attain it.

NOTE: Failure to mount the Quattro robot within 0.75mm of a flat plane will result in inconsistent robot motions.

Mounting Options

Using the mounting frame design provided, there are several options for mounting the Quattro robot:

Lower the robot into the frame from above, or Lift the robot into the frame from below.

Place the robot mounting pads on top of the frame mounting pads, or Place the robot mounting pads under the frame mounting pads.

Mounting hardware can be bolts threaded directly into the robot base mounting pads, or bolts that go through the robot base mounting pads into nuts.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK Do not attempt to lift the robot from any points other than with eyebolts or slings as described here, or with a padded board, as described here.

Mounting Procedure from Above the Frame

The Quattro robot has four mounting pads. Each pad has one M16 x 2.0 threaded throughhole. The robot can be mounted either on top of the frame pads, using the bottom surface of the robot base mounting pads, or to the bottom of the frame pads, using the top surface of the robot base mounting pads.

Mounting to Top of Frame Pads

This procedure uses two user-supplied M16 x 2.0 eyebolts and jam nuts.

Remove all lag bolts from the robot base mounting pads.

Screw the M16 eyebolts into opposing robot mounting pads, so that the robot will be balanced when lifted.

Lock each eyebolt with a jam nut.

Connect slings to the M16 eyebolts and take up any slack in the slings.

WARNING: PERSONALINJURYORPROPERTYDAMAGERISK Do not to lift the robot from any points other than the eyebolts. Failure to comply could result in the robot falling and causing either injury or equipment damage.

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3.6 Mounting the Robot Base

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

Slowly lower the robot while aligning the M16 holes in the robot mounting pads with the holes in the frame mounting pads.

When the mounting pad surfaces are touching, start a bolt in each of the two unused mounting holes. Refer to Install Mounting Hardware on page 37.

Remove the slings and M16 eyebolts.

Follow the instructions in Install Mounting Hardware on page 37.

Mounting to Bottom of Frame Pads

NOTE: Since eyebolts would be in the way of this mounting method, you will have to use slings or other means to lift the robot base. Nylon slings can be wrapped across the center of the robot base, away from the inner arms. See the following figure.

Remove all lag bolts from the mounting pads before lifting the robot base.

Wrap slings around the robot base. See the following figure for two methods.

NOTE: Make sure the slings do not touch the status panel or inner arms.

Figure 3-5. Location of Slings for Lifting Robot Base, (A) Slings

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

Slowly lower the robot while rotating it slightly, so that the four mounting pads are lowered past the frame mounting pads without touching.

When the robot base mounting pads are below the lower surface of the frame mounting pads, rotate the robot base so that the M16 threaded holes in the robot base mounting pads align with the holes in the frame mounting pads.

Lift the robot base up, keeping the holes in the robot base pads and the frame pads aligned, until the top surfaces of the robot base pads are touching the bottom surface of

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Chapter 3: Robot Installation - H

the frame mounting pads.

Follow the instructions in Install Mounting Hardware on page 37.

Mounting Procedure from Below the Frame

The Quattro robot has four mounting pads. Each pad has one M16 x 2.0 threaded hole. The robot can be mounted either on top of the frame pads, using the bottom surface of the robot base pads, or to the bottom of the frame pads, using the top surface of the robot base pads.

The Quattro robot can be mounted from beneath the mounting frame using a forklift. Use a padded board as a support under the robot base. The robot base can be rotated by hand, once mounted on the lifting pad on a forklift, when needed for clearing obstacles.

Mounting to Bottom of Frame Pads

Remove all lag bolts from the mounting pads before lifting the robot base.

Lift the robot and position the robot directly under the mounting frame.

Slowly lift the robot and align the M16 holes in the robot mounting pads with the holes in the frame mounting pads.

Lift the robot until the top of the robot base mounting pads are touching the bottom of the frame mounting pads.

Follow the instructions in Install Mounting Hardware on page 37.

Mounting to Top of Frame Pads

Remove all lag bolts from the mounting pads before lifting the robot base.

Lift the robot so the mounting pads are directly under the mounting pads of the frame.

Slowly lift the robot while rotating it slightly, so that the four mounting pads are raised past the frame mounting pads without touching.

When the robot base mounting pads are above the top surface of the frame mounting pads, rotate the robot base back, so that the M16 threaded holes in the robot base mounting pads align with the holes in the frame mounting pads.

Slowly lower the robot base while aligning the M16 holes in the robot mounting pads with the holes in the frame mounting pads.

Continue lowering the robot base until the bottom surface of the robot base mounting pads are touching the top surface of the frame mounting pads.

Follow the instructions in Install Mounting Hardware on page 37.

Install Mounting Hardware

NOTE: When mounting the robot, note the following:

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

Verify that the robot is mounted squarely before tightening the mounting bolts.

All mounting hardware is user-supplied.

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3.6 Mounting the Robot Base

Place split lock, then flat washers on the bolts.

Bolts are M16 x 2.0 if threaded into the robot base mounting tabs.

Bolts are M12 or ½ in. if going through the robot base mounting tabs into nuts.

NOTE: When M16 x 2.0 bolts are used, the bolt must engage at least 24 mm into the threads of the base mounting pad.

Insert the bolts through the holes in the frame mounting pads and into the threaded holes in the robot base mounting pads.

If using through-bolts, insert the bolts through the holes in both the mounting pads and through the threaded holes in the robot base mounting pads into nuts.

Tighten the mounting hardware to the specifications listed in the following table.

NOTE: Check the tightness of the mounting bolts one week after initial installation, and then recheck every 6 months. For periodic maintenance, see Periodic Maintenance Schedule on page 165.

Table 3-2. Mounting Bolt Torque Specifications

Standard Size Minimum Specification Torque

Threaded into base (aluminum):

Metric M16 x 2.0 ISO Property Class 5.8 98 N·m (74 ft-lb)

Using base mounting pad hole as through-hole:

Metric M12 ISO Property Class 9.8 100 N·m (75 ft-lb)

SAE ½ in. 100 N·m (75 ft-lb)

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3.7 Attaching the Outer Arms and Platform

Chapter 3: Robot Installation - H

Callout Description Callout Description

A Mounting Pads F Motor Cover

B eAIB G Outer Arms

C Cable Inlet Box H Platform

D Base J Ball Joints (Spring Assemblies not shown)

Figure 3-6. Major Robot Components, Top View

E Inner Arm

The Quattro robot platform is attached to the inner arms by the outer arms.

NOTE: Except for attaching the outer arms and end-effector tooling, the platform is shipped fully assembled.

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3.7 Attaching the Outer Arms and Platform

Clocking the Platform to the Base

The rotational alignment (clocking) of the platform to the base is critical to the correct operation of the Quattro robot.

NOTE: Incorrect clocking of the platform will result in incorrect robot performance.

On the hard-anodized and stainless steel platforms, the ends of the platform crosspieces (between each pair of ball studs) are labeled with numbers (1–4).

In addition, +X and +Y World Coordinates are labeled on the platform near the flange. See the following figure.

When installing the platform, the numbers on the platform must match the numbers on the underside of the robot base.

Figure 3-7. Platform Orientation Labeling (P32 shown)

Version Information: The labeling on all anodized platforms is the same except for the part number.

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Chapter 3: Robot Installation - H

X+

Y+

Figure 3-8. Platform Orientation, P31 Platform, (A) Tool Flange

Attaching the Outer Arms

One pair of outer arms attaches between each inner arm and the platform. No tools are needed to install or remove the outer arms.

Each outer arm has a ball joint socket at each end.

The inner arms and the platform have corresponding pairs of ball studs.

CAUTION: PINCHRISK Ball joints are spring-loaded. Be careful not to pinch your fingers.

Figure 3-9. Inner Arm Ball Studs

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3.7 Attaching the Outer Arms and Platform

Outer arm pairs are shipped assembled. Each pair has two springs and two horseshoes at each end.

Figure 3-10. Ball Joint Assembly (Quattro HS shown)

Callout Description Callout Description

A Ball Joint Stud E Ball Joint Socket Insert

B Inner Arm F Outer Arm Springs

C Ball Joint Socket G Spring Horseshoe

D Pressed Pin H Outer Arms

CAUTION: PROPERTYDAMAGERISK Ensure that the bearing insert is in place in the end of each outer arm. If an insert has fallen out of the arm, press it back into place, ensuring that the insert is centered and bottomed-out in the ball joint socket.

NOTE: In the following steps, take care not to trap debris between the ball studs and their sockets.

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Chapter 3: Robot Installation - H

NOTE: The procedure for attaching outer arms is the same for all platforms.

Attach one pair of outer arms to each inner arm.

As illustrated in the following figure, this is most easily achieved by pivoting the two arms away from each other lengthwise. This requires the least stretching of the spring to attach the ball joints.

Slip one ball joint socket over the corresponding ball stud.

Swing the bottom end of the outer arm pair sideways as you slip the other ball joint socket over the corresponding ball stud.

CAUTION: PROPERTYDAMAGERISK Do not overstretch the outer arm springs. Separate the ball joint sockets only enough to fit them over the ball studs.

Figure 3-11. Installing Outer Arms (Quattro HS shown)

Attach one pair of outer arms to each of the four pairs of ball studs on the platform.

NOTE: Ensure that the numbers on the platform match the numbers on the underside of the robot base. This will place the platform tool flange closest to the Status Display Panel. See Clocking the Platform to the Base on page 40. The platform is installed flange-down.

Swing the bottom end of the outer arm pair to the right, as far as possible.

Slip the right ball joint socket over the right ball stud. (Move the platform as needed to do this.)

Move the platform and outer arm pair to the left as you slip the left ball joint socket over the corresponding ball stud.

Ensure that all spring hooks are fully-seated in the grooves of the horseshoes, as shown in the following figure:

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3.8 Mounting the Front Panel

Figure 3-12. Horseshoe and Spring Assembly

3.8 Mounting the Front Panel

The Front Panel must be installed outside of the workspace.

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

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Chapter 4: Robot Installation - HS

4.1 Transport and Storage

Use a forklift, pallet jack, or similar device to transport and store the packaged equipment.

The Quattro robot weighs 118 to 123 kg (260 to 271 lb) with no options installed.

4.2 Unpacking and Inspecting the Quattro Equipment

Before Unpacking

Carefully inspect all shipping crates for evidence of damage during transit. If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked.

Upon Unpacking

If the items received do not match the packing slip, or are damaged, do not sign the receipt. Contact your local Omron support as soon as possible.

If the items received do not match your order, please contact your local Omron support immediately.

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

Unpacking

The Quattro HS robot is shipped in a crate that holds the robot base, outer arms, platform, controller, miscellaneous hardware, and any accessories ordered.

The top of the crate should be removed first.

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4.2 Unpacking and Inspecting the Quattro Equipment

Figure 4-1. Robot Base in Crate, (A) Outer Arms

1. Remove the ancillary items (controller, outer arms, platform, etc.) that are in cardboard boxes and attached to the crate bottom.

Figure 4-2. Outer Arms

The robot base is secured to the crate with four machine bolts, one in each crate post.

Place a protective pad over the eAIB to protect it from damage from tools during the removal of the bolts.

Remove the bolt from each crate post.

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Chapter 4: Robot Installation - HS

Figure 4-3. Removal of Bolt

4.3 Repacking for Relocation

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

CAUTION: PROPERTYDAMAGERISK The robot must always be shipped in an upright orientation.

4.4 Environmental and Facility Requirements

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

Table 4-1. Robot System Operating Environment Requirements

Ambient temperature 1 to 40°C (34 to 104°F)

Humidity 5% to 90%, non-condensing

Altitude up to 2000 m (6500 ft) above sea level

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4.5 Mounting Frame

Pollution degree 2

Protection class: robot base IP66

Protection class: platform, arms IP67

NOTE: For robot dimensions, see Top Dimensions, Work Envelope, 650 (HS shown) (units in mm) on page 135.

NOTE: For power requirements, see Connecting 24 VDC Power to Robot on page 83 and Connecting 200-240 VAC Power to Robot on page 86.

NOTE: The SmartController must be installed inside a NEMA-1 rated enclosure. The controller must not come into contact with liquids.

NOTE: For chemical cleaning information, refer to Chemical Compatibility on page 190.

4.5 Mounting Frame

The design of the robot mounting frame is the user’s responsibility.

The sample given for the 650H robot, while stiff enough for use with the Quattro HS robots, was not designed for USDA applications.

The thickness of the frame mounting tabs is critical, as is the flatness of those tabs. See Frame Mounting Tabs (following) and Mounting Surfaces on page 56.

The frame must be stiff enough to prevent excessive vibration.

You may want to design the frame so that the robot can be installed by lowering it from the top.

The Quattro HS robot is designed to be mounted above the work area suspended on a user-supplied frame. The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace.

While we do not offer robot frames for purchase, and the frame design is the responsibility of the user, we provide some general guidelines as a service to our users.

Frame Mounting Tabs

To achieve the correct compression of the sealing gaskets, the mounting tabs on the frame must be 12.7 mm, +1.3, -0.7 mm thick (0.5 in., +0.05, -0.028 in.).

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Chapter 4: Robot Installation - HS

Because the junction of the robot base mounting pad and the frame mounting pad is sealed with a gasket, the frame mounting pads must be at least as big as the robot base mounting pads. If the frame pad does not cover the entire robot pad, the gasket will not seal properly.

The design of the Quattro HS robot mounting bolts and seals requires fairly tight tolerances for the robot mounting holes in the frame. These should be 17.25 ± 0.75 mm (0.68 ± 0.03 in.) in diameter.

Robot-to-Frame Considerations

The Quattro robot has a moderately-complex mounting requirement due to the nature of the parallel-arm kinematics and the need to minimize the robot size and mass. Arm Travel Volume (650 shown) (units in mm) on page 143 shows the inner arm travel and how it may encroach on the robot mounting points. As a starting point, for a frame that is 2 meters in each direction, (allowing use of the full range of the Quattro 650 robots), you should attempt to attain a frame frequency of 25 Hz.

For specialized applications, such as heavy payloads and/or aggressive moves, you may want to attain a frame frequency of 40 Hz.

In general, a smaller frame will yield a higher frequency. If you aren’t going to use the entire work envelope, you can increase the frequency simply by using a smaller frame.

A lower frequency frame, more aggressive robot moves, and heavier payloads will all contribute to longer settling times.

Mounting

Mounting Hole Dimensions, Quattro HS Robots (units in mm) on page 137 shows the mounting hole pattern for the Quattro HS robot. Note the hole location and mounting pad tolerances for position and flatness.

Deviation from this flatness specification will, over time, cause a possible loss of robot calibration.

NOTE: We suggest welding the robot mounting tabs as a last step in the frame fabrication, using a flat surface as a datum surface during the tack welding operation.

Gussets

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4.6 Cable Inlet Box

4.6 Cable Inlet Box

The cable inlet box (P/N 09564-000) must be mounted on the top of the robot during the robot installation process. This is best done before the robot is mounted on the frame.

Assembling Cable Inlet Box

The cables entering the cable inlet box are sealed with a Roxtec compression block kit.

Figure 4-4. Cable Inlet Box and Cover

Components

Cable Inlet box

Cable Inlet box cover

Cable Inlet box-cover gasket

Cable Inlet box-eAIB gasket

Compression Block kit - Roxtec CF 8-8

NOTE: The Roxtec CF 8 consists of a frame and integrated compression unit (a wedge and bolt that compress the modules once they are assembled inside the CF frame). See Cable Inlet Box with Cables on page 53.

4 x Screws, M4 x 40 (cable box-eAIB; one is used for the ground)

Roxtec CF 8 frame

4 x 2-hole Roxtec modules

These are dense foam blocks surrounding pre-cut half-sleeves that can be peeled away to match the diameter of the cable to be sealed. The installation procedure follows.

Roxtec grease, used to assemble and seal the modules.

1 x Washer, ETL, SS M4 (for ground screw)

4 x Screws, M4 x 16 mm (for the back cover)

4 x Washer seals (for the back cover screws)

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Tasks

4 x Screws, M4 x 12 mm (for attaching the cable tray)

The following may be included as spares:

4 x Screws, M4 x 16 mm (for the cable tray)

4 x Washer seals (for the cable tray screws)

4 x Washers, ETL, SS M4 (for the cable tray)

Measure and mark cables to establish service length

Adapt Roxtec modules to fit cables

Install cables through cable inlet box (via Roxtec modules)

Attach cables to eAIB

Install eAIB cable inlet box

Attach cable inlet box back cover

Chapter 4: Robot Installation - HS

Procedure

1. Measure and mark all eAIB cables at 10 - 12 in. from the cable ends.

Figure 4-5. Quattro HS Cable Inlet Box with Roxtec Frame, (A) CF Frame, (B) Compression unit

This amount of slack is needed to make the cable connections to the eAIB before the cable inlet box is installed. See Cable Inlet Box with Cables on page 53.

(wedge, screw), (C) Cable Inlet Box

2. Adapt Roxtec modules to fit the cables that will be used. There should be a 0.1 to 1.0 mm gap between the halves of the modules for a proper seal. See the following figure.

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4.6 Cable Inlet Box

Figure 4-6. Adapting a Module to the Cable Size, Checking the Gap

3. Grease the Roxtec modules, using Roxtec grease. See the following figure.

Figure 4-7. Greasing a Roxtec Module

Grease the inside of the CF frame, where the modules will touch, using Roxtec grease.

Install each eAIB cable through its corresponding module, and insert the modules into the frame. See the following figure. Ensure that the terminated cable ends have 10 - 12 in. of slack. See Cable Inlet Box with Cables on page 53.

Figure 4-8. Installing Roxtec Modules into the Frame

When all of the modules are in place, tighten the compression unit to 8 - 12 N·m (6-9 ft-lbf). See the following two figures. There should be no visible gaps between the modules or around the cables.

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Chapter 4: Robot Installation - HS

Figure 4-9. Tightening the Compression Unit

Figure 4-10. Cable Inlet Box with Cables

In the preceding figure, note the four holes around the Roxtec box. These are for attaching a cable tray. See Attaching the Cable Tray on page 65.

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Page 54

4.6 Cable Inlet Box

Connecting the Cables

Place the cable inlet box-eAIB gasket around the eAIB connection panel.

Attach the ground lug to the eAIB. The ground lug is for the cable shield of the user-supplied 24 VDC cable. See the following figure.

Figure 4-11. Cable Shield Ground Lug on eAIBPanel

Callout Description Callout Description

A XSYSTEM F XIO

B Ground Point G XBELTIO

C +24 V Pin H Smart-Servo Ports

D 24 VDC Input J Ethernet Ports

E 200-240 VAC

Hand-tighten all cables to the eAIB.

NOTE: All cables must be screwed into the eAIB.

The protective earth ground will be installed in the following section.

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Page 55

Installing the Cable Inlet Box

Install the cable inlet box on the top of the eAIB using three M4 x 40 bolts.

Ensure that the gasket is seated between the eAIB surface and the cable inlet box.

Do not yet use the hole labeled as a ground.

Apply Loctite 222 in these bolt holes, not on the bolts themselves.

Torque the bolts to 1.1 N·m (10 in-lb).

NOTE: The cable inlet box should be installed with the cables exiting away from the eAIB. The cable tray attachment was designed assuming the cables would exit away from the eAIB.

Chapter 4: Robot Installation - HS

Figure 4-12. Cable Inlet Box, showing Ground Label, (A) Ground Bolt and Label

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Page 56

4.7 Mounting the Robot Base

Install the M4 protective earth ground bolt, with toothed washer, through the cable inlet box into the eAIB. See the preceding figure.

Ensure that the protective earth ground wire lug is under the toothed washer.

This bolt does not need Loctite.

Torque the bolt to 1.1 N·m (10 in-lb).

Attach the cable inlet box back cover with four M4 x 16 bolts.

Ensure that the gasket is seated between the cover and the cable inlet box.

Put one washer seal under each bolt head.

Use Loctite 222 in these bolt holes, not on the bolts themselves.

Torque bolts to 1.1 N·m (10 in-lb).

4.7 Mounting the Robot Base

CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK Remove all ancillary components (controller, outer arms, platform, etc.) from the shipping crate before lifting the robot base.

Robot Orientation

We recommend mounting the Quattro HS robot so that the Status Display Panel faces away from the conveyor belt. Although the work envelope of the robot is symmetrical, this orientation gives better access to the status display, status LED, and Brake-Release button. It also balances the arm loading for aggressive moves across the belt.

This orientation places the robot World Y-axis along the conveyor belt, and the X-axis across the belt.

Mounting Surfaces

Mounting surfaces for the robot mounting tabs must be within 0.75 mm of a flat plane.

NOTE: Failure to mount the Quattro robot within 0.75mm of a flat plane will result in inconsistent robot locations.

Because the junction of the robot base mounting pad and the frame mounting pad is sealed with a gasket, the frame mounting pads must be at least as big as the robot base mounting pads.

NOTE: If the frame pad does not cover the entire robot pad, the gasket will not seal properly.

Mounting Options

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

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Chapter 4: Robot Installation - HS

NOTE: Because of USDA requirements, the mounting holes in the robot base mounting tabs are not through-holes. This eliminates the possibility of mounting the robot with the robot tabs on top of the frame tabs. This is different than the Quattro H robots.

Depending on the mounting frame design used, there may be two options for mounting the Quattro HS robot:

Lower the robot into the frame from above

Lift the robot into the frame from below

CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK Do not attempt to lift the robot from any points other than with slings as described here, or with a padded board, as described here.

The Quattro HS robot has four mounting pads. Each pad has one M16x2.0 threaded hole. The robot must be mounted to the bottom of the frame pads, using the top surface of the robot base mounting pads.

Mounting Procedure from Above the Frame

NOTE: Nylon slings can be wrapped across the center of the robot base, away from the inner arms. See the following figure.

Remove all machine bolts securing the robot to the crate before lifting the robot base.

Retain the removed hardware for future packing of the robot for relocation.

Wrap slings around the robot base. See the following figure for two methods.

NOTE: Make sure the slings do not touch the status panel or inner arms.

09955-000 Rev. N Quattro User's Guide 57

Figure 4-13. Location of Slings for Lifting Robot Base, (A) Slings

Page 58

4.7 Mounting the Robot Base

Insert a base-pad sealing-gasket into the groove machined in each robot base mounting pad. The gasket and its positioning are shown in the following figure.

Figure 4-14. Robot Base Pad Sealing Gasket, Top View, (A) Robot Base, (B)Raised Area (Limits Gasket

Compression), (C) M16 Hole, (D) Sealing Gasket

The area of the mounting pad surrounded by the groove serves as a spacer, to ensure that the sealing gasket is properly compressed.

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

Slowly lower the robot while rotating it slightly, so that the four mounting pads are lowered past the frame mounting pads without touching.

Lift the robot base up, keeping the holes in the robot base pads and the frame pads aligned, until the sealing gaskets are touching the bottom surfaces of the frame mounting pads.

Follow the instructions in Install Mounting Hardware on page 59.

Mounting Procedure from Below the Frame

The Quattro HS robot can be mounted from beneath the mounting frame using a forklift. Use a padded board as a support under the robot base. The robot base can be rotated by hand, once supported by the lifting pad on a forklift, when needed for clearing obstacles.

Remove all machine bolts securing the robot to the crate before lifting the robot base.

Retain the removed hardware for future packing of the robot for relocation.

Insert a base-pad sealing-gasket into the groove machined in each robot base mounting pad. The gasket and its positioning are shown in Robot Base Pad Sealing Gasket, Top View, (A) Robot Base, (B)Raised Area (Limits Gasket Compression), (C) M16 Hole, (D) Sealing Gasket on page 58.

Lift the robot and position it directly under the mounting frame.

Slowly lift the robot and align the M16 holes in the robot mounting pads with the holes

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Chapter 4: Robot Installation - HS

in the frame mounting pads.

Lift the robot base up, keeping the holes in the robot base pads and the frame pads aligned, until the gaskets on the top surfaces of the robot base pads are touching the bottom surfaces of the frame mounting pads.

Follow the instructions in Install Mounting Hardware on page 59.

Install Mounting Hardware

To achieve the correct compression of the sealing gaskets, the mounting tabs on the frame must be 12.7 mm, +1.3, -0.7 mm (0.5 in., +0.05, -0.028 in.) thick.

If you choose to use a different frame pad thickness and provide your own mounting bolts, the bolts need to be M16-2.0, 316 stainless steel flange bolt (DIN 6921 standard). The threads must engage at least 24 mm (0.94 in.) of the robot base threads (HeliCoil), for sufficient support. The bolts must not bottom out, or the washer seals and gaskets will not be compressed enough to form a good seal.

NOTE: When mounting the robot, note the following:

Verify that the robot is mounted squarely before tightening the mounting bolts.

Verify that the gaskets between the robot pads and the mounting frame are in their grooves in the pads, and completely covered by the mounting frame pads.

USDA requires that all exposed screws be sealed with a gasket, which must be compressed to specific standards. To achieve this, the Quattro HS robot mounting bolts use a spacer that fits inside a compressible sealing gasket. See the following figure.

Figure 4-15. Robot Mounting Bolt, Seal, and Gasket, (A) Mounting Bolt, M 16-2.0 X 40 mm Lg. 316

Stainless Steel (DIN 6921 Standard), (B)Mounting Bolt Spacer, (C)Mounting Bolt Sealing Gasket

Place a spacer, then a sealing gasket, on each bolt.

Insert the bolts through the holes in the frame mounting pads and into the threaded

09955-000 Rev. N Quattro User's Guide 59

holes in the robot base mounting pads. See the following table for torque specifications.

Page 60

4.8 Attaching the Outer Arms and Platform

Check the position of the gaskets between the robot base pads and the mounting frame. The frame pads should completely cover the gaskets.

Tighten the bolts to 98 N·m (74 ft-lb).

NOTE: The robot base-mounting tabs have spring-lock HeliCoils in the M16 holes, so a lock washer is not needed on the M16 mounting bolts.

NOTE: Check the tightness of the mounting bolts one week after initial installation, and then recheck every 3 months. See Periodic Maintenance on page 191.

Table 4-2. Mounting Bolt Torque Specifications

Standard Size Minimum Specification Torque

Metric M16-2.0 x 40 mm ISO Property Class 5.8 98 N·m (74 ft-lb)

4.8 Attaching the Outer Arms and Platform

Figure 4-16. Major Robot Components, Top View

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Chapter 4: Robot Installation - HS

Callout Description Callout Description

A Mounting Pads F Motor Cover

B eAIB G Outer Arms

C Cable Inlet Box H Platform

D Base J Ball Joints (Spring Assemblies not shown)

E Inner Arm

The Quattro robot platform is attached to the inner arms by the outer arms.

NOTE: Except for attaching the outer arms and end-effector tooling, the platform is shipped fully assembled.

Clocking the Platform to the Base

The rotational alignment (clocking) of the platform to the base is critical to the correct operation of the robot.

NOTE: Incorrect clocking of the platform will result in incorrect robot performance.

NOTE: Stainless steel platforms are labeled to indicate which pair of ball studs should be connected to which inner arm.

When the platform is installed correctly, the tool flange will be closest to the status display on the robot base.

NOTE: The tool flange face on the P30 platform is centered, so that platform can be installed in any orientation.

The bottom of the robot base has embossed numbers, 1 through 4, indicating the motor numbers. The corresponding numbers for the platform, as viewed from the top, are indicated in the following figure, where each number represents a pair of ball studs. When the platform numbers match the robot base numbers, the platform will be correctly aligned.

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4.8 Attaching the Outer Arms and Platform

X+

Y+

Figure 4-17. Platform Orientation (P31 shown), Top View, (A) Tool Flange

Attaching the Outer Arms

One pair of outer arms attaches between each inner arm and the platform. No tools are needed.

Each outer arm has a ball joint socket at each end.

The inner arms and the platform have corresponding pairs of ball studs.

Figure 4-18. Inner Arm Ball Studs

CAUTION: PINCHRISK Ball joints are spring-loaded. Be careful not to pinch your fingers.

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Chapter 4: Robot Installation - HS

Outer arm pairs are shipped assembled. Each pair has two springs and two horseshoes at each end. See the following figure.

Figure 4-19. Ball Joint Assembly

Callout Description Callout Description

A Ball Joint Stud E Ball Joint Socket Insert

B Inner Arm F Outer Arm Springs

C Ball Joint Socket G Spring Horseshoe

D Pressed Pin H Outer Arms

CAUTION: PROPERTYDAMAGERISK Ensure that the bearing insert is in place in the end of each outer arm. If an insert has fallen out of the arm, refer to Replacing a Ball Joint Insert for instruc-

NOTE: In the following steps, take care not to trap debris between the ball studs and their sockets.

NOTE: The procedure for attaching outer arms is the same for all platforms.

tions on re-inserting it.

NOTE:This is a different procedure than for the Quattro H robots.

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Page 64

4.8 Attaching the Outer Arms and Platform

Attach one pair of outer arms to each inner arm.

As illustrated in Installing Ball Joints (Quattro H shown) on page 64, the outer arm assembly is most easily achieved by pivoting the two arms away from each other lengthwise. This requires the least stretching of the spring to attach the ball joints.

Slip one ball joint socket over the corresponding ball stud.

Swing the bottom end of the outer arm pair sideways as you slip the other ball joint socket over the corresponding ball stud.

CAUTION: PROPERTYDAMAGERISK Do not overstretch the outer arm springs. Separate the ball joint sockets only enough to fit them over the ball studs.

Figure 4-20. Installing Ball Joints (Quattro H shown)

Attach one pair of outer arms to each of the four pairs of ball studs on the platform.

NOTE: Ensure that the platform is rotated so that the tool flange is closest to the Status Display Panel. See Clocking the Platform to the Base on page 61. The platform is installed flange-down.

Swing the bottom end of the outer arm pair to the right, as far as possible.

Slip the right ball joint socket over the right ball stud. (Move the platform as needed to do this.)

Move the platform and outer arm pair to the left as you slip the left ball joint socket over the corresponding ball stud.

Ensure that all spring hooks are fully-seated in the grooves of the horseshoes, as shown in the following figure:

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Chapter 4: Robot Installation - HS

Figure 4-21. Horseshoe and Spring Assembly

4.9 Mounting the Front Panel

The Front Panel must be installed outside of the workspace.

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

4.10 Attaching the Cable Tray

NOTE: The cable inlet box must be installed on the eAIB before the cable tray can be attached. Refer to Cable Inlet Box on page 50.

NOTE: We do not provide a cable tray or a cable-tray gasket.

To comply with USDA regulations, the cables from the cable inlet box must be contained in a tray until they are no longer over the robot work area. The cable inlet box provides four M4threaded holes for attaching a cable tray. Four M4 x 12 screws and toothed washers are provided, for attaching the user-provided cable tray.

The tray should match the holes in the cable inlet box, and be wide enough at the box to avoid touching the Roxtec assembly, and leave room for the cabling exiting the Roxtec assembly. See Side View of Roxtec Cable Seal Frame (units are mm [inches]) on page 67.

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Page 66

4.10 Attaching the Cable Tray

44.45 [1.75]

7.95

[0.313]

76.2

[3.00]

4x M4 x 0.7 - 6H

7.87 [.31]

170.82 [6.725]

140.00 [5.512]

77.52 [3.05]

Figure 4-22. Dimensions of Cable Tray Attachment to Cable Inlet Box, (A) Roxtec Frame Exterior (units

are mm [inches])

Attach the cable tray to the cable inlet box, with a gasket between the two.

Use M4 x 12 bolts with toothed washers.

These bolt heads do not have to be sealed, as they are contained by the cable tray.

These bolts do not need Loctite.

Torque the bolts to 1.1 N·m (10 in-lb).

Ensure that the cable tray is adequately supported at the end where the cables exit it.

An example of a three-sided gasket, which seals between the cable tray and the cable inlet box, is shown in the following figure:

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Chapter 4: Robot Installation - HS

87.7 [3.45]

[0.313]

[0.63]

168.4 [6.63]

176.2 [6.94]

184.2 [7.25]

11.5 [0.45]

16.0 [0.63]

95.25 [3.75]

[0.125 ± 0.003]

4x7.4 [0.290]

3.175 ± 0.076

[2.42]

[1.60]

[0.472]

[0.157]

Figure 4-23. Example Cable Tray Gasket (units are mm [inches]), (A) Through Hole

NOTE: This cable-tray gasket is available as an option as part number 09751-

000.

Figure 4-24. Side View of Roxtec Cable Seal Frame (units are mm [inches])

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4.10 Attaching the Cable Tray

The following apply to the example cable tray.

Material

Item 1 Aluminum 5052-H32

Item 2 Aluminum 6061-T6

Clean part thoroughly using the following process:

Soak part in strong alkaline bath followed by light chemical clean

Finish

Electroless nickel plate per MIL-C-2607E, Class 4, Grade A

0.025 -0.038 mm [0.001 - 0.0015 in.] thick, high phosphorus (10-13% by wt.)

RoHS-compliant process

While we do not supply a cable tray, the following sample design is provided:

Figure 4-25. Sample Cable Tray, Isometric View

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Chapter 4: Robot Installation - HS

[4.00]

[4.15]

[3.75]

[7.25]

[31.75]

[3.75]

2.0°

[R1.00]

101.6

R25.4

95.3

806.5

105.4

95.3

184.2

Figure 4-26. Sample Cable Tray, Dimension Drawing 1, (A)View A-A, (B) PEM Standoffs Protrude

This Side, (C) Fill Gap, (D) See Flat Pattern (SH. 2) for Detail of this Flange (units are mm [inches])

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4.10 Attaching the Cable Tray

[3.000]

3.6

2X R635

[0.63]

95.3

16.0

[7.250]

[6.00]

7.9

[0.45]

[6.625]

[0.367]

4X 12.0

805.5

[1.88]

[38.93]

[3.63]

[31.72]

[42.65]

96.8

[7.59]

[0.03]

989.3

84°

[11.29]

[3.86]

[7.55]

[0.50] 88.0°

[31.44]

25.7

[1.07]

2X X 45°

[R1.00]

6.35

[3.70]

4.8 THRU

27.2

12.7

94.0

192.8

[0.25]

92.2

47.8 R25.4

[1.01]

[0.189]

[0.472]

9.2

[3.75]

[R0.14]

16.0

[38.95]

[31.75]

[0.31]

[0.63]

184.2

152.4

[R0.25]

168.3

11.4

76.2

1083.3

805.7

988.8

798.6

0.8

98.0

191.8

286.8

[3.81]

Figure 4-27. Sample Cable Tray, Dimension Drawing 2 (units are mm [inches])

Callout Description Callout Description

A Item 1-Flat Pattern F R3.6 This Corner Only [R0.14]

B To Bend Line G Item 2

Bend up 36 Degrees H 4X PEM Through Hole Standoff Number SOS-

D Bend up 90 Degrees J (RELIEF CUT)

E PEM Standoffs Flush with

this side

M4-12 (OR EQUIV.)

K Benddown 2.0 Degrees

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Chapter 5: System Installation

This chapter does not cover I/O. Refer to Connecting Digital I/O to the System on page 110 for more information.

This chapter assumes you are not using a PLC in the system.

5.1 System Cable Diagram

The letters in the following figure correspond to the letters in Table 5-1. Cables and Parts Description. The numbers in the following figure correspond to the numbers in Table 5-2. Connections Installation Steps.

The Pendant, Front Panel, and XUSR connections must connect to the SmartController EX.

Figure 5-1. System Cable Diagram

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5.2 Installing the SmartController EX

5.2 Installing the SmartController EX

Refer to the SmartController User’s Guide for complete information on installing the SmartCon- troller EX. This list summarizes the main steps. Refer to Table 5-2. Connections Installation 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 user-supplied 24 VDC power to the controller.

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

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

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 Table 5-2. Connections Installation Steps.

Table 5-1. Cables and Parts Description

Part Description

A Robot eAIB n/a X

B Robot eAIB

InterfacePanel

C User-supplied Ground

Wire

D T20 Pendant

Assembly

E T20 Pendant Bypass

Plug

Part

Number

n/a X

10054010

10048000

Standard Option

User-

supplied

X Optional T20

X (G) XMCPJumper

Notes

Pendant Kit (10046-010) includes items D, E, and F.

Plug, (E) T20 Pendant Bypass Plug, or (D) T20 Pendant Assembly must be used.

F T20 Pendant Adapter

Cable

G XMCPJumper Plug 10052-

10051003

000

X 3 m in length

X (G) XMCPJumper

Plug, (E) T20

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Chapter 5: System Installation

Part Description

H SmartController EX 19300-

J Front Panel 90356-

K Front Panel Cable 10356-

L Front Panel Jumper

Plug

M User E-stop, Safety

Gate

Part

Number

000

10358

10500

10052000

n/a X

Standard Option

X X

X X (J) Front Panel or

X X 10 ft. in length

X (J) Front Panel or

User-

supplied

Notes

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

Front Panel (L) Jumper Plug must be used.

N XUSRJumper Plug 04736-

000

P User-supplied

GroundWire

Q PC Running ACE Soft-

ware

R Ethernet Cable n/a X

S IEEE 1394 Cable 13632-

T eAIB XSYSCable 13323-

Items U, V and Ybelow are available, as an option, in the power supply / cable kit 90565-010.

U 24VDC, 6 A Power

Supply

V DCPower Cable 04120-

n/a X

045

000

04536000

000

X Required if no E-

stop, safety gate or muted safety gate used.

X 4.5 m in length

X 6 ft. in length

X X 85 - 264

VACuniversal input.

X X 5 m in length

W 85 - 264

VACUniversal Input

n/a X When used with

04536-000.

09955-000 Rev. N Quattro User's Guide 73

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5.2 Installing the SmartController EX

Part Description

X 200 - 240 VAC Single

Phase, 10A

Y ACPower Cable 04118-

Part

Number

n/a X

000

Standard Option

X X 200 - 240 single

User-

supplied

Notes

phase.

5 m in length

NOTE: See Installing 24 VDC Robot Cable on page 80 for additional information on system grounding.

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 a Quattro system, in production mode, with all three jumpers installed. This would leave the system with no EStops.

Cable Installation Overview

Use the following table to make all system connections.

Refer to Description of Connectors on Robot Interface Panel on page 81 eAIB connector information.

Refer to the SmartController EXUser’s Guide for SmartController EX connector information.

Table 5-2. Connections Installation Steps

Step Connection Description Item

1 Connect eAIB XSYSTEM cable to XSYSTEM on the eAIB and XSYS on the

SmartController EX.

2 Connect a user-supplied (2) E-Stop or Muted Safety Gate to the XUSR con-

nector or verify(2a) XUSR jumper plug is installed on the XUSR connector.

Refer to Installing User-Supplied Safety Equipment on page 94 for more information.

3 Connect Front Panel cable to Front Panel and XFP connector.

If no Front Panel is used, install (3a) FP jumper on the XFP connector.

4 Connect T20 Pendant adapter cable and the T20 Pendant Assembly to the

XMCP connector.

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

B, H, T

H, N, M

J, K, L

D, E, F, G

5 Connect user-supplied ground.

Refer to Grounding the Quattro Robot System on page 90 for more inform-

C, P

74 Quattro User's Guide 09955-000 Rev. N

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Chapter 5: System Installation

Step Connection Description Item

ation.

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 86 for more information.

7 Connect 24 VDC to DC Input on Interface Panel and the SmartController EX.

Refer to Connecting 24 VDC Power to Robot on page 83 for more information.

8 Connect IEEE 1394 cable between the SmartController EX and the eAIB

Interface Panel.

9 Connect Ethernet cable from PC to SmartController EX, if used. H, Q, R

5.3 Optional Cables

XIOBreakout Cable

The XIO Breakout cable is for using the I/O on the eAIB. This cable provides access to 12 inputs and 8 outputs (5 m). Refer to XIO Breakout Cable on page 119 for more information.

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.

B, X, Y

B, H, U, V, W

B, H, S

eAIB XBELTIOAdapterCable

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 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.

09955-000 Rev. N Quattro User's Guide 75

Page 76

5.3 Optional Cables

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 5-2. System Cable Diagram with Belt Encoders (Units in mm)

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Chapter 5: System Installation

Table 5-3. 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 (optional) 19300-

J SmartController Belt

Encoder Y Adapter Cable Connector

13463000

09443000

000

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

09955-000 Rev. N Quattro User's Guide 77

Page 78

5.3 Optional Cables

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 5-3. eAIBXBELTIOAdapterCable Pinout - Encoder 1 and 2 Connections

NOTE: Cable shields connected to DSUBshell.

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

NOTE: Cable shields connected to DSUBshell.

78 Quattro User's Guide 09955-000 Rev. N

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

NOTE: Cable shields connected to DSUBshell.

Page 79

Chapter 5: System Installation

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 5-6. eAIBXBELTIOAdapterCable Pinout - Force / EXPIO Connections

NOTE: Cable shields connected to DSUBshell.

09955-000 Rev. N Quattro User's Guide 79

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5.4 Connecting User-Supplied PC to Robot

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

Figure 5-7. eAIBXBELTIOAdapterCable Pinout - Force / EXPIO Connections

5.4 Connecting User-Supplied PC to Robot

The Quattro robots must be connected to a user-supplied PC for setup, control, and programming. The user loads the ACE software onto the PC and connects it to the robot via an Ethernet cable.

PC Requirements

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

80 Quattro User's Guide 09955-000 Rev. N

NOTE: Cable shields connected to DSUBshell.

Page 81

5.5 Installing ACE Software

You install ACE from the ACE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.

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 software menu, click Install the ACE Software.

The ACE Setup wizard opens. Follow the instructions as you step through the installation process.

When the install is complete, click Finish.

After closing the ACE Setup wizard, click Exit on the menu and proceed to the Start-up Procedure.

Chapter 5: System Installation

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

5.6 Description of Connectors on Robot Interface Panel

Figure 5-8. Robot Interface Panel

09955-000 Rev. N Quattro User's Guide 81

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5.7 Cable Connections from Robot to SmartController

Callout Description Callout Description

A XSYSTEM F XIO

B Ground Point G XBELTIO

C +24 V Pin H SmartServo Ports

D 24 VDC Input J Ethernet Ports

E 200 - 240 VAC

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.

SmartServo x2 (IEEE 1394) — for connecting the IEEE 1394 cable from the controller (SmartServo 1.1) to the robot. The other robot connector can be used to connect to a second robot or another 1394-based motion axis.

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 Using Digital I/O on Robot XIO Connector on page 112. That section also contains details on how to access these I/O signals via eV+.

XSYSTEM — includes the functions of the XPANEL and XSLV on the legacy AIB. This requires either the eAIB XSLV Adapter cable, to connect to the XSYS cable, or an eAIB XSYS cable, which replaces the XSYS cable. See Cable Connections from Robot to SmartController in the following section.

XBELTIO (eAIB only) — adds two belt encoders, EXPIO at the back of the robot (which was not available on the AIB), and an RS-232 interface.

Ethernet x2 — these are not currently used with the SmartController EX.

5.7 Cable Connections from Robot to SmartController

The following cables are shipped in the cable/accessories box.

Locate the IEEE 1394 cable (length 4.5 M)

Locate the eAIB XSYS cable or eAIB XSLV Adapter cable, which can be used with an existing XSYS cable

Install one end of the IEEE 1394 cable into a SmartServo port on the SmartController, and the other end into a SmartServo connector on the eAIB interface panel. See Figure 5-8.

l For a new SmartController system with an eAIB, the system will be supplied with a 15

ft (4.5 m) cable with connectors for XSYS (DB9) on one end and XSYSTEM (DB44) on the other. Connect the XSYSTEM end to the eAIB, and the XSYS end to the SmartController

l For a field upgrade from an old AIB, if you already have the old XSYS (DB9-DB9) cable

routed and all you want to do is adapt your new eAIB to plug into the old cable, use the eAIB XSLV Adapter cable. This is a 1 ft (250 mm) long adapter that essentially turns the

82 Quattro User's Guide 09955-000 Rev. N

Page 83

XSYSTEM into the old XSLV connector. Connect the XSYSTEM end to the eAIB, and the XSLV end to the old XSYS cable

Quattro HS Cables

Note that, for a USDA-Accepted robot, you must install a tray under the cables, starting at the eAIB on the robot, and continuing beyond the area in which food is processed. Any washdown dripping from the cables must be contained by this tray, to a location beyond the food-processing area.

5.8 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Robot and Controller Power

Table 5-4. VDC User-Supplied Power Supply

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

Chapter 5: System Installation

(21.6 V< Vin< 26.4 V)

Circuit Protection

Output must be < 300 W peak, or 8 Amp in-line fuse

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

Shield Termination Braided shield connected to ground at

both ends of cable. See User-Supplied 24 VDC Cable on page 85.

User-supplied 24 VDC power supply must incorporate overload protection to limit peak power to less than 300 W, or an 8 A in-line fuse protection must be added to the 24 VDC power source. (In case of multiple robots on a common 24 VDC supply, each robot must be fused individually.)

NOTE: Fuse information is located on the eAIB electronics.

The requirements for the user-supplied power supply will vary depending on the configuration of the robot and connected devices. We recommend a 24 VDC, 6 A power supply to allow for startup current draw and load from connected user devices, such as solenoids and digital I/O loads. If multiple robots are to be sourced from a common 24 VDC power supply, increase the supply capacity by 3 A for each additional robot.

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

Table 5-5. 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

09955-000 Rev. N Quattro User's Guide 83

Page 84

5.8 Connecting 24 VDC Power to Robot

1 2

Details for 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 5-6. 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

Item 1:Ground

Item 2: +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 tools: Molex P/N 63811-0400

Digi-Key P/N WM9907-ND

Procedure for Creating 24 VDC Cable

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 72.

Locate the connector and pins shown in the preceding table.

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.

NOTE: A separate 24 VDC cable is required for the SmartController. That cable uses a different style of connector. See the SmartController EX User’s Guide.

Crimp the pins onto the wires using the crimping tool.

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

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

84 Quattro User's Guide 09955-000 Rev. N

Page 85

Installing 24 VDC Robot Cable

24V, 6A

–

eAIB

SmartController EX

24V, 5A

–

Connect one end of the shielded 24 VDC cable to the user-supplied 24 VDC power supply. See User-Supplied 24 VDC Cable on page 85.

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 inSystem Operation on page 105.

Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the top of the robot.

Connect the cable shield to the ground point on the interface panel.

Chapter 5: System Installation

Figure 5-9. User-Supplied 24 VDC Cable

09955-000 Rev. N Quattro User's Guide 85

Page 86

5.9 Connecting 200-240 VAC Power to Robot

Callout Description Callout Description

A Quattro 650/800 Robot F SmartController

B User-Supplied Shielded Power

Cable

C User-Supplied Power Supply 24

VDC

D Frame Ground I Attach shield from user-supplied

E Attach shield from user-supplied

cable to ground screw on robot interface panel

G Ground

H Attach shield from user-supplied cable

NOTE: We recommend that DC power be delivered over a shielded cable, with the shield connected to ground at both ends of the cable.

5.9 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.

to side of controller using star washer and M3 x 6 screw

cables to frame ground on power supply

Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system.

Specifications for AC Power

Table 5-7. Specifications for 200-240 VAC User-Supplied Power Supply

Auto-Ranging Nominal Voltage Ranges

Minimum Operating Voltage

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

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

performance.

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

Maximum Operating Voltage

Frequency/ Phasing

1-phase

Recommended External Circuit Breaker, User-Supplied

10 Amps

86 Quattro User's Guide 09955-000 Rev. N

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Chapter 5: System Installation

NOTE: Quattro robots are designed for connection to symmetrically-earthed, three-phase AC mains systems (with grounded neutral). Connections called out as single-phase can be wired Line-to-Neutral or Line-to-Line.

WARNING: ELECTROCUTIONRISK Our 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.

WARNING: ELECTROCUTIONRISK AC power installation must be performed by a skilled and instructed person see the Robot Safety Guide. During installation, unauthorized third parties must be prevented, through the use of fail-safe lockout measures, from turning on power.

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 Overvoltage Protection

The robot must be protected 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 overvoltage 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.

In the industrial environment, non-periodic 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. Take the necessary steps to prevent damage to the robot system (for example, by interposing a transformer). See IEC 1131-4 for additional information.

09955-000 Rev. N Quattro User's Guide 87

Page 88

5.9 Connecting 200-240 VAC Power to Robot

10 A

eAIB

1Ø 200-240 VAC

1Ø 200–240 VAC 20 A

10 A

LNE

L1 L2 L3

10 A

3Ø 200–240 VAC

200–240 VAC

eAIB

1Ø 200-240 VAC

AC Power Diagrams

Figure 5-10. Typical AC Power Installation with Single-Phase Supply

NOTE: F1 is user-supplied, and must be slow-blow.

Callout Description Callout Description

B User-Supplied AC Power Cable N Neutral

E Earth Ground F1 10 A

L Line

Figure 5-11. Single-Phase Load across L1 and L2 of a Three-Phase Supply

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Chapter 5: System Installation

Callout Description Callout Description

A User-Supplied AC Power Cable L Line 1

E Earth Ground N Line 2

Details for AC Mating Connector

The AC mating connector is supplied with each system. It is shipped in the Robot Accessory Kit. The plug is internally labeled for the AC power connections (L, E, N).

Table 5-8. 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. However, it is available in the optional Power Cable kit. See List of Cables and Parts on page

72.

Procedure for Creating 200-240 VAC Cable

Locate the AC mating connector shown in AC Mating Connector Details on page 89.

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

Loosen the two screws on the cable clamp. See AC Power Mating Connector on page

90.

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 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 secure the connector.

10.

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

09955-000 Rev. N Quattro User's Guide 89

Page 90

5.10 Grounding the Quattro Robot System

Figure 5-12. AC Power Mating Connector

Callout Description Callout Description

A Removable Bushing L Line

B Cable Clamp N Neutral

E Earth

Installing AC Power Cable to Robot

Connect the AC power cable to your facility AC power source. See Typical AC Power Installation with Single-Phase Supply on page 88 and Single-Phase Load across L1 and L2 of a Three-Phase Supply on page 88. 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.

5.10 Grounding the Quattro Robot System

Proper grounding is essential for safe and reliable robot operation.

NOTE: You must ground the robot to the frame for all installations.

Quattro Robot Base

One of the base mounting pads has two small holes (in addition to the M16 mounting hole). One of these is an M8 hole, provided as a protective earth ground.

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Chapter 5: System Installation

Figure 5-13. Base Mounting Pad with Ground Hole, Top View

Callout Description Callout Description

A Robot D Mounting Hole

B Ground Label E Ground Hole

C Alignment Hole

Quattro HS Robot Base

Because of the need to seal the junction between the robot base and the frame, the protective earth ground connection for the HS robots has been moved from the base mounting pad to inside the eAIB cable inlet box, which is electrically connected to the robot base.

The ground screw is marked inside the cable inlet box with a label.

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

Robot-Mounted Equipment

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

If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling,

09955-000 Rev. N Quattro User's Guide 91

you must install a ground connection for that equipment or tooling. Hazardous voltages can be considered anything in excess of 30 VAC (42.4 VAC peak) or 60VDC.

If there will be hazardous voltages present at the tool flange or end-effector, you must:

Page 92

5.10 Grounding the Quattro Robot System

Quattro H Robots

Connect the robot base protective earth ground.

Ground the end-effector to the robot base.

NOTE: A ground strap from the end-effector to the base mounting pad must include a service loop that allows full rotation and movement of the tool flange.

Quattro HS Robots

Connect the robot cable inlet box protective earth ground.

Ground the end-effector to the robot cable inlet box ground screw.

NOTE: A ground strap from the end-effector to the robot cable inlet box ground must include a service loop that allows full rotation and movement of the tool flange.

Configuration

If the replacement platform has the same part number as the old platform, the robot does not need to be reconfigured.

If the replacement platform is a different type of platform, for instance, replacing a 185° platform with a P31 platform, the new configuration needs to be loaded using ACE software.

NOTE: The P30, P31, P32, and P34 platforms have stainless steel ball studs, and must be used with special brown acetal inserts. Contact your local Omron support for details.

Binary SPEC files are available in the SPECDATA directory on the CompactFlash card of the controller. These files contain configuration data for the available Quattro robot platforms. The robot will not operate correctly if the wrong SPEC file is loaded. (If these files are not on your CompactFlash card, you can copy them from your eV+ system disk.)

Platform Data Files:

Platform Tool Rotation SPEC File

P31 ±46.25° QP09503.SPC

P30 0° QP09730.SPC

P32 ±92.5° QP09732.SPC

P34 ±185° QP09734.SPC

From the ACE software:

Open the robot object editor.

You can do this by double-clicking on the robot in the tree structure pane.

Click the Configure tab.

Select Load Spec File . . .

92 Quattro User's Guide 09955-000 Rev. N

Page 93

Select Load Platform File.

Click Next.

Select the new platform from the list.

Click Next.

Chapter 5: System Installation

The wizard will say Working - Please wait, and then return to the robot object editor.

You can do this by double-clicking on the robot in the tree structure pane.

Once back to object editor, select Control < Servo Reset < Save Before Reboot

Click Yes.

This ensures that your configuration is saved.

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5.11 Installing User-Supplied Safety Equipment

5.11 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 97 for the XUSR wiring diagram.

Table 5-9. Contacts Provided by the XUSR Connector

Pin Pairs Description Comments

Voltage-Free Contacts Provided by Customer

1, 14 User E-Stop CH 1 (mushroom push-but-

ton, safety gates, etc.)

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

1, 14)

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

assembly line E-Stop interconnection. Does not affect E-Stop indication (pins 7,

20))

N/C contacts, Shorted if NOT Used

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-Stop in

Automatic mode only)

N/C contacts, Shorted if NOT Used

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Chapter 5: System Installation

Pin Pairs Description Comments

6, 19 Muted Safety Gate CH 2 (same as pins 5,

18)

Voltage-Free Contacts provided by Quattro

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

8, 21 E-Stop indication CH 2 (same as pins 7,

20)

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

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

11, 12, 13, 24, 25

No connection

N/C contacts, Shorted if NOT Used

Panel, pendant, and customer EStops are not tripped

Contacts are closed when Front Panel, pendant, and customer EStops are not tripped

mode

Table 5-10. 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

6, 14 Remote High Power on/off momentary push-but-

ton

Optional - jumper closed for Auto Mode-only operation

User must supply momentary 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

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5.11 Installing User-Supplied Safety Equipment

Pin 1

Pin 8

Pin 9

Pin 15

XFP

Pin Pairs

Description Requirements for User-

Supplied Front Panel

See the figure System Installation on page 71 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.

Table 5-11. 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 System Installation on page 71 for a description of the functionality of this circuit.

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Chapter 5: System Installation

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)

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)

AM2 AM1

6 V, 1.2 W

I I

Figure 5-14. E-Stop Circuit on XUSR and XFP Connectors

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5.11 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

A B C D

Callout Description Callout Description

A ESTOP 24 V Source K Auto/Manual Output

B Bulb L T20 Pendant Enable

C Front Panel High Power On/OFF M Muted Safety Gate - Activated in

auot mode only (Jumper closed when not used)

D Front Panel ESTOP Push button N Manual Mode Path

E T20 ESTOP Push button O Auto Mode Path

F Front Panel Auto/Manual Key-

switch

H User ESTOP and Gate Interlock

P Force-Guided Relay Cyclic Check

Control Circuit

Q Auto/Manual Output (Jumper closed when not used, MUST open both channels independently if used.)

I Coil R Single-Phase AC Input 200 - 240

VAC

J LINE ESTOP (External User ESTOP

System)

S High Power to Amplifiers

(Internal Connections)

Figure 5-15. Front Panel Schematic

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Chapter 5: System Installation

Callout Description Callout Description

A System Power LED C High Power On/Off

B Manual/Auto D 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 5-14.

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.

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 Omron Adept Technologies, Inc. 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 5-14. and the table Contacts Provided by the XFP Connector on page 95 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

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5.11 Installing User-Supplied Safety Equipment

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 97 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.

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

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 101 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 98. 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.

100 Quattro User's Guide 09955-000 Rev. N

Omron Quattro 650H, Quattro 650HS, Quattro 800H, Quattro 800HS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1: Introduction

1.1 Quattro Robots, Product Description

Controllers

Sizes and Materials

Major Differences between Quattro H and HS Robots

eAIB

Quattro Robot Base

Inner Arms

Ball Joints, Outer Arms

Platforms

SmartController EX

1.2 Installation Overview

1.3 How Can I Get Help?

Related Manuals

Chapter 2: Safety

2.1 What to Do in an Emergency / Abnormal Situation

Releasing the Brakes

General Hazards

Releasing an E-Stop

2.2 Dangers, Warnings, and Cautions

Alert Levels

Alert Icons

Special Information

2.3 User's Responsibilities

Electrical Hazards

Pinch Hazard

Qualification of Personnel

2.4 Robot Behavior

Hardstops

2.5 Intended and Non-intended Use

Intended Use

Non-Intended Use

Robot Modifications

2.6 Additional Safety Information

Robot Safety Guide

T20 Manual Control Pendant (Option)

Disposal

Chapter 3: Robot Installation - H

3.1 Transport and Storage

3.2 Unpacking and Inspecting the Equipment

Before Unpacking

Upon Unpacking

Unpacking

3.3 Repacking for Relocation

3.4 Environmental and Facility Requirements

3.5 Mounting Frame

Frame Orientation

Frame Construction

Robot-to-Frame Considerations

Mounting

Gussets

3.6 Mounting the Robot Base

Robot Orientation

Mounting Surfaces

Mounting Options

Mounting Procedure from Above the Frame

Mounting Procedure from Below the Frame

Install Mounting Hardware

3.7 Attaching the Outer Arms and Platform

Clocking the Platform to the Base

Attaching the Outer Arms

3.8 Mounting the Front Panel

Chapter 4: Robot Installation - HS

4.1 Transport and Storage

4.2 Unpacking and Inspecting the Quattro Equipment

Before Unpacking

Upon Unpacking

Unpacking

4.3 Repacking for Relocation

4.4 Environmental and Facility Requirements

4.5 Mounting Frame

Frame Mounting Tabs

Robot-to-Frame Considerations

Mounting

Gussets

4.6 Cable Inlet Box