Omron Viper 650, Viper 680 User Manual

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Viper 650/850 Robot with eMB-60R

User’s Guide

I599-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 9

1.1 Product Description

SmartController EX (Option) 10 eMotionBlox-40/60R 10

1.2 How Can I Get Help?

Corporate WebSite 11 Related Manuals 12

Chapter 2: Safety 13

2.1 Dangers, Warnings, and Cautions

Alert Levels 13 Alert Icons 13 Falling Hazards 13 Special Information 14

2.2 What to Do in an Emergency or Abnormal Situation

Releasing the Brakes 14 Releasing an E-Stop 14

2.3 Safety Precautions

User's Responsibilities 15 General Hazards 16 Qualification of Personnel 16

2.4 Robot Behavior

Hardstops 17 Limiting Devices 17 Singularities 17

2.5 Intended and Non-intended Use

Intended Use 17 Non-Intended Use 17 Robot Modifications 18

2.6 Additional Safety Information

Manufacturer’s Declaration of Incorporation 18 Robot Safety Guide 18 Manual Control Pendant (option) 18

2.7 Disposal

Chapter 3: Robot Installation 21

3.1 Unpacking and Inspecting the Equipment

3.2 Repacking for Relocation

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Table of Contents

3.3 Environmental and Facility Requirements

3.4 Transporting the Robot

Precautions when Transporting Robot 23 Transport Procedure 24

3.5 Mounting the Robot

3.6 Grounding the Robot

3.7 Mounting the Front Panel

3.8 Description of Connectors on Robot Interface Panel

3.9 Air Lines and Signal Wiring

Optional Solenoid Cable 30 Solenoid Valve Specifications 32 External Mounting Locations on Robot 33

3.10 Designing End-Effectors

Continuous Turn on J6 33 Mass of End-Effector 33 Center of Gravity Position of End-Effector 34 Moment of Inertia Around J4, J5, and J6 34

Chapter 4: eMotionBlox-40/60R 39

4.1 Introduction

4.2 Connectors on eMB-40/60R Interface Panel

4.3 eMB-40/60R Operation

Status LED 41 Status Panel 42 Brake Release Button 43 Brake Release Connector 44

4.4 Connecting Digital I/O to the System

4.5 Using Digital I/O on eMB-40/60R XIO Connector

Optional I/O Products 48 XIO Input Signals 48 XIO Output Signals 50 XIO Breakout Cable 52

4.6 Mounting the eMB-40/60R

Dimensions and Mounting Holes 54 Mounting Clearances 55

Chapter 5: System Installation 57

5.1 System Cables, without SmartController EX

List of Cables and Parts 58 Cable Installation Overview 59

5.2 System Cables, with SmartController EX

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Table of Contents

Installing a SmartController EX Motion Controller 61 List of Cables and Parts 62 Cable Installation Overview 63

5.3 Optional Cables

XIO Breakout Cable 64 DB9 Splitter Cable 64 eAIB XBELT IO Adapter Cable 64 SmartController EX Belt Encoder Y-Adapter Cable 64

5.4 ACE Software

5.5 Connecting Cables from the eMB-40/60R to the Robot

5.6 Connecting 24 VDC Power to eMB-40/60R Servo Controller

Specifications for 24 VDC Power 70 Details for 24 VDC Mating Connector 71 Procedure for Creating 24 VDC Cable 71 Installing the 24 VDC Cable 72

5.7 Connecting 200-240 VAC Power to eMB-40/60R

Specifications for AC Power 73 Facility Overvoltage Protection 74 AC Power Diagrams 75 Details for AC Mating Connector 76 Procedure for Creating 200-240 VAC Cable 76 Installing AC Power Cable to eMB-40/60R 77

5.8 Grounding the Robot System

Ground Point on Robot Base 78 Ground Point on eMotionBlox-40/60R 78 Robot-Mounted Equipment Grounding 79

5.9 Installing User-Supplied Safety Equipment

Emergency Stop Circuits 85 Remote Manual Mode 87 User Manual/Auto Indication 87 User High Power On Indication 88 Remote High Power On/Off Control 88 High Power On/Off Lamp 88 Remote Front Panel or User-Supplied Control Panel Usage 88 Remote Pendant Usage 89

Chapter 6: System Operation 91

6.1 Status Panel Codes

6.2 Brakes

Installing and Using the Brake Release Box 91 Using the Brake Release Switch on UL Robots 92

6.3 Front Panel

6.4 Starting the System for the First Time

Verifying Installation 95

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Table of Contents

System Start-up Procedure 96 Running the ACE Software 96 Verifying E-Stop Functions 97 Verify Robot Motions 98

6.5 Learning to Program the Robot

6.6 Installing Joint Labels

6.7 Caution Label on Robot

100

Chapter 7: Maintenance 101

7.1 Field-replaceable Parts

7.2 Periodic Maintenance Schedule

7.3 Checking Safety Systems

7.4 Checking Robot Mounting Bolts

7.5 Replacing Encoder Backup Batteries

Battery Replacement Intervals 102 Battery Replacement Procedure 102

7.6 Replacing the eMB-40/60R Amplifier

Remove the eMB-40/60R Amplifier 106 Installing a New eMB-40/60R 107

7.7 Commissioning a System with an eMB-40/60R

Safety Commissioning Utilities 108 E-Stop Configuration Utility 109 E-Stop Verification Utility 110 Teach Restrict Configuration Utility 110 Teach Restrict Verification Utility 111

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

101

102

106

107

112

Chapter 8: Technical Specifications 115

8.1 Robot Dimensions

8.2 Robot Flange Dimensions

8.3 Specifications

Physical 120 Performance 121 Stopping Distances and Times 122

115

119

120

Chapter 9: IP54/65 Option 129

9.1 Introduction

9.2 Differences from the Standard Robot Model

Installation Environment 130 Robot Connector Panel 130 Cable Clearance 131

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130

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Table of Contents

Replacing Encoder Backup Battery 131

Chapter 10: Cleanroom Option 133

10.1 Introduction

10.2 Differences from Standard Robot Model

Cleanroom Technical Specifications 134 Robot Connector Panel 134

10.3 Air Lines and Signal Wiring

10.4 Cleanroom Cover at J6 Flange

10.5 Cable Clearance

10.6 Replacing Encoder Backup Battery

133

135

137

138

Chapter 11: Status Codes 139

11.1 Introduction

Status Panel Display 139 Status Panel 139

139

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Revision History

Revision

code

Date Revised Content

01 April,

2016

02 January,

2017

03 July,

2017

04 October,

2018

05 March,

2019

Original release

Added ISO-required text for stopping distances and times.

l Added photos showing good and bad connections for the Arm

Power/Signal Cable; added to related text.

l Noted how Cleanroom Arm Power/Signal Cable connects in

Options chapter.

l Corrected ambient temperature to 5 to 40°C.

l Changed transport and lift position of joints to match what the

user will receive.

l Updated Safety chapter to newer format. l Added WEEE information. l Changed eAIB to eMB-40/60R in several places. l Added graphics of display panel LED to eMB-40/60R chapter. l Added display panel codes chapter.

l Copyright date updated to include 2019. l Corrected bore hole distance. l Revised encoder battery replacement procedure. l Updated Safety chapter with latest information. l Removed duplicated chapter 5. l System Installation chapter added as chapter 5. l Changed XMCP jumper plug P/N from 04737-000 to 10052-000. l Changed T20 Pendant P/N from 10055-000 to 10054-010. l Removed references to obsolete sDIO units from table 4-5

(optional sDIO Module, connects to controller), figure 4-4, table 4-6, and table 1-1.

l Dual robot configuration guide renamed to single and multiple

robot configuration guide.

l Added call outs to figures. l Added humidity range of 5% to 90% to table 3-1; previously it

noted 90% or less.

l Moved optional cable information and System Cables, with Two

Conveyor Encoders section to new section 5.3 Optional Cables. This section includes new details and figures to illustrate all encoder cable configurations and pinouts.

l Minor text changes to Line E-Stop Input and Emergency

StopCircuits sections in Chapter 5: System Installation.

l Added part number for IEEE 1394 cable in Chapter 5: System

Installation.

l Changed ACEsoftware disk to ACE software media. l Added a note about typical IOBlox configurations in Chapter 4:

eMotionBlox-40/60R.

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1.1 Product Description

The Viper 650 robot and Viper 850 robots are high-performance, six-joint robots designed specifically for assembly applications. The speed and precision of the Viper robots also make them ideal for material handling, packaging, machine tending, and many other operations requiring fast and precise automation.

NOTE: The descriptions and instructions in this manual apply to both the Viper 650 and the Viper 850 robots, except for instances where there is a difference, as in dimension and work envelope drawings. In those cases, the information is presented for both robots. The robot motors are powered by an eMB40/60R servo-controller/amplifier. Either robot can be controlled by the eMB40/60R, running eV+, or an optional SmartController EX motion controller.

Chapter 1: Introduction

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Figure 1-1. Robot Joint Identification

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1.1 Product Description

Key Meaning Key Meaning

A Base (1st Joint) G 2nd Arm

B 2nd Joint H 3rd joint motor cover (rear side)

C 3rd joint motor cover (rear side) J 4th Joint

D 1st Arm K 2nd arm cover

E 3rd Joint L 5th Joint

F 4th joint cover M 6th Joint

SmartController EX (Option)

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

eCobra robots

Quattro robots

Viper robots

Hornet robots

The SmartController EX supports a conveyor tracking option, as well as other options. The SmartController EX uses the eV+ Operating System (as does the eMB-40/60R). 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, the distributed controls architecture supporting our products. The SmartController also includes Fast Ethernet and DeviceNet.

Figure 1-2. SmartController EX Motion Controller

eMotionBlox-40/60R

The eMotionBlox-40/60R (eMB-40/60R) distributed servo controller contains the amplifiers to power the high-power motors of the Viper 650/850 robots, and runs the eV+ operating system for motion control.

The eMB-40/60R features:

Six AC servo motor amplifiers

Emergency stop circuitry

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Chapter 1: Introduction

DC IN 24V

GND

200 -

240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

High servo rate, to deliver low positional errors and superior path following

Sine wave commutation, for low cogging torque and improved path following

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

Integral temperature sensors and status monitoring for maximum reliability

Dual-digit diagnostics display for easy troubleshooting

Figure 1-3. eMotionBlox-40/60R (eMB-40/60R)

1.2 How Can I Get Help?

Corporate WebSite

You can access information sources on our corporate web site:

http://www.ia.omron.com

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1.2 How Can I Get Help?

Related Manuals

This manual covers the installation, operation, and maintenance of a Viper 650/850 robot system. There are additional manuals that cover programming the system, reconfiguring installed components, and adding other optional components. See the following table.

Table 1-1. Related Manuals

Manual Title Description

Robot Safety Guide Contains general safety information for all of our robots. A prin-

ted copy of this guide ships with each robot.

SmartController EXUser’s Guide

T20 Pendant User's Guide

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

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

Single and Multiple Robot Configuration Guide

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

Describes the T20 pendant.

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

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2.1 Dangers, Warnings, and Cautions

Alert Levels

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

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

WARNING: Identifies a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, and might result in serious injury, fatality, or significant property damage.

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

Chapter 2: Safety

Alert Icons

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

Icon Meaning Icon Meaning

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

Falling Hazards

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

This identifies a hazardous electrical situation.

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2.2 What to Do in an Emergency or Abnormal Situation

Safety Barriers

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

Special Information

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

IMPORTANT: Information to ensure safe use of the product.

NOTE: Information for more effective use of the product.

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

tices.

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

2.2 What to Do in an Emergency or Abnormal Situation

Press any E-Stop button (a red push-button on a yellow background) and then follow the internal procedures of your company or organization for an emergency or abnormal situation. If a fire occurs, use CO2to extinguish the fire.

Releasing the Brakes

In case of an emergency or abnormal situation, the joints of the robot can be manually moved without high voltage. However, only qualified personnel who have read and understood the robot user's guide and Robot Safety Guide should manually move the robot into a safe state. See Brakes on page 91.

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

Releasing an E-Stop

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

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

There are two ways to enable the motors:

Enable power through ACE software installed on your PC

Press the ROBOTPOWER button on the Pendant

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Once the motors are enabled, the robot will wait two seconds and then resume commanded

motion, if there is adequate space to maneuver.

2.3 Safety Precautions

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

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

User's Responsibilities

Safe use of Viper robots is your responsibility. To ensure compliance with safety rules and regulations:

Chapter 2: Safety

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

All personnel who design a Viper robot system must read this guide, read the Robot Safety Guide, and must comply with all local and national safety regulations for the loc-

ation in which the robot is installed.

Figure 2-1. Read Manual and Impact Warning Labels

The Viper system must not be used for purposes other than described in Intended Use on page 17. Contact your local Omron support if you are not sure of the suitability for your application.

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

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

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

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2.3 Safety Precautions

l The Vipers must be well maintained, so that their control and safety functions continue

to work properly.

General Hazards

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

Do not place objects on the robot.

Do not exceed the maximum payload capacity.

Do not exceed the maximum limits given in technical specifications. See Technical Specifications on page 115.

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

l Do not use unauthorized parts.

Qualification of Personnel

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

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

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

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

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

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

Have the necessary qualifications

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

Have read the guides

Understand the guides

Will work in the manner specified by the guides

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2.4 Robot Behavior

Hardstops

If the Viper runs into one of its hardstops, the robot’s motion will stop completely, an envelope error will be generated, and power will be cut to the robot motors.

The robot cannot continue to move after hitting a hardstop until the error has been cleared.

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

Limiting Devices

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

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

Singularities

There are no singularities with a Viper robot that cause a hazard.

Chapter 2: Safety

2.5 Intended and Non-intended Use

Intended Use

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

The Viper robots are intended for use in parts assembly and material handling for payloads less than 5 kg (11 lb). See Specifications on page 120 for complete information on the robot specifications. Refer to the Robot Safety Guide for details on the intended use of robots.

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

Guidelines for safe use:

Clean, dry mounting surfaces — The robot shall not be installed in an environment where it will be directly exposed to water, oil, or cutting chips.

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

Non-Intended Use

Viper 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

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2.6 Additional Safety Information

Use in medical or life saving applications

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

Use before performing a risk assessment

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

Non-intended use of Vipers can:

Cause injury to personnel

Damage itself or other equipment

Reduce system reliability and performance

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

Robot Modifications

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

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

2.6 Additional Safety Information

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

Manufacturer’s Declaration of Incorporation

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

Robot Safety Guide

The Robot Safety Guide provides detailed information on safety for fixed robots. It also gives resources for more information on relevant standards. It ships with each robot.

Manual Control Pendant (option)

The E-Stop provided in the T20 Pendant complies with ISO 10218-1 (per clause 5.5.2), with stop category 1 (per IEC 60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d per ISO 13849.

The protective stop category for the pendant enable switch is category 1, which complies with the requirements of ISO 10218-1.

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

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

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2.7 Disposal

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 designated collection facilities. For information about disposal of your old equipment, contact your local Omron support.

Chapter 2: Safety

Dispose of in accordance with applicable regulations.

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Chapter 3: Robot Installation

3.1 Unpacking and Inspecting the Equipment

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

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

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

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

Inspect each item for external damage as it is removed from its container. If any damage is evident, contact your local Omron support.

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

3.2 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. Specify this to the carrier if the robot is to be shipped.

CAUTION: Before transportation, set the robot in a transport position by manually moving the second, third, and fourth axes. See the following figure.

Figure 3-1. Robot in Transport Position

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3.3 Environmental and Facility Requirements

3.3 Environmental and Facility Requirements

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

Table 3-1. Robot System Operating Environment Requirements

Item Condition

Flatness of the

0.1 mm/500 mm

mounting surface

Installation type Floor-mount or Overhead-mount

Ambient temperature

During operation: 5 to 40°C (41 to 104° F) During storage and transportation: -25 to 60°C

Humidity During operation: 5% to 90% (Non-condensing)

During storage and transportation: 75% or less (Non-condensing)

Altitude up to 1000 m

Vibration During operation: 4.9 m/s2(0.5 G) or less

During storage and transportation: 29.4 m/s2(3 G) or less

Safe Installation Environment

The robot should not be installed in an environment where:

There are flammable gases or liquids

There are any acidic, alkaline, or other corrosive gases

There is sulfuric or other types of cutting or grinding oil mist

There are any large-sized inverters, high output/high frequency transmitters, large contractors, welders, or other sources of electrical noise

There are any shavings from metal processing or other conductive material flying about

It may be directly exposed to water, oil, or cutting chips

Working space, etc.

Sufficient service space must be available for inspection and disassembly.

Keep wiring space (230 mm or more) behind the robot, and fasten the wiring to the mounting face or beam so that the weight of the cables will not be directly applied to the connectors.

Protective Earth Ground

Grounding resistance: 10 Ω or less See Robot Installation on page 21.

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3.4 Transporting the Robot

Precautions when Transporting Robot

The robots weigh 34 and 36 kg (74 and 79 lb). Use a crane suitable for the robot weight.

Have at least two workers handle this job.

Workers should wear hardhats, safety shoes, and gloves during transport.

Do not hold the first arm, elbow, either side of the 2nd arm, 2nd-joint cover, or 3rd-joint cover, or apply force to any of them. See Robot Joint Identification on page 9.

WARNING: Do not attempt to lift the robot at any points other than the eyebolts provided. Do not attempt to move any robot links until the robot has been secured in position. Failure to comply could result in the robot falling and causing either personnel injury or equipment damage.

Chapter 3: Robot Installation

Figure 3-2. Robot in Hoisting Sling

Key Meaning Key Meaning

A Sling C Eyebolt

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B Waste Cloth

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3.4 Transporting the Robot

Transport Procedure

Step Procedure Drawing

1 Before transportation, set the robot in

a transport position as shown at right by manually moving the second, third, and fourth joints. When initially unpacked, the robot is in the transport position, so this step is not required.

Transport Position

Joint Angle

First joint (J1) 90°

Second joint (J2) -155°

2 Disconnect the robot control cable, air

hoses, and user signal cables from the robot. When the robot is first unpacked, this step is not required.

3 As shown at right, mount the eye-

bolts. When delivered, the robot is packed with eyebolts attached, so this step is not required. (A) is one of two eyebolts.

Third joint (J3) +245°

Fourth joint (J4) -90°

Fifth joint (J5) -90°

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Step Procedure Drawing

4 As shown at right, place a waste cloth

on the second joint and pass the sling through the two eyebolts.

Note: Before transporting the robot, check that the path to the mounting location is free of obstacles. Callouts are defined following Figure 3-2. (A) is the sling, (B) is a waste cloth for padding, (C) is one of two eyebolts.

5 Worker A: Remove the four bolts

while supporting the robot to prevent it from tipping over.

6 Worker B: Operate the crane and

move the robot to the mounting location.

Chapter 3: Robot Installation

7 Worker B: Put the robot down in the

mounting location. Worker A: Temporarily secure the robot base with four bolts.

8 Secure the robot according to the

instructions in Mounting the Robot on page 26.

9 Remove the eyebolts from the robot.

WARNING: Before running the robot, be sure to remove the eyebolts. Otherwise, the robot arm will strike these eyebolts.

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3.5 Mounting the Robot

2X Ø6

200

160

R20

66 ±0.05 142.3

184 ±0.05

160

200

+0.012

- 0

3.5 Mounting the Robot

Figure 3-3. Mounting Hole Pattern for Robot. Units are mm.

Key Meaning

See the preceding figure for the location and dimensions of the robot mounting holes.

A 4x Ø12 for Thru, or tap for M10

B Diamond-shaped pin

Drill four bolt holes (M10), 20 mm deep or more.

These either need to be tapped for M10, or you can drill 12 mm thru-holes, and use nuts on the other side of the mounting surface.

Drill a dowel pin hole Ø4 mm, H7 for the diamond-shaped pin, 10 mm deep or more.

NOTE:The diamond-shaped pin has a Ø6 mm diamond-shaped section, but the shank is only Ø4 mm. The hole in the base of the Viper is Ø6, but you need to drill a Ø4 hole in your mounting surface for the shank of that pin.

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Chapter 3: Robot Installation

Drill a dowel pin hole Ø6 mm, H7 for the internally threaded positioning pin, 10to 15 mm deep.

Locate two alignment pins, one round and one diamond-shaped, supplied as part of the robot bundle.

Drive the diamond-shaped pin into one Ø6, H7 hole in the robot base so that it is oriented as shown in the preceding figure.

Drive the internally threaded alignment pin into the other Ø6, H7 hole in the robot base.

NOTE: Be sure to use the alignment pins. It can minimize positional deviations that may be caused by the removal/installation of the robot for maintenance and reduce vibration during operation.

Set the robot into place on the robot mount. When transporting the robot, follow the instructions given in Transporting the Robot on page 23.

Secure the robot to the mount with four bolts:

Bolt: M10, strength class: 12.9

Tightening torque: 70 ± 14 N·m (52 ± 10 ft-lbf)

For threaded M10 holes, use plain washers and 30 mm M10 bolts.

For 12 mm thru holes, use plain and lock washers on both sides.

3.6 Grounding the Robot

Ground the grounding terminal of the robot with a wire of 12 AWG or larger. Ground resistance must be less than 10 Ohms. See Grounding the Robot System on page 77.

3.7 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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3.8 Description of Connectors on Robot Interface Panel

CN22

CN20

AIR1

AIR2

CN20

3.8 Description of Connectors on Robot Interface Panel

Figure 3-4. Robot Interface Panel

Key Meaning Key Meaning

A CN22 Power/Signal Cable to eMB-40/60R C Grounding Terminal, M5

B Ground Label D Air 1 and Air 2

Table 3-2. Robot Interface Connections

CN22 The Arm Power/Signal cable from the eMB-40/60R is installed at this connector.

CN20 Pins 1 to 10 are wired directly to corresponding pins 1 to 10 on CN21 on the upper

arm. Pins 12 to 18 are for solenoid control. See Air Lines and Signal Wiring on page 28.

AIR 1 Air line connector (BSPT1/4) for three solenoids in robot. Air Lines and Signal Wir-

ing on page 28.

AIR 2 Air line connector (BSPT1/4), connects directly to AIR 2 on the second (upper)

arm.

Grounding Terminal

Protective earth ground point on the robot. See Grounding the Robot on page 27.

3.9 Air Lines and Signal Wiring

The robot is equipped with seven air lines. Six lines, from AIR1 input, are controlled by the three internal solenoid valves. One line, from AIR2 input, is connected directly to AIR2 on the second arm. There are ten user electric lines. See the following figures and tables.

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Chapter 3: Robot Installation

Air intake/Exhaust States.

Air tubing joint Valve Signal

AIR1 Air

intake

1A 1B

1B 1A

2A 2B

2B 2A

3A 3B

3B 3A

AIR2

Exhaust Solenoid

valve

Solenoid

A B

ON OFF

OFF ON

ON OFF

OFF ON

ON OFF

OFF ON

CN20 Pin Assignments

NPN type (source IN, sink OUT)

Note 1: Pins #1 to #10 on CN21 and those on CN20 are connected with each other. The allowable current per line is 1 A.

Note 2: Use the supplied mating connector sets

CN20 pin

No.

12 0 V

13 Solenoid 1A (solenoid valve 1)

14 Solenoid 1B (solenoid valve 1)

15 Solenoid 2A (solenoid valve 2)

16 Solenoid 2B (solenoid valve 2)

17 Solenoid 3A (solenoid valve 3)

Used for:

for CN20 and CN21. See Cleanroom Option on page 133 for information about the mating connectors on Cleanroom and IP54/65 robots.

Key Meaning

A CN21 pin layout

18 Solenoid 3B (solenoid valve 3)

NPN type (source IN, sink OUT)

CN20 pin

No.

Used for:

B Connector CN21

C Air lines (x7)

D Connector CN20

E CN20 pin layout

F AIR1 (BSPT ¼) - Air line

G AIR2 (BSPT ¼) - Air line

H Ground terminal, M5

12 0 V

13 Solenoid 1A (solenoid valve 1)

14 Solenoid 1B (solenoid valve 1)

15 Solenoid 2A (solenoid valve 2)

16 Solenoid 2B (solenoid valve 2)

17 Solenoid 3A (solenoid valve 3)

18 Solenoid 3B (solenoid valve 3)

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3.9 Air Lines and Signal Wiring

Connector set part

No.

05019-000 for CN20 SRCN6A25-24S (round type con-

Connector No. Model and part name Appearance

nector) Japan Aviation Electronics Industry Ltd.

for CN21 JMLP1610M (L type plug con-

nector) DDK Electronics, Inc.

Optional Solenoid Cable

An optional 4 meter solenoid cable is available that connects between the XDIO connector on the SmartController and the CN20 connector on the robot. The part number is 05739-040.

NOTE: The optional solenoid cable does not work with the IP54/65 or the Cleanroom robots.

Installing this cable allows you to control the three internal robot solenoids directly from either the ACE software, using the digital outputs, or programmatically, with eV+. Refer to the following screen shots:

Figure 3-5. ACE Digital I/O Icon

Figure 3-6. ACE Digital I/O Box (Output Shown)

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Chapter 3: Robot Installation

See the following section for the details on activating the individual ports on each solenoid.

Table 3-3. Viper Solenoid Control

Active Output Port Signal States

Solenoid 1 A 0001 –0002

B –0001 0002

Solenoid 2 A 0003 –0004

B –0003 0004

Solenoid 3 A 0005 –0006

B –0005 0006

The two-position, double solenoids require both signal states to be

activated. Invalid states will result in indeterminate outputs.

In addition to controlling the internal robot solenoids, the Solenoid cable brings a portion of the other XDIO signals out to the CN21 connector at the top of the robot. See the following table for details of which signals are available at CN21. See the SmartController EXUser’s Guide's for the electrical specifications for the signals from the XDIO connector.

Table 3-4. CN21 Signal List When Using Solenoid Cable

CN21 Pin #

1 Input 1001

Signal from XDIO on SmartController CN21 Pin #

6 Not connected

Signal from XDIO on SmartController

2 Input 1002

3 Input 1003

4 Input 1004

5 Input 1005

Inputs 1001 to 1005 are preconfigured as low-active (sinking) inputs.

Outputs 0007 and 0008 are preconfigured as high-side (sourcing) outputs.

Limited to a combined total of 1A of current.

7 Output 0007

8 Output 0008

9 24 V Output

10 Ground

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3.9 Air Lines and Signal Wiring

Solenoid Valve Specifications

Table 3-5. Solenoid Valve Specifications

Item Specifications

Valve Switching system 2-position double

Applicable fluid Air

Operating system Pilot type

Effective cross section (Cv value)

Lubrication Oilless

Operating pressure range 0.1 to 0.7 MPa (14 to 101 psi)

Response time 15 ms or less at 0.5 MPa (72.5 psi)

Maximum operating frequency 10 Hz

1.2 mm

Ambient temperature -5 to 50° C (Dry air, non-condensing)

Solenoid Operating voltage 24 V ±10%

Power consumption (current) 0.5 W (21 mA)

Surge voltage protection circuit Zener diode

Note that the robot is rated at 0.1 to 0.39 MPa, 0.49 Max (14 - 56.6 psi, 71.1 Max). This

upper limit is lower than the solenoid's upper limit.

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External Mounting Locations on Robot

100 (850) 100 (650)

2x M3 7

2x M4 16

2x M5 12

2x M8 25

Chapter 3: Robot Installation

Figure 3-7. External Mounting Holes on Robot. Units are mm.

3.10 Designing End-Effectors

Design an end-effector such that it is in compliance with items described in this section.

Continuous Turn on J6

Mass of End-Effector

As an option, the Viper 650/850 can be ordered so that Joint 6 (J6) is programmed for continuous turn. Note that if J6 is programmed for continuous turn, it may lose its calibration. However, the other robot joints (J1 - J5) will not be affected.

Design the end-effector so that the total mass of the end-effector (including workpiece) will be lighter than the maximum payload capacity of the robot (5 kg). The total mass includes the wiring, tubing, etc.

CAUTION: If the end-effector design precautions are not observed, the clamped parts of the robot may become loose, rattle, or be out of position. The mechanical parts of the robot and robot controller may become damaged.

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3.10 Designing End-Effectors

Center of Gravity Position of End-Effector

Design an end-effector so that the center of gravity of the end-effector (including workpiece) is within the range shown in the following figure.

Figure 3-8. Allowable Range of Center of Gravity of End-effector. Units are mm.

Moment of Inertia Around J4, J5, and J6

Design an end-effector so that its moments of inertia around J4, J5, and J6 (including mass of workpiece) do not exceed the maximum allowable moments of inertia of the robot.

Maximum allowable moment of inertia around J4 and J5: 0.295 kgm

Maximum allowable moment of inertia around J6: 0.045 kgm

When calculating the moment of inertia around J4, J5, and J6 of the end-effector, use the formulas given in the following table. See Robot Installation on page 21.

Table 3-6. Moment of Inertia Formulas

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Key Meaning

A Cylinder 1

B Axis of rotation = Center axis

C Cylinder 2

D Axis of rotation passes through the center of gravity

E Rectangular Parallelepiped

F Axis of rotation passes through the center of gravity

G Sphere

H Axis of rotation = Center axis

J Center of gravity not on the axis of rotation

K Ig: Inertia moment around center of gravity (kgm2)

I = Moment of inertia (kgm2)

Chapter 3: Robot Installation

m = Mass (kg)

r = Radius (m)

b, c,l= Length (m)

Calculation Example

When calculating the moment of inertia of a complicated shape, divide the shape into simple parts as much as possible for easier calculations.

The following diagrams and tables use an example end-effector shape to demonstrate how to calculate the moment of inertia.

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3.10 Designing End-Effectors

Figure 3-9. Moment of Inertia Around J6

Key Meaning Key Meaning

Moment of Inertia around J6

A Center of gravity of ①

B Center of gravity of ②

Moment of inertia around J6 of ① : I1(from 3 and 5 in previous table)

Moment of inertia around J6 of ② : I2(from 1 and 5 in previous table)

Moment of inertia around J6 of ③ : I3(from 1 and 5 in previous table)

Moment of inertia around J6 of entire end-effector: I

C Center of gravity of ③

D Rotation around J6

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Chapter 3: Robot Installation

Figure 3-10. Moment of Inertia Around J4 and J5

For the end effector shown above, the moment of inertia around J4 and J5 can be calculated according to the same formula.

l Moment of inertia around J4 and J5 of ① : I

l Moment of inertia around J4 and J5 of ② : I

l Moment of inertia around J4 and J5 of ③ : I

l Moment of inertia around J4 and J5 of entire end-effector: I

(from 3 and 5 in previous table)

(from 2 and 5 in previous table)

J4IJ5

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Page 39

4.1 Introduction

DC IN 24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

The eMotionBlox-40/60R (eMB-40/60R) is a distributed servo controller and amplifier. It is designed with a dedicated digital signal processor to communicate, coordinate, and execute servo commands. It is the platform on which the eV+ operating system runs.

NOTE: The eMB-40/60R has in previous manuals been referred to as both an eMB-60R and an eMB-40R. They are, in fact, the same exact component.

The eMB-40/60R consists of:

a distributed servo amplifier

a RISC processor for servo loop control

a node on the IEEE 1394 network

a power controller that uses single-phase AC power, 200-240 Volts

a status panel with 2-digit alpha-numeric display to show operating status and fault codes

Chapter 4: eMotionBlox-40/60R

Figure 4-1. (A)Robot Interface Panel and (B) Robot Connector on eMB-40/60R

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4.2 Connectors on eMB-40/60R Interface Panel

4.2 Connectors on eMB-40/60R Interface Panel

Figure 4-2. eMB-40/60R Interface Panel

Key Name Meaning

A XSYSTEM Connects to the eAIB XSYSTEM cable or the eAIB XSYS

cable (for SmartController EX).

B Ground Point For cable shield from user-supplied 24 VDC cable.

C +24 V Pin +24 V pin of the 24 VDC connector.

D 24 VDC For user-supplied 24 VDC power. The mating connector is

provided.

E 200/240

VAC

F XIO For user I/O signals for peripheral devices. Provides 8 out-

G XBELTIO Adds two belt encoders, Force or EXPIO, and an RS-232

H Smart-Servo For the IEEE 1394 cable from the controller.

For 200-240 VAC, single-phase, input power. The mating connector is provided.

puts and 12 inputs. See eMotionBlox-40/60R on page 39 for connector pin allocations for inputs and outputs. That section also contains details on how to access these I/O signals. (DB-26, high density, female)

interface, which is reserved for future use.

I ENET Two Ethernet ports are available. One will be needed to

connect to a PC running ACE software.

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Chapter 4: eMotionBlox-40/60R

Table 4-1. Connectors on the eMB-40/60R Interface Panels

24 VDC For connecting user-supplied 24 VDC power. The mating connector is provided.

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

200/240 VAC

SmartServo For connecting the IEEE 1394 cable from the controller

XIO For user I/O signals for peripheral devices. This connector provides 8 outputs

XSYSTEM Includes the functions of the XPANEL and XSLV on the legacy MB-40/60R. Con-

ENET Reserved for future use.

XBELTIO Adds two belt encoders, EXPIO, and an RS-232 interface (which is reserved for

For connecting 200-240 VAC, single-phase, input power. The mating connector is provided.

SmartServo to a SmartServo on the eMB-40/60R.

and 12 inputs. See Connecting Digital I/O to the System on page 45 for connector pin allocations for inputs and outputs. That section also contains details on how to access these I/O signals. (DB-26, high density, female)

nects to the controller XSYS connector. This requires either an eAIB XSLV Adapter cable to connect to the XSYS cable, or an eAIB XSYS cable (HDB44-to-DB9, male), which replaces the XSYS cable.

future use).

4.3 eMB-40/60R Operation

Status LED

The Status LED Indicator is located near the top of the eMB-40/60R. See the following figure. This is a bi-color, red and green LED. The color and blinking pattern indicates the status of the robot. See the following table.

Figure 4-3. Controls and Indicators on eMB-40/60R

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4.3 eMB-40/60R Operation

Key Meaning Key Meaning

A Brake Release Button D Brake Connector

B Status Panel Display E EXPIO Connector

C Status LED Indicator

Table 4-2. Status LED Definition

LED Status Description

Off 24 VDC not present

Green, Slow Blink High Power Disabled

Green, Fast Blink High Power Enabled

Green/Red Blink Selected Configuration Node

Red, Fast Blink Fault - refer to the following table

Solid Green or Red Initialization or Robot Fault

Status Panel

The status panel, shown in the preceding figure, displays alpha-numeric codes that indicate the operating status of the eMB-40/60R. These codes provide details for quickly isolating problems during troubleshooting.

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

0 1 2 3 4 5 6 7 8 9

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Chapter 4: eMotionBlox-40/60R

Table 4-3. Status Panel Codes

LED Text Status Code LED Text Status Code

OK No Fault

ON High Power ON Status

MA Manual Mode HV High Voltage Bus Fault

24 24 V Supply Fault

A# Amp Fault (Joint #)

AC AC Power Fault

BA Backup Battery Low Voltage PR Processor Overloaded

B# IO Blox Fault (Address #) RC RSC Fault

D# Duty Cycle Exceeded (Joint #)

E# Encoder Fault (Joint #) SE E-Stop Delay Fault

ES E-Stop SW Watchdog Timeout

F# External Sensor Stop

FM Firmware Mismatch TR Teach Restrict Fault

h# High Temp Amp (Joint #)

H# High Temp Encoder (Joint #)

I# Initialization Stage (Step #)

M# Motor Stalled (Joint #)

P# Power System Fault (Code #)

S# Safety System Fault (Code #)

T# Safety System Fault

(Code 10 + #)

FW 1394 Fault

NOTE: Due to the nature of the Viper 650/850 robot’s bus line encoder wiring, a single encoder wiring error may result in multiple channels of displayed encoder errors. Reference the lowest encoder number displayed.

V# Hard Envelope Error (Joint #)

Brake Release Button

A Brake Release button is located at the top right of the eMB-40/60R. See Controls and Indicators on eMB-40/60R on page 41. When pressed, the button will disable High Power and display “BK” on the eMB-40/60R, but no brakes will be released.

NOTE: If this button is pressed while high power is on, high power will automatically shut down.

For manual release of the brakes on the Viper 650/850 robot, a Brake Release connector is provided on the eMB-40/60R for connecting a manual brake release box. See the following section for more details. Also, an integrated brake release switch is provided on UL robots. See Brakes on page 91.

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4.3 eMB-40/60R Operation

Brake Release Connector

The 9-pin Brake Release connector provides an interface for connecting a manual brake release box.

Table 4-4. Brake Release Connector Pinouts

Pin # Description Pin Location

1 Release1_N

2 Release2_N

3 Release3_N

4 Release4_N

5 Release5_N

6 Release6_N

7 GND

8 Not connected

9 24 V

Mating Connector:

D-Subminiature 9-Pin Male

DB-9 Female

Brake Connector

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4.4 Connecting Digital I/O to the System

eMB-40/60R

DC IN 24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

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

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

Table 4-5. Digital I/O Connection Options

Product I/O Capacity For more details

Chapter 4: eMotionBlox-40/60R

XIO Connector on eMB-40/60R

XDIO Connector on optional SmartController EX

Optional IO Blox Devices, connect to EXPIO connector on the eMB-40/60R

12 inputs 8 outputs

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

see Using Digital I/O on eMB-40/60R XIO Connector on page 46

see SmartController

EXUser’s Guide

see IO Blox User’s Guide

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

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4.5 Using Digital I/O on eMB-40/60R XIO Connector

Table 4-6. Digital I/O Signal Ranges

Item Description Type Signal Range

1 SmartController XDIO connector Inputs 1001 - 1012

Outputs 0001 - 0008

2 eMB-40/60R XIO connector Inputs 1097 - 1108

Outputs 0097 - 0104

3 IO Blox 1 Inputs 1113 - 1120

Outputs 0105 - 0112

4 IO Blox 2 Inputs 1121 - 1128

Outputs 0113 - 0120

5 IO Blox 3 Inputs 1129 - 1136

Outputs 0121 - 0128

6 IO Blox 4 Inputs 1137 - 1144

Outputs 0129 - 0136

4.5 Using Digital I/O on eMB-40/60R XIO Connector

The XIO connector on the eMB-40/60R interface panel offers access to digital I/O, 12 inputs and 8 outputs. These signals can be used by eV+ to perform various functions in the workcell. See the following table for the XIO signal designations.

12 Inputs, signals 1097 to 1108

8 Outputs, signals 0097 to 0104

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Table 4-7. XIO Signal Designations

Chapter 4: eMotionBlox-40/60R

No.

1 GND

2 24 VDC

3 Common 1 1

4 Input 1.1 1 1097

5 Input 2.1 1 1098

6 Input 3.1 1 1099

7 Input 4.1 1 1100

8 Input 5.1 1 1101

9 Input 6.1 1 1102

10 GND

11 24 VDC

12 Common 2 2

13 Input 1.2 2 1103

Designation

Signal

Bank

eV+

Signal

Number

Pin Locations

14 Input 2.2 2 1104

15 Input 3.2 2 1105

16 Input 4.2 2 1106

17 Input 5.2 2 1107

18 Input 6.2 2 1108

19 Output 1 0097

20 Output 2 0098

21 Output 3 0099

22 Output 4 0100

23 Output 5 0101

24 Output 6 0102

25 Output 7 0103

26 Output 8 0104

XIO 26-pin female

connector on

eMB-40/60R Interface

Panel

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4.5 Using Digital I/O on eMB-40/60R XIO Connector

Optional I/O Products

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

XIO Breakout Cable, 5 meters long, with flying leads on user’s end. See XIO Breakout Cable on page 52 for information. This cable is not compatible with the XIO Termination Block mentioned below.

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

XIO Input Signals

The 12 input channels are arranged in two banks of six. Each bank is electrically isolated from the other bank and is optically isolated from the eMB-40/60R ground. The six inputs within each bank share a common source/sink line.

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

The XIO inputs cannot be used for REACTI programming, high-speed interrupts, or vision triggers. Refer to the eV+ user guides on the corporate website.

XIO Input Specifications

Parameter Value

Operational voltage range 0 to 30 VDC

OFF state voltage range 0 to 3 VDC

ON state voltage range 10 to 30 VDC

Typical threshold voltage Vin= 8 VDC

Operational current range 0 to 7.5 mA

OFF state current range 0 to 0.5 mA

ON state current range 2.5 to 6 mA

Typical threshold current 2.0 mA

Impedance (Vin/I

Current at Vin= +24 VDC I

Turn on response time (hardware) Software scan rate/response time

Table 4-8. XIO Input Specifications

) 3.9 KΩminimum

≤ 6 mA

5 µsec maximum 16 ms scan cycle/ 32 ms max response time

Turn off response time (hardware) Software scan rate/response time

5 µsec maximum 16 ms scan cycle/ 32 ms max response time

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NOTE: The input current specifications are provided for reference. Voltage

XIO – DB-Sub 26 F

1097 1098 1099 1100 1101 1102

1103 1104 1105 1106 1107 1108

+24V

S1 S2

sources are typically used to drive the inputs.

Typical Input Wiring Example

Chapter 4: eMotionBlox-40/60R

Figure 4-5. Typical User Wiring for XIO Input Signals

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

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4.5 Using Digital I/O on eMB-40/60R XIO Connector

Key Meaning

A Supplied Equipment

B1 Input Bank 1

B2 Input Bank 2

C Signals

D1 Bank 1 Common

D2 Bank 2 Common

G Ground

H (equivalent circuit)

M User-Supplied Equipment

N Wiring Terminal Block

O Typical User Input Signals

P1 Bank 1 configured for Sinking (NPN) Inputs

P2 Bank 2 configured for Sourcing (PNP) Inputs

Note: All Input signals can be used for either sinking or sourcing configurations.

S1 Part Present Sensor

S2 Feeder Empty Sensor

S3 Part Jammed Sensor

S4 Sealant Ready Sensor

XIO Output Signals

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

The outputs are accessed through direct connection to the XIO connector (see Table 4-7. ), or through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.

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XIO Output Specifications

XIO D-Sub 26 F

0097 0098 0099 0100 0101 0102 0103 0104

19 20 21 22 23 24 25 26 1 10

+24 VDC

Parameter Value

Power supply voltage range See System Operation

Chapter 4: eMotionBlox-40/60R

Table 4-9. XIO Output Circuit Specifications

Operational current range, per channel

Total Current Limitation, all channelsonI

On-state resistance (I

Output leakage current I

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

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

Output voltage at inductive load turnoff (I

= 0.5 A, Load = 1 mH)

out

DC short circuit current limit 0.7 A ≤ I

Peak short circuit current I

Typical Output Wiring Example

out

= 0.5 A)

≤ 700 mA

out

≤ 1.0 A @ 50° C ambient

total

≤ 1.5 A @ 25° C ambient

total

≤ 0.32 Ω@ 85° C

≤ 25 µA

out

(hardware only)

(+V - 65) ≤V

ovpk

LIM

≤ 4 A

demag

≤ 2.5 A

≤ (+V - 45)

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 51

Figure 4-6. Typical User Wiring for XIO Output Signals

Page 52

4.5 Using Digital I/O on eMB-40/60R XIO Connector

Key Meaning Key Meaning

A Supplied Equipment H User-Supplied Equipment

B Outputs 1-8 J Wiring Terminal Block

C (equivalent circuit) K Typical User Loads

D Signal L Customer AC Power 10 Supply

G Ground M Motor (example of a load)

XIO Breakout Cable

The XIO Breakout cable is available as an option - see the following figure. This cable connects to the XIO connector on the eMB-40/60R, and provides flying leads on the user’s end, for connecting input and output signals in the workcell. The part number for the cable is 04465-000, and the length is 5 M (16.4 ft).

See the following table for the wire chart on the cable.

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

Figure 4-7. Optional XIO Breakout Cable

52 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 53

Table 4-10. XIO Breakout Cable Wire Chart

Signal

Pin No.

1 GND White

2 24 VDC White/Black

3 Common 1 Red

4 Input 1.1 Red/Black

5 Input 2.1 Yellow

6 Input 3.1 Yellow/Black

7 Input 4.1 Green

8 Input 5.1 Green/Black

9 Input 6.1 Blue

10 GND Blue/White

Designation Wire Color Pin Locations

Chapter 4: eMotionBlox-40/60R

11 24 VDC Brown

12 Common 2 Brown/White

13 Input 1.2 Orange

14 Input 2.2 Orange/Black

15 Input 3.2 Gray

16 Input 4.2 Gray/Black

17 Input 5.2 Violet

18 Input 6.2 Violet/White

19 Output 1 Pink

20 Output 2 Pink/Black

21 Output 3 Light Blue

22 Output 4 Light Blue/Black

23 Output 5 Light Green

24 Output 6 Light Green/Black

25 Output 7 White/Red

26 Output 8 White/Blue

26-pin male connector on XIO Breakout Cable

Shell Shield

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 53

Page 54

4.6 Mounting the eMB-40/60R

425.5

20.6

204.2

404.9

51.6

331.7

9.8

228.6

67.3

222.3

106.7

182.9

170.2

6x, SHCS,M4 X 6

47.6

377.8 0

7.6

45.7

129.54

32.7

197.8

7.6

45.7

32.7

197.8

7.6

45.7

47.6

7.6

45.7

32.7

197.8

47.6

377.8

20x M4, 7 mm

24V

GND

200 -

240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

4.6 Mounting the eMB-40/60R

Dimensions and Mounting Holes

Figure 4-8. eMB-40/60R Mounting Dimensions. Units are mm.

NOTE: 112 mm clearance required in front of unit to remove amps from box enclosure.

54 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 55

Mounting Clearances

100

200

NOTE: The mounting of the eMB-40/60R and all terminations at the eMB40/60R must be performed in accordance with all local and national standards.

Chapter 4: eMotionBlox-40/60R

Figure 4-9. Clearance for the eMB-40/60R. Units are mm.

Surface Air Gap

(A) Sides 50 mm (2 inches)

(B)Back 0 mm

The following two dimensions are from the front of the heat sink.

(D)Front, when flat-mounted 200 mm (8 inches)

NOTE: These dimensions assume the eMB-40/60R has exposure to outside air, rather than being in a sealed container. Any sealed container would need to provide sufficient cooling for the eMB-40/60R’s internal fan to be effective.

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 55

Page 56

Page 57

Chapter 5: System Installation

DC IN 24 V

GND

200 240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

24 VDC, 6 A

200-240 VAC

10 A, 1 Ø

PC, ACE

XMCP

XFP

XUSR

eAIB XSYSTEM

T20

85 - 264 VAC

eMB-40/60R

Viper 650

CN22

CN20

AIR1

AIR2

DC IN

24V

GND

200 -

240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

SmartVision MX

5.1 System Cables, without SmartController EX

The letters in the following figure correspond to the letters in the table of cables and parts. The numbers correspond to the steps in the cable installation overview table. The tables are on the pages following the figure.

Figure 5-1. System Cable Diagram for Viper 650/850 Robots with eMB-40/60R, Pendant, and Vision

The figure includes the optional T20 pendant and optional SmartVision MX industrial PC.

NOTE: See Installing the 24 VDC Cable on page 72 for additional system grounding information.

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 57

Page 58

5.1 System Cables, without SmartController EX

List of Cables and Parts

Locate the eAIB XSYSTEM cable in the Accessory box. Connect the cables and peripherals as shown in the preceding figure. Parts and steps are covered in the following two tables.

Part Cable and Parts List Part # Standard Option User-

Supplied

A eAIB XSYSTEM Cable Assembly 13323-

000

B User E-Stop, Safety Gate n/a X

C XUSR Jumper Plug 04736-

000

D Front Panel 90356-

10358

E Front Panel Cable 10356-

10500

F Front Panel Jumper Plug 10053-

000

G XMCP Jumper Plug 10052-

000

H T20 Pendant Bypass Plug 10048-

000

J T20 Pendant Adapter Cable 10051-

003

K T20 Pendant Assembly

Optional T20 Pendant Kit (10046-010) includes items H, J, and K.

10054010

Items L, M and N below are available, as an option, in the power supply/cable kit 90565-010.

L AC Power Cable 04118-

000

M 24 VDC Power Cable 04120-

000

N 24 VDC, 6 A Power Supply 04536-

000

P Ethernet Cable - PC ->Switch, if used n/a X

Q Ethernet Cable - switch -> eMB-40/60R n/a X

R Ethernet Cable - switch -> SmartVisionMX n/a X

X X

58 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 59

Chapter 5: System Installation

Part Cable and Parts List Part # Standard Option User-

Supplied

S Ethernet switch, if used n/a X X

T Camera and cable n/a X X

U Grounding Terminal, M5 n/a X

V Arm Power/Signal Cable 05438-

000

W eMB-40/60R Interface Panel n/a X

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

The XUSR is for a User E-Stop/Safety Gate or a Muted Safety Gate. The jumper plug is required if neither of these is used.

Either the Front Panel or the Front Panel plug must be used.

Either the T20 Pendant , T20 Bypass Plug, or XMCP Jumper Plug must be used.

WARNING: Under no circumstances should you run a Viper system, in production mode, with all three jumpers installed. This would leave the system with no E-Stops.

Cable Installation Overview

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

Step Connection Part

1 Connect eAIB XSYSTEM cable to XSYSTEM on eMB-40/60R. A

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

XUSR connector or

2a verify XUSR jumper plug is installed in eAIB XSYSTEM cable XUSR con-

nector.

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

nector or

3a if no Front Panel, install FP jumper on eAIB XSYSTEM cable XFP connector.

See NOTE after table.

4 Connect T20 Pendant adapter cable to eAIB XSYSTEM cable XMCP con-

nector or

4a if no T20 Pendant, install XMCP jumper

D, E

J, K

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 59

Page 60

5.1 System Cables, without SmartController EX

Step Connection Part

T20 Pendant Adapter Cable with T20 Pendant bypass plug. H

5 Connect user-supplied ground to robot. See System Installation on page

57.

6 Connect 200-240 VAC to AC Input on eMB-40/60R Interface Panel; secure

with clamp.

7 Connect 24 VDC to DC Input on Interface Panel. N, M

7a Connect 24 VDC and shield ground to SmartVision MX, if used. See SmartVi-

sion MX user's guide for location.

8 Connect Ethernet cable from PC to switch, if a switch is used. S

8a Connect Ethernet cable from SmartVision MX to switch, if used. R, S

9 Connect Ethernet cable from switch to eMB-40/60R. Q, S

10 Connect optional camera and cable to SmartVision MX, if used. T

n/a

N, M

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

60 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 61

5.2 System Cables, with SmartController EX

SmartController EX

MOUSE KEYBD

MOUSE

KEYBD

T20

SmartVision MX

Front Panel

eMB-40/60R

24 VDC, 6 A

200-240 VAC 10 A, 1 Ø

PC + ACE

85 - 264 VAC

DC IN 24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

DC IN 24 V

GND

200 240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Viper 650

CN22

CN20

AIR1

AIR2

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

Chapter 5: System Installation

Figure 5-2. System Cable Diagram with SmartController EX

Installing a SmartController EX Motion Controller

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

Mount the SmartController EX and Front Panel.

Connect the Front Panel to the SmartController EX.

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 61

Page 62

5.2 System Cables, with SmartController EX

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

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

Connect user-supplied 24 VDC power to the controller.

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

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

List of Cables and Parts

Part

Cable and Parts List

A eAIB XSYS Cable X

B User E-Stop, Safety Gate n/a X

C XUSR Jumper Plug 04736-

D Front Panel 90356-

E Front Panel Cable 10356-

F Front Panel Jumper Plug 10053-

G XMCP Jumper Plug 10052-

H T20 Pendant Bypass Plug 10048-

J T20 Pendant Adapter Cable 10051-

P/N Standard Option

000

10358

10500

000

003

Supplied

User-

K T20 Pendant Assembly

Optional T20 Pendant Kit (10046-

010) includes items H, J and K.

Items L, M and N below are available, as an option, in the power supply/cable kit 90565-

010.

L AC Power Cable 04118-

M 24 VDC Power Cable 04120-

N 24 VDC, 6 A Power Supply 04536-

P Ethernet Cable, PC -

SmartController EX,

10054010

000

n/a X

X X

62 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 63

Chapter 5: System Installation

Part

Cable and Parts List

SmartVision MX if used

R IEEE 1394 cable 13632-

S Camera and cable n/a X X

T Switch, if used n/a X

U M5 Grounding Terminal X

V Arm Power/Signal Cable X

W Robot Interface Panel X

P/N Standard Option

045

User-

Supplied

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

The XUSR is for a User E-Stop/Safety Gate or a Muted Safety Gate. The jumper plug is required if neither of these is used.

Either the Front Panel or the Front Panel plug must be used.

Either the T20 Pendant , T20 Bypass Plug, or XMCP Jumper Plug must be used.

WARNING: Under no circumstances should you run a Viper system, in production mode, with all three jumpers installed. This would leave the system with no E-Stops.

Cable Installation Overview

Step Connection Part

1 Connect eAIB XSYS cable to XSYSTEM on eMB-40/60R A

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

2a verify XUSR jumper plug is installed in XUSR connector. C

3 Connect Front Panel cable to Front Panel and XFP connector or D, E

3a if no Front Panel, install FP jumper on XFP connector. F

4 Connect Pendant adapter cable to XMCP connector or J, K

4a if no Pendant, install XMCP jumper or bypass plug. G or

5 Connect user-supplied ground to robot. See robot user's guide for location. n/a

5a Connect user-supplied ground to SmartController EX. See SmartController

EXuser's guide for location.

5b Connect user-supplied ground to SmartVision MX, if used. See SmartVision MX

user's guide for location.

n/a

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 63

Page 64

5.3 Optional Cables

Step Connection Part

6 Connect 200-240 VAC to AC Input on eMB-40/60R; secure with clamp. L

7 Connect 24 VDC to DC Input on eMB-40/60R and SmartController EX. N,M

7a Connect 24 VDC to SmartVision MX, if used. N,M

8 Connect Ethernet cable from PC to SmartController EX. P

9 Connect Ethernet cable to SmartVision MX, if used. Q

10 Connect IEEE1394 cable between SmartController EXand eMB-40/60R

SmartServo.

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

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 52 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 Configuration Guide.

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 EX Belt Encoder Y-Adapter Cable

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

Find the pin connection diagrams in the figures below.

64 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 65

Chapter 5: System Installation

24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

600 ± 25

3000 ± 50

500 ± 25

XBELT IO

13463-000

BELT

ENCODER

FORCE/

EXPIO

RS232

BELT ENC.

09443-000

BELT ENC.

09443-000

BELT ENC.

09443-000

BELT ENC.

09550-000

BELT ENC.

#1 AND #2

BELT ENC.

#3 AND #4

SmartController EX

Figure 5-3. System Cable Diagram with Belt Encoders (Units in mm)

User-

supplied

X X HDB26

Notes

Female

DB9 Male

X X DB15

Female

8-pin

Table 5-1. 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

13463000

D Force / EXPIOBranch Con-

nector

E RS232 Branch Connector DB9 Male

F Belt Y Splitter Cable Con-

nector

09443000

G Belt Encoder 1 Connector M12 Female,

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 65

Page 66

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

Item Description Part # Standard Option

User-

supplied

Notes

H Belt Encoder 2 Connector M12 Female,

8-pin

I SmartController EX

(optional)

J SmartController EX Belt

Encoder Y Adapter Cable Con-

19300000

09550000

X X HDB26

Female

nector

K Belt Branch Connector,

DB15 Male

Encoder 1 and 2

L Belt Branch Connector,

DB15 Male

Encoder 3 and 4

Figure 5-4. eAIBXBELTIOAdapterCable Pinout - Encoder 1 and 2 Connections

NOTE: Cable shields connected to DSUBshell.

66 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

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

Page 67

Chapter 5: System Installation

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

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

NOTE: Cable shields connected to DSUBshell.

Figure 5-6. eAIBXBELTIOAdapterCable Pinout - RS232 Connections

NOTE: Cable shields connected to DSUBshell.

Figure 5-7. Belt YSplitter Cable Pinout - 2 Encoder Connections

NOTE: Cable shields connected to DSUBshell.

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 67

Page 68

5.4 ACE Software

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

5.4 ACE Software

Load the ACE software onto the PC and connect it to the eMB-40/60R via an Ethernet cable. Your system may have an Ethernet switch between the two.

The ACE software is installed from the ACE software media.

Insert the media into your PC.

If Autoplay is enabled, the ACEsoftware menu is displayed. If Autoplay is disabled, you will need to manually start the disk.

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

From the ACE software media menu, select:

68 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Figure 5-8. SmartController EX Belt Encoder Y Adapter Cable Connections

NOTE: Cable shields connected to DSUBshell.

Page 69

Chapter 5: System Installation

Install the ACE Software

The ACE Setup wizard opens.

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

When the installation is complete, click Finish.

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

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

5.5 Connecting Cables from the eMB-40/60R to the Robot

The cable between the robot and the eMB-40/60R is called the Arm Power/Signal cable.

Connect one end of the Arm Power/Signal cable to the CN22 connector on the back plate of the robot. Tighten the thumb-screw securely.

For both ends of the cable, line up the slot with the matching key in the connector, apply firm pressure straight in, and thread the lock ring fully onto the connector. There should be no visible threads when connected.

Connect the other end of the cable to the large, circular connector on the eMB-40/60R. See Figure 5-1.

WARNING: Verify that all connectors are fully-inserted and screwed down. Failure to do this could cause unexpected robot motion. Also, a connector could get pulled out or dislodged unexpectedly.

Figure 5-9. Incorrect and Correct Arm Power/Signal Cable Insertion

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 69

Page 70

5.6 Connecting 24 VDC Power to eMB-40/60R Servo Controller

Key Meaning Key Meaning

A Incorrect Assembly:No threads should be visible! D Viper Interface Panel

B Correct Assembly:No threads are visible E Lock Ring

C Viper Bodies F Arm Power/Signal Cable

5.6 Connecting 24 VDC Power to eMB-40/60R Servo Controller

Specifications for 24 VDC Power

Table 5-2. Specifications for 24 VDC User-Supplied Power Supply

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

(21.6 V< Vin< 26.4 V)

Circuit Protection

Output must be less than 300 W peak

8 Amp in-line fuse

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

Shield Termination Cable shield connected to frame ground on

power supply and ground point on eMB-40/60R. See User-Supplied 24 VDC Cable on page 72.

User-supplied 24 VDC power supply must incorporate overload protection to limit peak power to less than 300 W, or 8 A in-line fuse protection must be added to the 24V power source.

NOTE: Fuse information is located on the eMB-40/60R electronics.

The power requirements for the user-supplied power supply will vary depending on the configuration of the robot and connected devices. We recommend a 24 V, 6 A power supply to allow for startup current draw and load from connected user devices, such as digital I/O loads.

CAUTION: 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.

70 Viper 650/850 Robot with eMB-40/60R User's Guide 05173-060 M

Page 71

Chapter 5: System Installation

A B

Table 5-3. Recommended 24 VDC Power Supplies

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

OMRON S8VK-S24024C 24 VDC, 10 A, 240 W Front Mount

OMRON S8VK-S24024CD 24 VDC, 10 A, 240 W DIN-Rail Mount

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 5-4. 24 VDC Mating Connector Specs

Connector Details

A: Ground (pin 1, labeled on under side)

B:+24 VDC

Pin Details Molex connector crimp terminal,

Recommended crimping tool, Molex Hand Crimper

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

Molex P/N 44441-2002

Digi-Key P/N WM18463-ND

female, 14-18 AWG

Molex P/N 43375-0001

Digi-Key P/N WM18493-ND

Molex P/N 63811-0400

Digi-Key P/N WM9907-ND

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 58.

Procedure for Creating 24 VDC Cable

Locate the connector and pins from the preceding table.

Use shielded two-conductor cable with 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 eMB-40/60R base.

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 71

Page 72

5.6 Connecting 24 VDC Power to eMB-40/60R Servo Controller

24 V, 6 A

–

eMB-40/60R

SmartController EX

24 V, 5 A

–

NOTE: You also must create a separate 24 VDC cable for the SmartController EX. That cable uses a different style of connector. See the SmartCon- troller EXUser’s Guide.

Crimp the pins onto the wires using the recommended crimping tool.

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

Install a user-supplied ring lug (for an M3 screw) on the shield at the eMB-40/60R end of the cable.

Prepare the opposite end of the cable for connection to the user-supplied 24VDC power supply, including a terminal to attach the cable shield to frame ground.

Installing the 24 VDC Cable

Do not turn on the 24 VDC power until instructed to do so in the next chapter.

Connect one end of the shielded 24 VDC cable to your user-supplied 24 VDC power supply. See User-Supplied 24 VDC Cable on page 72. The cable shield should be connected to frame ground on the power supply.

Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the back of the eMB-40/60R. The cable shield should be connected to the ground point on the interface panel.

Figure 5-10. User-Supplied 24 VDC Cable

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Chapter 5: System Installation

Key Meaning Key Meaning

A eMB-40/60R F SmartController EX Option

B User-Supplied Shielded Power Cable G Ground

C User-Supplied Power Supply 24 VDC H Attach shield from user-supplied cable to

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

D Attach shield from user supplied cables

to frame ground on power supply.

E Attach shield from user-supplied cable

to ground screw on eMB-40/60R Interface Panel.

NOTE: We recommend that DC power be delivered over shielded cables, with the shield connected to frame ground at the power supply, and to the ground points shown in the diagram above for the eMB-40/60R and SmartController. The length of the wire from the cable shield to the ground points should be less than 50 mm.

I Attach shield from user-supplied cables

to frame ground on power supply.

5.7 Connecting 200-240 VAC Power to eMB-40/60R

WARNING: ELECTROCUTIONRISK Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system.

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.

Specifications for AC Power

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

Auto-Ranging

Nominal

Voltage

Ranges

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

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

formance.

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

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 73

Minimum

Operating

Voltage

Maximum

Operating

Voltage

Frequency/

Phasing

1-phase

Recommended External Circuit

Breaker, User-

Supplied

10 Amps

Page 74

5.7 Connecting 200-240 VAC Power to eMB-40/60R

Table 5-6. Typical Robot Power Consumption

Robot Move Average Power Peak Power

Viper 650 No load - Adept cycle

5.0 kg - Adept cycle

5.0 kg - all joints move 834 W 2088 W

Viper 850 No load - Adept cycle

5.0 kg - Adept cycle

5.0 kg - all joints move 704 2090

Typical power data is with 220 VAC, 60 Hz, 1-phase nominal input.

For short durations (100 ms).

Adept cycle: The robot tool performs continuous path, straight-line motions 25 mm (1 inch) up, 305 mm (12 inches) over, 25 mm (1 inch) down, and back along the same path, at 20° C ambient. COARSE is enabled and BREAKs are used at each end location. Not achievable over all paths.

371 W 947 W

477 W 1526 W

358 W 1237 W

407 W 1202 W

DANGER: ELECTROCUTIONRISK AC power installation must be performed by a skilled and instructed person refer to the Robot Safety Guide. During installation, unauthorized third parties must be prevented from turning on power through the use of fail-safe lockout measures, as mandated by ISO 10218-1, Clause 5.2.4.

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 user must protect the robot from excessive overvoltages and voltage spikes. If the country of installation requires a CE-certified installation, or compliance with IEC1131-2, the following information may be helpful: IEC 1131-2 requires that the installation must ensure that CategoryII overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed 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 over-voltage peaks may appear on mains power supply lines as a result of power interruptions to high-energy equipment (such as a blown fuse on one branch in a 3-phase system). This will cause high-current pulses at relatively low voltage levels. The user shall take the necessary steps to prevent damage to the robot system (such as by interposing a transformer). See IEC 1131-4 for additional information.

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AC Power Diagrams

10 A

eMB-40/60R

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

eMB-40/60R

1Ø 200-240 VAC

Figure 5-11. Typical AC Power Installation with Single-Phase Supply

Key Meaning Key Meaning

B User-Supplied ACPower Cable L Line

Chapter 5: System Installation

E Earth Ground N Neutral

F1 Fuse, 10A

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

Figure 5-12. Single-Phase Load across L1 and L2 of a Three-Phase Supply

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5.7 Connecting 200-240 VAC Power to eMB-40/60R

Key Meaning Key Meaning

A User-Supplied ACPower Cable L1 Line 1

E Earth Ground L2 Line 2

F4 Fuse, 10A L3 Line 3

F5 Fuse, 10A N Neutral

L Line 1

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

Details for AC Mating Connector

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

Table 5-7. 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, but is available in the optional Power Cable kit.

Procedure for Creating 200-240 VAC Cable

Locate the AC mating connector shown in the preceding table.

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 77.

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 eMB-40/60R base.

Strip approximately 18 to 24 mm of 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.

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Chapter 5: System Installation

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

10.

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

Figure 5-13. AC Power Mating Connector

Key Meaning Key Meaning

A Removable Bushing E Earth

B Cable Clamp N Neutral

L Line

Installing AC Power Cable to eMB-40/60R

Connect the unterminated end of the AC power cable to your facility AC power source. See Figure 5-11. and Figure 5-12.

Do not turn on AC power at this time.

Plug the AC connector into the AC power connector on the interface panel on the eMB-40/60R.

Secure the AC connector with the locking latch.

5.8 Grounding the Robot System

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

WARNING: ELECTROCUTIONRISK Wiring must be performed by authorized or certified personnel. Failure to observe this precaution may result in fire or electric shock.

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5.8 Grounding the Robot System

CN22

CN20

AIR1

AIR2

CN20

NOTE: Ground the grounding terminal of the robot with a wire of 12 AWG or larger. Ground resistance must be ≤ 10 Ω.

NOTE: Use a dedicated grounding wire and grounding electrode. Do not share them with any other electric power or power equipment, such as a welder.

Ground Point on Robot Base

The user can install a protective earth ground wire at the robot base to ground the robot. See the following figure. The ground wire is user-supplied.

Figure 5-14. Ground Point on Robot Base

Key Meaning Key Meaning

A CN22 Power/Signal Cable to eMB-40/60R C Grounding Terminal, M5

B Ground Label D Air 1 and Air 2

Ground Point on eMotionBlox-40/60R

The user can install a ground wire at the eMB-40/60R chassis. Use the hole below the eMB40/60R interface panel. See the following figure. The user should provide a ground wire and use the provided M4 screw and external tooth lock washer to connect to earth ground. Make sure to tighten the screw on the ground wire to create a proper ground connection. Optionally, two tapped holes are provided to attach user-supplied strain relief.

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24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Figure 5-15. User Ground Location

Key Meaning Key Meaning

Chapter 5: System Installation

A eMB-40/60R

C Ground Screw

Interface Panel

B Ground Label

Robot-Mounted Equipment Grounding

The robot tool flange is not reliably grounded to the robot base. If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection from that equipment/tooling to the ground point on the robot base. Hazardous voltages can be considered anything in excess of 30 VAC (42.4 VAC peak) or 60VDC.

DANGER: Failing to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the endeffector when an electrical fault condition exists.

5.9 Installing User-Supplied Safety Equipment

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

The user-supplied safety and power-control equipment connects to the system through the XUSR and XFP connectors on the eMB-40/60R 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, and Table 5-9. for the XFP pin-out descriptions. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 83 for the XUSR wiring diagram.

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5.9 Installing User-Supplied Safety Equipment

Table 5-8. Contacts Provided by the XUSR Connector

Pin Pairs

Voltage-Free Contacts Provided by Customer

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

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

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

4, 17 Line E-Stop (same as pins 3, 16)

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

6, 19

Description Comments

button, safety gates, etc.)

1, 14)

assembly line E-Stop interconnection. Does not affect E-Stop indication (pins 7, 20))

Stop in Automatic mode only)

Muted Safety Gate CH 2 (same as pins 5, 18)

Voltage-Free Contacts provided by Viper

7, 20

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

N/C contacts, Shorted if NOT Used

pendant, and customer E-Stops are not tripped

8, 21

9, 22

10, 23

11, 12, 13, 24, 25

E-Stop indication CH 2 (same as pins 7, 20)

Contacts are closed when Front Panel, pendant, and customer E-Stops are not tripped

Manual/Automatic indication CH1Contacts are closed in Automatic mode

Manual/Automatic indication CH2Contacts are closed in Automatic mode

No connection

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Chapter 5: System Installation

915

XFP

Table 5-9. Contacts Provided by the XFP Connector

Pin Pairs

Description Requirements for User-

Supplied Front Panel

Voltage-Free Contacts Provided by Customer

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

tacts

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

tacts

3, 11 Remote Manual/Automatic switch CH 1.

Manual = Open Automatic = Closed

4, 12 Remote Manual/Automatic switch CH 2.

Manual = Open Automatic = Closed

Optional - jumper closed for Auto Mode-only operation

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

ary push-button to enable High Power to system

Non-voltage-Free Contacts

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

On/Off Switch Lamp

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

7, 15aController system 5 V power on LED, 5 V, 20mA Optional - indicator only

8 No connection

See the figure Front Panel Schematic on page 85 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.

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5.9 Installing User-Supplied Safety Equipment

Table 5-10. Remote Pendant Connections on the XMCP Connector

Pin XMCP (15-Pin D-Sub)

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

Description

The following figure shows an E-Stop diagram for the system. See Emergency Stop Circuits on page 85 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

05173-060 M Viper 650/850 Robot with eMB-40/60R User's Guide 83

Figure 5-16. E-Stop Circuit on XUSR and XFP Connectors

Page 84

5.9 Installing User-Supplied Safety Equipment

Key Meaning Key Meaning

A ESTOP 24 V Source K Auto/Manual Output

B Bulb, 6 V, 1.2 W L T20 Pendant Enable

C Front Panel High

Power ON/OFF

D Front Panel ESTOP

Pushbutton

E T20 ESTOP Push-

button

F Front Panel

Auto/Manual Keyswitch

G ESTOPGround Q User ESTOPOutput

H User E-Stop and Gate Interlock

NOTE: Jumper closed when not used, MUSTopen both channels independently if used.

I Coil R Single-Phase ACInput, 200-240

J LINEE-Stop

(External User EStop System)

M Muted Safety Gate - Active in Auto

mode only (Jumper closed when not used)

N Manual Mode Path

O Auto Mode Path

P Force-Guided Relay Cycle Check Con-

trol Circuit

VAC

S High Power to Amplifiers (Internal

Connections)

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Chapter 5: System Installation

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

Figure 5-17. Front Panel Schematic

Key Meaning Key Meaning

A Front Panel Schematic D HIGHPOWERON/OFF

B System Power LED E EMERGENCYSTOP

C MANUAL/AUTO

Emergency Stop Circuits

The eMB-40/60R 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 5-16.

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.

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5.9 Installing User-Supplied Safety Equipment

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

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

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

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

These voltage-free contacts are provided by a redundant, cyclically-checked, positive-drive, safety relay circuit for Category 3 PL-d per ISO 13849 operation (see Figure 5-16. and the table Contacts Provided by the XFP Connector on page 81 for the customer E-Stop circuitry).

Line E-Stop Input

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

The Line E-Stop input comes into the circuit at a point where it cannot affect the customer EStop indication relays and will not cause such a lock-up situation. For any situation where two systems should be cross-coupled, for example, the customer E-Stop indication of one controller is to be connected to the input of another controller, the Line E-Stop input is the point to bring in the other controller’s output contacts. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 83 for more information.

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

Muted Safety Gate E-Stop Circuitry

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

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

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

CAUTION: 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 88 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 85. In this situation, a pair of contacts should be wired in series with the Front Panel Manual/Automatic mode contacts. Thus, both the Front Panel and the customer contacts need to be closed to allow Automatic mode.

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

User Manual/Auto Indication

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

WARNING: PERSONALINJURYRISK Any safeguards that were suspended must be returned to full functionality prior to selecting Automatic Mode.

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5.9 Installing User-Supplied Safety Equipment

User High Power On Indication

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

Remote High Power On/Off Control

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

However, if the user needs to control high power on/off from other control equipment or from a location other than the Front Panel, then a custom splitter cable will be required. See the Front Panel schematic (Front Panel Schematic on page 85) for details of the Front Panel’s wiring. In this situation, a second momentary contact for high power on/off would be placed in parallel with the Front Panel push-button contact. This second contact should be suppressed when in Manual mode (see the note on “Single Point of Control” below).

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

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

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

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

High Power On/Off Lamp

The Front Panel High Power On/Off Lamp (p/n: 27400-29006) will cause an error, from eV+, if the lamp burns out. This error prevents High Power from being turned on. This safety feature prevents a user from not realizing that High Power is enabled because the High Power indicator is burned out. See Changing the Lamp in the Front Panel High-Power Indicator on page 112 for information on changing this lamp.

Remote Front Panel or User-Supplied Control Panel Usage

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

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Chapter 5: System Installation

Schematic on page 85 for a schematic drawing of the Front Panel, and see the table System Installation on page 57 for a summary of connections and pin numbers.

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

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

Wire Size: must be larger than 26 AWG.

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

Maximum cable length is 10 meters.

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

Remote Pendant Usage

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

Wire Size: must be larger than 26 AWG.

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

Maximum cable length is 10 meters.

CAUTION: PERSONALINJURYORPROPERTYDAMAGERISK Do not modify the cable that is attached to the pendant. This could cause unpredictable behavior from the robot system.

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6.1 Status Panel Codes

The status panel display on the eMB-40/60R displays alpha-numeric codes that indicate the operating status of the robot, including detailed fault codes. The chapter on eMotionBlox40/60R gives definitions of the fault codes. These codes provide details for quickly isolating problems during troubleshooting. See Status Panel on page 42.

6.2 Brakes

UL robots have an integrated brake-release switch located on the robot. On non-UL robots, you can install a manual brake-release box. In both cases, you can release the brakes on a specific joint.

WARNING: Pressing the Brake Release button may cause robot arms and the tool flange to fall.

Secure the robot prior to releasing the brakes on joints 2 or 3, to prevent injury to personnel or equipment damage.

Chapter 6: System Operation

Installing and Using the Brake Release Box

This procedure describes how to install and use a manual brake release box on non-UL robots. See the following figure.

Make sure that high power is disabled (off).

Connect the 9-pin male D-sub connector into the 9-pin female D-sub connector marked Brake on the eMB-40/60R.

Press one of the E-Stops (Pendant, Front Panel, or external).

NOTE: An E-Stop must be activated in order for the brake release box to work.

Using the joint selector switch, select the joint for which you want to release the brake.

Depress the Brake Release push button to release the brake.

Repeat steps 4 and 5 above for releasing the brake on another joint.

NOTE: When the Status LED (Green) is on, it indicates that the circuit is enabled, when the Brake Release push button is pressed.

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6.2 Brakes

OFF

BRAKE

RELEASE

Figure 6-1. Manual Brake-Release Box

Key Meaning

A Joint selector switch

B Status LED

C Brake Release Push Button

D 9-pin male D-Sub connector

Using the Brake Release Switch on UL Robots

This procedure describes how to use the brake release switch on the base of UL robots. See the following figure.

Make sure that high power is disabled (off).

Press one of the E-Stops (Pendant, Front Panel, or external).

NOTE: An E-Stop must be activated in order for the brake release to work.

Using the joint selector switch, select the joint for which you want to release the brake.

Depress the Brake Release push button to release the brake.

Repeat steps 3 and 4 above to release the brake on another joint.

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6.3 Front Panel

C1 C2

Chapter 6: System Operation

NOTE: When the Status LED (Green) is on, it indicates that the circuit is enabled, when the Brake Release push button is pressed.

Figure 6-2. Brake Release Switch on UL Robots

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

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

Figure 6-3. Front Panel

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6.3 Front Panel

XFP connector

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

System 5 V Power-On LED

Indicates whether or not power is connected to the robot.

Manual/Automatic Mode Switch

Switches between Manual and Automatic mode. In Automatic mode, executing programs control the robot, and the robot can run at full speed. In Manual mode, the system limits robot speed and torque so that an operator can safely work in the cell. Manual mode initiates hardware and software restrictions on robot speed, commanding no more than 250 mm/sec.

C1. Manual Mode

C2. Auto Mode

There is no high speed mode in manual mode.

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

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

High Power On/Off Switch and Lamp

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

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

WARNING: PERSONALINJURYRISK Disabling the High Power button violates IEC 60204-1. It is strongly recommended that you not alter the use of the High Power button.

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

Emergency Stop Switch

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

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NOTE: The Front Panel must be installed to be able to Enable Power to the

robot. To operate without a Front Panel, the user must supply the equivalent circuits.

6.4 Starting the System for the First Time

The first time you power-up the system, you must follow the steps in this section to safely bring up your robot system. The tasks include:

Verifying installation, to confirm all tasks have been performed correctly.

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

Verifying all E-Stops in the system function correctly.

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

Verifying Installation

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

Chapter 6: System Operation

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

Mechanical Checks

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

Verify that any end-of-arm tooling is properly installed.

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

System Cable Checks

Verify the following connections:

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

Front Panel to the XSYSTEM on the eMB-40/60R.

Pendant to the XSYSTEM on the eMB-40/60R.

XUSR to the XSYSTEM on the eMB-40/60R.

User-supplied 24 VDC power to the eMB-40/60R 24 VDC connector.

User-supplied 200/240 VAC power to the eMB-40/60R 200/240 VAC connector.

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6.4 Starting the System for the First Time

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

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

Front Panel to the SmartController EX.

Optional pendant to the SmartController EX.

User-supplied 24 VDC power to the controller.

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

One end of the IEEE 1394 cable into a SmartServo portconnector on the SmartController EX, and the other end into a SmartServo connector on the eMB-40/60R.

User-Supplied Safety Equipment Checks

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

System Start-up Procedure

Once the system installation has been verified (see Verifying Installation on page 95), you are ready to start up the system.

Switch on AC power to the eMB-40/60R.

Switch on the 24 VDC power to the controller (if used)and the eMB-40/60R.

Follow the instructions, beginning with Starting the ACE Software, in the following section.

Running the ACE Software

Starting the ACE Software

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

Turn on the PC and start the ACE software.

Double-click the ACE icon on your Windows desktop

or, from the Windows Start menu bar,

Select Start > Programs > Omron > ACE x.y

x.y where x is the ACE major version, and y is the ACE minor version.

For example, for ACE 3.6, it would be: Start > Programs > Omron > ACE 3.6

2. On the ACE Startup menu, click New SmartController Workspace.

3. Click-select the SmartController you want to use, and click OK.

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Chapter 6: System Operation

Enabling High Power

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

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

If the High Power button on the Front Panel is blinking, press and release it.

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

The Front Panel, which is mounted just outside the workcell safety barrier, is shown in the following figure. If enabled, the High Power button must be pressed while blinking (default time-out is 10 seconds). If the button stops blinking, you must enable power again.

Figure 6-4. High Power Button on Front Panel

Key Meaning

A Press High Power Enable Button when Blinking

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

The amplifier status LED blinks green rapidly (a slow green blink has a different meaning).

In addition, for IP65 Viper robots, the lamps on the robot glow solid amber.

l The status panel on the robot or amplifier chassis displays ON.

Verifying E-Stop Functions

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

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6.5 Learning to Program the Robot

Verify Robot Motions

Use the pendant (or jog control)to test the motion of each joint on the robot to confirm it moves in the proper directions.

Refer to the T20 Pendant User's Guide for instructions on using the pendant.

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

NOTE: When using a pendant with a Viper robot, the Free mode is disabled for safety reasons.

6.5 Learning to Program the Robot

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

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

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6.6 Installing Joint Labels

J5 J3

The system includes a set of joint directional labels that can be installed on the robot. See the following table. Also refer to Robot Joint Identification on page 9 for a drawing of the joint identification. The yellow X-Y label can be used to indicate the X and Y axes in the World coordinate system in your workcell.

Chapter 6: System Operation

Table 6-1. Joint and Axes Directional Labels

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6.7 Caution Label on Robot

6.7 Caution Label on Robot

The Caution label shown in the following figure refers to rotation of Joint 4. When power is turned off, do not manually rotate Joint 4 more than the Joint Limits of ±190°. If Joint 4 is rotated beyond these limits, the internal wiring can be damaged.

Figure 6-5. Caution Label on Joint 4 Rotation

NOTE: There is no CALSET operation on the Viper robot, and there is no Installation and Maintenance Guide.

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Omron Viper 650, Viper 680 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Product Description

Chapter 1: Introduction

SmartController EX (Option)

eMotionBlox-40/60R

1.2 How Can I Get Help?

Related Manuals

2.1 Dangers, Warnings, and Cautions

Alert Levels

Chapter 2: Safety

Alert Icons

Falling Hazards

Special Information

2.2 What to Do in an Emergency or Abnormal Situation

Releasing the Brakes

Releasing an E-Stop

2.3 Safety Precautions

User's Responsibilities

General Hazards

Qualification of Personnel

2.4 Robot Behavior

Hardstops

Limiting Devices

Singularities

2.5 Intended and Non-intended Use

Intended Use

Non-Intended Use

Robot Modifications

2.6 Additional Safety Information

Manufacturer’s Declaration of Incorporation

Robot Safety Guide

Manual Control Pendant (option)

2.7 Disposal

Chapter 3: Robot Installation

3.1 Unpacking and Inspecting the Equipment

3.2 Repacking for Relocation

3.3 Environmental and Facility Requirements

3.4 Transporting the Robot

Precautions when Transporting Robot

Transport Procedure

3.5 Mounting the Robot

3.6 Grounding the Robot

3.7 Mounting the Front Panel

3.8 Description of Connectors on Robot Interface Panel

3.9 Air Lines and Signal Wiring

Optional Solenoid Cable

Solenoid Valve Specifications

External Mounting Locations on Robot

3.10 Designing End-Effectors

Continuous Turn on J6

Mass of End-Effector

Center of Gravity Position of End-Effector

Moment of Inertia Around J4, J5, and J6

4.1 Introduction

Chapter 4: eMotionBlox-40/60R

4.2 Connectors on eMB-40/60R Interface Panel

4.3 eMB-40/60R Operation

Status LED

Status Panel

Brake Release Button

Brake Release Connector

4.4 Connecting Digital I/O to the System

4.5 Using Digital I/O on eMB-40/60R XIO Connector

Optional I/O Products

XIO Input Signals

XIO Output Signals

XIO Breakout Cable

4.6 Mounting the eMB-40/60R

Dimensions and Mounting Holes

Mounting Clearances

Chapter 5: System Installation

5.1 System Cables, without SmartController EX

List of Cables and Parts

Cable Installation Overview

5.2 System Cables, with SmartController EX

Installing a SmartController EX Motion Controller

List of Cables and Parts