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Adept Hornet 565 User`s Guide

1. O 67 T O with an Optional SmartController EX 20 22222222 ee cece cece eee ee eeee neces ee n nns 67 4 6 Using Digital I O on eAIB XIO Connector 2 0 00 0 20 o ence cece cence cence eee ees 69 Optional VO Products 14 2 sohosso ceo ddsunte eod pastore AR Ende cro dnad o ede ddsabds es epods oues da 70 XIO Input Signals 55 2 odisk D cisco a E a ka aea a a araa ae 70 XIO Output Signals asero ecc eegener e Ea e EE a E e Oro QUIS EEES aE 72 XIO Breakout Cable P eie aea i ees eiea rda aS aee EERE esa 74 4 7 Starting the System for the First Time uisi eoi ead e are oc carb edipi 76 Veritying Installation 222221362 oe ean ole a ees 76 Turning on Power and Starting Adept ACE 2222222 cc eeecee eee eee eee eee eee e ee n II II 77 Enabling Hich Powet ossessi eee LL nck ice hae caches enenctecetad dense deme Lt Ieee tan 78 Verifying E Stop Functions 2240 25 1212l9nlllip MR ih dle Leelee de cd 78 Aligning the Platform and J4 Motor 2 0 22222222 ceee eee aora iaa E 78 Verify Robot Motions 2 2 22 2 2 s 22seeeesee22 sheen ewe es eects idres isee hais oesi irie iepr 79 JG Mb a ena eee oR Re eee ee ee eae aep eNOS OP EEE 79 Straight line Motions 222226 o 51 4162 ctiieid te ET 79 Containment Obstacles esseeys segevdeecie see ier sceni leve ai a PEAD r ceuee ede red Tcl bd gcr rQie 79 49 Learning
2. Figure 1 6 Adept SmartController EX Refer to the Adept SmartController EX User s Guide for SmartController specifications 1 2 Warnings Cautions and Notes in Manual There are five levels of special alert notation used in Adept manuals In descending order of importance they are DANGER This indicates an imminently hazardous electrical situation which if not avoided will result in death or serious injury Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 15 of 142 Chapter 1 Introduction DANGER This indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING This indicates a potentially hazardous electrical situation which if not avoided could result in injury or major damage to the equipment WARNING This indicates a potentially hazardous situation which if not avoided could result in injury or major damage to the equipment CAUTION This indicates a situation which if not avoided could result in damage to the equipment gt gt gt gt NOTE Notes provide supplementary information emphasize a point or procedure or give a tip for easier operation 1 3 Safety Precautions DANGER An Adept Hornet robot can cause serious injury or death or damage to itself and other equipment if the following safety precautions are not observed gt e All personnel who install operate teach program or maintain the syst
3. Figure 3 10 E Stop Circuit on XUSR and XFP Connectors Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 57 of 142 Chapter 3 System Installation Adept Front Panel Schematic ESTOPSRC XFP 15PDSUBM ko 9 ESTOPFP1 10 ESTOPFP2 11 MANUALRLY1 12 MANUALRLY2 13 HIPWRLT 14 HIPWRREQ 15 Cx 9 MANUALSRC1 MANUALSRC2 u HPLT5V SYSPWRLT System Power LED MANUAL AUTO HIGH POWER ON OFF EMERGENCY STOP ESTOPSRC MANUALSRC2 SYSPWRLT MANUALSRC1 eo ja cT 2 PIN MINI v HIPWRLT LHIPWRET g MANUALRLY2 HIPWRREQ LLL HIPWRREQ a MANUALRLY1 L_ESTOPFP2 m A ESTOPFP Figure 3 11 Front Panel Schematic Emergency Stop Circuits The eAIB XSYSTEM cable provides connections for Emergency Stop E Stop circuits on the XUSR and XFP connectors This gives the controller system the ability to duplicate E Stop functionality from a remote location using voltage free contacts See Figure 3 10 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 pins must be shorted if not used Both channels must open independently if used Although an Emergency Stop will occur the controller will flag an error state if one channel is jumpered close
4. Figure 3 8 AC Power Mating Connector Installing AC Power Cable to Robot 1 Connect the AC power cable to your facility AC power source Do not turn on AC power at this time See Typical AC Power Installation with Single Phase Supply on page 50 and Single Phase Load across L1 and L2 of a Three Phase Supply on page 50 2 Plug the AC connector into the AC power connector on the interface panel on the robot 3 Secure the AC connector with the locking latch 3 8 Grounding the Adept Robot System Proper grounding is essential for safe and reliable robot operation Grounding Robot Mounted Equipment DANGER Failing to ground robot mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end effector when an electrical fault condition exists If hazardous voltages are present at any user supplied robot mounted equipment or tooling you must install a ground connection for that equipment or tooling Hazardous voltages can be considered anything in excess of 30 VAC 42 4 VAC peak or 60 VDC If there will be hazardous voltages present at the tool flange or end effector you must e Connect the mounting frame to protective earth ground e Ground the robot base to the mounting frame The eAIB is grounded to the robot base through a conductive gasket e Ground the end effector to the robot base Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 52 of 142 Chapter 3
5. Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 97 of 142 Chapter 6 Maintenance NOTE These lists are not necessarily complete Checking Safety Systems These tests should be done every six months NOTE Operating any of the following switches or buttons must disable high power If any of the tests fail repairs must be made before the robot is put back into operation 1 Test operation of e E Stop button on front panel e E Stop button on pendant e Auto Manual switch on front panel e Enabling switch on pendant Manual mode only 2 Test operation of any user supplied E Stop buttons 3 Test operation of barrier interlocks etc Checking Robot Mounting Bolts Check the tightness of the base mounting bolts after the first week and then every 3 months Refer to the following table for torque specifications Table 6 4 Mounting Bolt Torque Specifications Metric M12 1 75 61 N m 45 ft lb Checking Robot Gear Drives NOTE Gear drive inspection and fan operation inspection require removal of the same robot parts and have the same schedules You will probably want to perform these two inspections at the same time NOTE The inner arm motor plugs are not used for this inspection because they cannot be removed without destroying them Adept Hornet 565 robots use gear drives which use oil in their components for lubrication Periodically inspect the robot for signs of oil on and around the gear drive
6. Chapter 4 System Operation Table 4 10 XIO Breakout Cable Wire Chart Signal Designation Pin Locations ho je meo b mesi eme eeu C 7 NN b me me ra Ba jme Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 75 of 142 Chapter 4 System Operation 4 7 Starting the System for the First Time Follow the steps in this section to safely bring up your robot system The tasks include Verifying installation to confirm that all tasks have been performed correctly Starting up the system by turning on power for the first time Verifying that all E Stops in the system function correctly Moving the robot with the pendant if purchased to confirm that each joint moves correctly 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 perform the following checks to ensure that the robot and controller have been properly installed DANGER 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 platform tooling is properly installed Verify that the platform has been aligned with the J4 motor J4 version only Verify that all peripheral equipment is properly
7. 24 VDC 6 A Power Supply 04536 000 90565 010 or user supplied option Ethernet Cable PC gt PLC n a user supplied Only while programming PLC n a Ia Ethernet Cable switch gt eAIB user supplied n a R Ethernet Cable switch gt n a Po a P user supplied SmartVision MX S Ethernet switch cable for n a n a option SmartVision MX user supplied The XUSR XMCP and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup WARNING Under no circumstances should you run an Adept system in production mode with all three jumpers installed This would leave the system with no E Stops Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 36 of 142 Chapter 3 System Installation Cable Installation Overview Power requirements for the SmartVision MX industrial PC are covered in that user guide For 24 VDC both the Hornet 565 robot and a SmartVision MX can usually be powered by the same power supply Connect eAIB XSYSTEM cable to XSYSTEM on eAIB 2 Connect a user E Stop or Muted Safety Gate to the eAIB XSYSTEM cable XUSR connector or verify XUSR jumper plug is installed in eAIB XSYSTEM cable XUSR connector 3 Connect Front Panel cable to optional Front Panel and eAIB XSYSTEM cable D E XFP connector or 3a if using user supplied Front Panel connect Front Panel to eAIB XSYSTEM cable A E XFP See warning after table 4 Conne
8. 5 Emergency Stop Switch The E Stop is a dual channel passive E Stop that supports Category 3 CE safety requirements Pressing this button turns off high power to the robot motors NOTE A Front Panel or equivalent circuits must be installed to be able to Enable Power to the robot To operate without the Adept Front Panel the user must supply the equivalent circuits 4 5 Connecting Digital I O to the System You can connect digital I O to the system in several different ways See the following table and figure I O on the eAIB Table 4 3 Digital I O Connection M oU E XIO Connector on eAIB 12 inputs see Using T O on eAIB 8 outputs XIO Connector on page 69 IO Blox using 12 inputs Adept IO Blox User s Guide optional eAIB XBELT IO Adapter 8 outputs Cable I O with an Optional SmartController EX e 4 4 More ae EN I O Connection ah Product vo 1 0 Capacity For more For more details XDIO Connector on 12 inputs see the Adept SmartController_ optional SmartController EX 8 outputs EX User s Guide lee Optional sDIO Module 32 inputs 32 outputs see the Adept SmartController connects to SmartController EX per module up to four EX User s TIU E sDIO per system Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 67 of 142 Chapter 4 System Operation Hornet 565 Robot SDIO 1 32 Input signals 1033 to 1064 32 Output signals 0033 to 0064 amt cC EN cH Opt
9. Page 23 of 142 Chapter 2 Robot Installation e The frame must be stiff enough to prevent excessive vibration The eAIB must be removable from the robot without removing the robot from the frame This is needed for maintenance and inspection of the robot The Hornet 565 robot is designed to be mounted above the work area suspended on a user supplied frame The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace While Adept does not offer robot frames for purchase and the frame design is the responsibility of the user we provide some general guidelines as a service to our users Any robot s ability to settle to a fixed point in space is governed by the forces masses and accelerations of the robot Since every action has an equal and opposite reaction these forces are transmitted to the robot frame and cause the frame and base of the robot to move and possibly vibrate in space As the robot system works to position the tool flange relative to the base of the robot any frame or base motion will be unobservable to the robot system and will be transmitted to the tool flange This transmitted base motion will result in inertial movement of the tool flange mass and will cause disturbance forces to be introduced into the robot control system These disturbance forces cause work to be done by the robot servo control system which may result in longer settling times for
10. Remove the tie downs NOTE The pallet will not fit inside most frames so the robot will need to be manually moved to the inside of the frame for mounting 2 3 Repacking for Relocation If the robot or other equipment needs to be relocated reverse the steps in the installation procedures in this chapter Reuse all original packing containers and materials and follow all safety notes used for installation Improper packaging for shipment will void your warranty CAUTION The robot must always be shipped in an upright orientation 2 4 Environmental and Facility Requirements The Hornet 565 robot system installation must meet the operating environment requirements shown in the following table Table 2 1 Robot System Operating Environment Requirements Ambient temperature 1 to 40 C 34 to 104 F Humidity 5 to 90 non condensing Altitude up to 2000 m 6500 ft NOTE For robot dimensions see Dimension Drawings on page 123 NOTE For power requirements see Specifications for 24 VDC Robot and Controller Power on page 46 and Specifications for AC Power on page 49 NOTE For chemical cleaning information refer to Chemical Compatibility on page 96 2 5 Mounting Frame The design of the robot mounting frame is the user s responsibility The flatness of the frame mounting tabs is critical See Robot to Frame Considerations following and Mounting Surfaces on page 25 Adept Hornet 565 Robot User s Guide User s Guide Rev A
11. XSYSTEM 31 XFP 6 XSYSTEM 3 XFP 5 Front Panel Front Panel XSYSTEM 33 XFP 13 High Power ETOR XSYSTEM 34 XFP 14 ONCER Pushbutton XSYSTEM 20 XFP 10 XFP 9 ESTOP 24 V Source XPND 7 XPND 6 XSYSTEM 5 XH T20 ESTOP Pushbutton XFP 3 XFP 4 XSYSTEM 24 XPND 23 Front Panel XPND 24 Auto Manual x Keyswitch XSYSTEM 4 XSYSTEM 19 XUSR 1 XUSR2 User E Stop and Gate Interlock XFP 11 XFP 12 Jumper closed when not used AM2 MUST open both channels Coil XUSR 14 XUSR 15 independently if used XSYSTEM 13 XSYSTEM 43 XUSR 3 XUSR 4 ND LINE E Stop External User E Stop System XSYSTEM 39 XUSR 17 XSYSTEM 9 XUSR 16 XSYSTEM 28 XUSR 10 I XSYSTEM 12 XUSR 9 l l gt Auto Manual AM2 AM1 Output one Z te XSYSTEM 42 XUSR 23 XPND 9 XSYSTEM 14 XSYSTEM 30 XUSR 5 XUSR 6 XSYSTEM 27 XUSR 22 T20 Pendant Enable Muted Safety Gate XSYSTEM 8 XSYSTEM 38 Active in Auto mode only XPND 26 XPND 25 Jumper closed when not used XSYSTEM 29 XUSR 18 Auto Mode C D Path XSYSTEM 44 XUSR 19 Manual Mode Path XSYSTEM 26 XUSR 8 XSYSTEM 10 XUSR 7 Force Guided Relay User ESTOP Cyclic Check Output Control Circuit XSYSTEM 25 XUSR 20 XSYSTEM 40 XUSR 21 Single Phase 1 High Power to AC Input Amplifiers 200 240 VAC 1 Internal Connections
12. robot performance NOTE The Adept robot system is intended to be installed as a piece of equipment in a permanently installed system NOTE If a three phase power source is used it must be symmetrically earthed with grounded neutral Connections called out as single phase can be wired Line to Neutral or Line to Line WARNING Adept systems require an isolating transformer for connection to mains systems that are asymmetrical or use an isolated impedant neutral Many parts of Europe use an impedant neutral DANGER AC power installation must be performed by a skilled and instructed person see the Adept Robot Safety Guide During installation unauthorized third parties must be prevented through the use of fail safe lockout measures from turning on power Facility Overvoltage Protection The robot must be protected from excessive overvoltages and voltage spikes If the country of installation requires a CE certified installation or compliance with IEC 1131 2 the following information may be helpful IEC 1131 2 requires that the installation must ensure that Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 49 of 142 Chapter 3 System Installation 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 impuls
13. used for other robot or N C contacts Shorted if NOT Used assembly line E Stop interconnection Does not affect E Stop indication pins 7 20 Line E Stop same as pins 3 16 N C contacts Shorted if NOT Used 5 18 Muted safety gate CH 1 causes E N C contacts Shorted if NOT Used Stop in Automatic mode only Muted Safety Gate CH 2 same as N C contacts Shorted if NOT Used pins 5 18 Voltage Free Contacts provided by Adept 7 20 E Stop indication CH 1 Contacts are closed when Front Panel pendant and customer E Stops are not tripped 8 21 E Stop indication CH 2 same as pins Contacts are closed when Front Panel 7 20 pendant and customer E Stops are not tripped Manual Automatic indication CH 1 Contacts are closed in Automatic mode 10 23 Manual Automatic indication CH 2 Contacts are closed in Automatic mode TT DENN Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 54 of 142 Chapter 3 System Installation Table 3 7 Contacts Provided by the XFP Connector Description Requirements for User Supplied Front Panel Voltage Free Contacts Provided by Customer Front Panel E Stop CH 1 User must supply N C contacts Front Panel E Stop CH 2 User must supply N C contacts Remote Manual Automatic switch CH Optional jumper closed for Auto 1 Mode only operation Manual Open Automatic Closed Remote Manual Automatic switch CH Optional jumper closed for Auto 2 Mode only operation Manual Open A
14. 0 59 THRU VIEW A A 9 5 0 38 O O Q SECTION D D 9 5 0 38 4 Places 126 SECTION C C 0 50 4 Places Figure 7 9 Mounting Frame Top View 150 25 5 91 7 80 8 15 Tuve eR ERES i 638 9 300 25 16 11 81 Detail of Item 5 749 2 27 29 50 60 ad 2 36 Detail of Item 10 30 Detail of Item 7 180 25 4 1 00 103 8 17 09 4 09 T 4 1 00 EO do uu an Ax 5 x 45 iu 22 o9 N 3x 025 4 1020x2971 1 00 THRU a 180 73 7 7 09 2 90 as Ny o ECE Detail of Item 9 Detail of Item 8 Detail of Item 4 Figure 7 10 Mounting Frame Details Items 4 5 7 10 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 133 of 142 Chapter 7 Technical Specifications Detail of Item 12 Detail of Item 13 Figure 7 11 Mounting Frame Detail Items 12 amp 13 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 134 of 142 Chapter 7 Technical Specifications 40 2 1 58 84 5 3 33 59 1 254 R 21 4 2 33 1 00 0 84 30 15 0 59 HPU 63 5 12 50 15 4 0 61 12 7 aes 1 71 Detail of Item 14 Figure 7 12 Mounting Frame Detail Item 14 Adept Hornet 565 Robot Use
15. 20 dog point set screw included through the shaft going through the hole in the side of the Ujoint and into the blind hole on the opposite side of the U joint The U joint is not threaded e Use Loctite 242 e Tighten to 5 N m 3 7 ft lbf of torque The head of the set screw should be flush with the outer surface of the U joint For the top U joint use a 3 mm hex key with a 10 15 mm short leg There is not enough room at the J4 motor shaft to use a standard hex key Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 32 of 142 Chapter 2 Robot Installation Figure 2 11 Short 3 mm Hex Key NOTE The platform and the J4 motor will have to be aligned after the ACE software is installed and the robot is power on See Aligning the Platform and J4 Motor on page 78 2 8 End Effectors You are responsible for providing and installing any end effector or other tooling as well as vacuum lines and wiring to the end effector See the drawing Tool Flange Dimensions Both Platforms on page 124 for dimensions of the tool flange Attaching an End Effector You can attach end effectors to the tool flange using either four M6 x 1 0 screws or a ring clamp Hardware for both methods is supplied in the accessories kit NOTE The combined weight of the end effector and the payload must not exceed the maximum rated payload Aligning an End Effector A 6 mm diameter x 12 mm dowel pin user supplied fits in a hole in the tool
16. A Page 79 of 142 Chapter 5 Options This section covers options that are available to enhance the Hornet 565 robot The options available are Tall Frame Mounting Adapters For mounting the Hornet 565 robot in a taller competitor s frame ePLC Connect For using a user supplied PLC to program the robot s motions SmartVision MX industrial PC To add vision processing power and connectivity to the robot SmartController EX motion controller To increase connectivity I O conveyor tracking and general processing speed for the Hornet 565 robot sDIO Module Add 32 inputs and 32 outputs up to 4 sDIO modules per system IO Blox I O Devices Add 8 inputs and 8 outputs up to 4 IO Blox devices per system eAIB XBELT IO Adapter cable Splits the EXPIO port into a belt encoder lead a RS 232 lead and a lead for either IO Blox or an Intelligent Force Sense System Inlet Cable Box To increase the overall robot s IP rating to IP 65 Intelligent Force Sense System Allows quick detection of forces in six dimensions at the gripper Ball Stud Locks To ensure that ball joints do not separate under extreme use 5 1 Tall Frame Adapters The Hornet 565 robot can be mounted in a tall frame previously used for a competitive parallel robot by installing a set of three frame adapters The frame adapters lower the height of the robot by 118 mm 4 65 in The lengths of the three mounting bolts will need to be increased by 118 mm
17. Consumption ae Averaged Peak Sustained Sustained Momentary RMS Time Power W Power W Current A Padaping re 257025 mm hg norton Adept yale 2530525 m 1kg rooson e NN NNNM 3 kg 90 rotation 0 41 sec Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 128 of 142 Chapter 7 Technical Specifications Payload Mass vs Acceleration To avoid excited vibrations the following acceleration values are recommended for given tool payloads Table 7 2 Payload Mass vs Acceleration Hornet 565 robot Both Platforms Payload Maximum Acceleration Preferred Acceleration a is the eV Accel Decel setting which for the Hornet 565 robot can be set as high as 75076 Payload Inertia vs Acceleration The following table provides a general guideline based on typical high performance use The practical inertia for any application will vary depending on the performance requirements Table 7 3 Payload Inertia vs Acceleration Acceleration Allowable Tool Inertia kg cm Value w wa 50 m 9 NOTE The fixed platform is not covered in this table because it does not rotate Payloads for the J4 platform should be designed with their center of mass in line with the center axis of the tool flange This will minimize induced torque during XYZ motions 7 6 Robot Mounting Frame The Adept Hornet 565 robot is designed to be mounted above the work area suspended from a user supplied frame The frame must
18. E Stop Safety Gate Adept Muted Safety Gate ii Hornet 565 The Jumper Plug is required if Robot neither of these is used ft Od XUSR Jumper Plug o 1 ol Front Panel option CT User Supplied Either Front Panel or FP Jumper Plug Ground Wire FP plug must be used T20 Adapts mo XMCP cam ed T20 Bypass Plug XMCP Jumper Plug Either T20 Pendant T20 Bypass Plug or T20 Pendant option XMCP Jumper Plug must be used 24 VDC 6A 85 264 VAC Power Supply Universal Input 1 Adept SmartVision MX option DC Power e e Cable Pot Pot El IG 1 7 EL a AC Power Cable to SmartVision MX RUM Camera R single phase option Ethernet Ethernet to eAIB li li User Supplied PC from Pe Ti oben ros i running Adept ACE Software Figure 3 1 System Cable Diagram eAIB Only See System Installation on page 35 for additional information on system grounding Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 35 of 142 Chapter 3 System Installation List of Cables and Parts Open the Accessory box and locate the eAIB XSYSTEM cable Connect the cables and peripherals as shown in the preceding figure Parts and steps are covered in the following two tables emmena parete pona rent wes EAB XSYSTEM Cable Aen 13523400 sandar eam c Front Panel pie seen erersureiet a0 Pedant pin Qmm qmm
19. Hornet 565 robot is shipped in a crate that holds the robot base outer arms platform theta drive shaft and any accessories ordered The crate is made of wood The top of the crate should be removed first 1 Remove the Klimp fasteners holding the top to the rest of the crate See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 21 of 142 Chapter 2 Robot Installation Figure 2 1 Klimp Fastener on Crate The robot base is shipped with the inner arms attached The outer arms are in a cardboard box assembled in pairs The platform is shipped fully assembled but separate from the robot base and outer arms The theta drive shaft is shipped with U joints attached but separate from the robot and platform 2 Lift the top off of the crate sides and set it aside Figure 2 2 Crate with Top Removed 3 Remove all cardboard boxes from inside the crate Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 22 of 142 Chapter 2 Robot Installation These will include the outer arms theta drive shaft and platform 4 Remove all fasteners Klimp and lag holding the crate sides to the base and lift off the crate sides The four sides will come off as a single piece so this requires two people lifting from opposite sides of the crate You will be left with the robot base with eAIB and inner arms attached to the pallet The robot base is held to the pallet with tie downs 5
20. SmartController EX 1 DC Power TE P 85 264 VAC Cable Universal N M gm Input 24 VDC 6A Power Supply User Supplied PC 200 240 VAC running PLC or ACE 10 A AC Power Cable Programming Software single phase Figure 3 2 System Cable Diagram with SmartController EX Installing a SmartController EX Motion Controller Refer to the Adept SmartController EX User s Guide for complete information on installing the optional Adept SmartController EX This list summarizes the main steps 1 Mount the SmartController EX and optional front panel 2 Connect the optional front panel to the SmartController EX Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 39 of 142 Chapter 3 System Installation 3 Connect the optional pendant to the SmartController EX 4 Connect user supplied 24 VDC power to the controller Instructions for creating the 24 VDC cable and power specification are covered in the Adept SmartController EX User s Guide 5 Install a user supplied ground wire between the SmartController EX and ground List of Cables and Parts eAIB XSYS Cable standard eAIB User E Stop Safety Gate user supplied XUSR Jumper Plug standard SmartController EX Front Panel option or user supplied Front Panel Cable or user supplied Front Panel Jumper Plug standard SmartController EX XMCP Jumper Plug standard SmartController EX T20
21. System Installation NOTE A ground strap from the end effector to the base mounting pad must include a service loop that allows full rotation and movement of the tool flange Grounding Robot Base to Frame NOTE You must ground the robot to the frame for all installations e Use any of the three M12 mounting screws for this connection Screws must be stainless or zinc plated steel e Use an external tooth star washer touching the mounting screw head Washers must be stainless or zinc plated steel If the frame is painted where the M12 screw makes contact with it use a ring terminal under the star washer and connect the other end of the wire from the terminal to a suitable grounding surface on the frame If the frame is not painted where the M12 screw makes contact with it you do not need to use a ring terminal just put an external tooth star washer under the mounting screw head If frame is painted under screw head Use ring terminal and run the other M12 Screw end to an unpainted part of the frame If frame is unpainted under screw head External tooth Use star washer but not ring terminal star washer lt L Frame Robot Base Both screws and star washers must be electrically conductive stainless or zinc plated steel Figure 3 9 Any of the Three M12 Mounting Screws can be used for Grounding 3 9 Installing User Supplied Safety Equipment The user is responsible for installing safety barriers to p
22. damage from normal shock and vibration You should protect the crate from excessive shock and vibration Use a forklift pallet jack or similar device to transport the packaged equipment The robot must always be stored and shipped in an upright position Do not lay the crate on its side or any other non upright position This could damage the robot The Adept Hornet 565 robot J4 model weighs 52 kg 115 Ib with no options installed The fixed model weighs 48 6 kg 107 Ib with no options installed The crate weighs 68 kg 150 Ib 2 2 Unpacking and Inspecting the Adept Equipment Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit If any damage is indicated request that the carrier s agent be present at the time the container is unpacked Upon Unpacking Before signing the carrier s delivery sheet compare the actual items received not just the packing slip with your equipment purchase order Verify that all items are present and that the shipment is correct and free of visible damage e If the items received do not match the packing slip or are damaged do not sign the receipt Contact Adept as soon as possible see How Can I Get Help on page 18 e If the items received do not match your order please contact Adept immediately Retain all containers and packaging materials These items may be necessary to settle claims or at a later date to relocate the equipment Unpacking The
23. eee eee ee eee eee eee eee cent eee ee eeeeeeeeeeeeeeeees 94 Chapter 6 Maintenance ttLttttussessssseeeee eere re enl 95 SM A 95 Water Shedding 2 205 0 jieahnsia cases gate Aepbecilseclicterelumb ereniDe vs eoswb uU e e d eedee sees 95 Wash DO Wil 2 sefee tot setae ie et c tcu DD e LEE LUME AMI LIRE Sate eek ea 95 Chemical Com patibility sc 22 22 9 gt cnc ote eetwnee dates aeaea a Aa a a ete nomena 96 6 2 Periodic Inspecti n NECS 96 Checking Safety Systems sisser tegt eede eE a e i a e E 98 Checking Robot Mounting Bolts 002 2 cece eee ee cee eee eee eee eee ee eee eeeeceeeeeeeeeeeeeeees 98 Checking Robot Gear Drives iiiiuuuuululllllllllllllllllllls s nnlli eeeeeeeeeeeeeeeeeee 98 Checking Fan Operati h 2 c seeeseuie Seabee oe deed Reet Seg eebe te Gee ip Eidreb et ce d emdoeie elio 99 6 3 Periodic Maintenance T 100 Replacing the Theta Drive Shaft 2222 2 22222222 ccc ee cece eee eee cece ee ee eee eeeeeeeeeeeeeeeeee 101 Replacing the Encoder Battery Pack 22 22222 ee eee eee cece ence ee eee eee eee e ee sss nnns 103 64 Non Periodic Maintenance RR 106 Changing the Lamp in the Optional Adept Front Panel High Power Indicator 106 Repla ing a Platform scili nases er pee cl dee e e Esee Egea 107 Replacing a Ball Joint Insert 52 bones ers Uo ea ete sends dca ENEE EASE e 108 Repl
24. extreme loading conditions you may want to install ball stud locks These attach to the ends of the outer arms and trap the ball to prevent the ball studs from separating from their sockets A ball stud lock kit 16 locks is available from Adept as part number 09824 000 The ball stud lock consists of slightly more than a half circle of hard plastic that slides over the end of the ball joint socket They can be installed and removed without tools See the following figures Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 92 of 142 Chapter 5 Options Figure 5 16 Ball Stud Locks Figure 5 17 Ball Stud Lock on Ball Joint Socket Installing a Ball Stud Lock The ball stud lock has a groove that mates with a lip around the end of the ball joint socket 1 To install a ball stud lock line up the groove in the ball stud lock with the lip in the ball joint socket and slide the lock on The lock is designed to be tight enough that it will not come off in use No tools are needed 2 Twist the ball stud lock back and forth slightly after installation to ensure that it is fully seated Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 93 of 142 Chapter 5 Options Figure 5 18 Installing a Ball Stud Lock Removing a Ball Stud Lock To remove a ball stud lock pull one end of the lock away from the ball joint socket The lock will slide off with resistance No tools are needed Figure
25. flange and can be used as a keying or anti rotation device in a user designed end effector Grounding If hazardous voltages are present at the end effector you must install a ground connection to the end effector See Grounding Robot Mounted Equipment on page 52 Accessing Vacuum The hole through the center of the tool flange has been made as large as possible to allow vacuum and or electric lines to pass through WARNING Do not tap the tool flange as this would weaken it Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 33 of 142 Chapter 2 Robot Installation Routing End effector Lines End effector lines either vacuum air lines or electrical wires can be routed to the platform by e Attaching them to the inner and outer arms and then to the platform e Routing them from the robot support frame to the outer arms e Routing them from the robot base directly to the platform If end effector lines are attached to the outer arms to reach the end effector either directly from the frame or along the inner arms e Make every attempt to keep the load on the outer arms as evenly balanced as possible The added weight should be attached symmetrically about the platform center e Verify that the arms can be fully extended without interference from the lines Ensure that there is enough line to reach the end effector at all platform locations e Verify that the platform can be fully rotated at all positions without af
26. robot operations It is important to note that even after the system reports the robot to be fully settled the tool flange will still be moving by any amount of motion that the suspended base of the robot may be experiencing Robot to Frame Considerations The Hornet 565 robot has a moderately complex mounting requirement due to the nature of the parallel arm kinematics and the need to minimize the robot size and mass Arm Travel Volume on page 125 shows the inner arm travel and how it may encroach on the robot mounting points As a starting point for a frame that is 1440 mm in the X and Y directions allowing use of the full range of the robots you should attempt to attain a frame frequency of 25 Hz For specialized applications such as heavy payloads and or aggressive moves you may want to attain a frame frequency of 40 Hz In general a smaller frame will yield a higher frequency If you aren t going to use the entire work envelope you can increase the frequency simply by using a smaller frame A lower frequency frame more aggressive robot moves and heavier payloads will all contribute to longer settling times Mounting Dimension Drawings on page 123 shows the mounting hole pattern for the Hornet 565 robot Note the hole location and mounting pad tolerances for position and flatness Deviation from this flatness specification will over time cause a possible loss of robot calibration NOTE Adept suggests welding the ro
27. sees har ae ae a 36 Cable Installation Overview 22 20e cece eee e cece cece cece cece cece cece cece cece eeeeeeeeeeeeeeeeteees 37 Optional Cables P 38 32 System Cables with SmartController EX 2 2 2 2 2 2 eceeeeececececeeeeseeeceeeceeeees 39 Installing a SmartController EX Motion Controller iiiiiiuseuullllllllllssllllls ss sssss 39 ListofCablesand Pants 52 2 eai ride rli acuu a Eaa uem mec rasada 40 Cable Installation Overview 2 2 ccce cece cece cece cece cece cc ece cece ceeeeceeeeeeeeeeececeeeeeeceeneeees 41 Less Common Cablesi 32 ae abs eS centu ee ee Ce ete Ae cel bee T ber Ati ts 41 33 System Cables for Systems with Belt Encoders 2 2 2 20 220eecee cece eee eeeeees 42 List of Cables and Parts 2252 02 02 ddecnosasccacacels vee dedaghnevencccekpetececeeesnesesscedebabececedscsacacs 43 Cable Installation Overview _ 2 2 2 2 c cece e cece eee e cece cece cece cece eee e cece ee eeeececeeeeeeeeeees 43 34 Adept ACE SoftWare S uc ees euis deot rier oten E ue eeu teca ecto ieee sus eoteceeetueteees 44 Wser suppliediP 1 ev sackets gesccta cece einl reed lei el DID M ERRNURPASRRUIQ MODERN ESSERE URDAREMEA 44 Installing Adept ACE Software lsssssuuullllsilllllllllllllss esce s aane EENE 44 3 5 Robot Interface Panel 2 20 2222 00 222 ccc ec ee cece cect e eee e eee ee eee eeeeeceececeeeeeeeeeees 45 3 6 Connecting 24 VDC Power
28. the actual rotation of the tool flange with respect to the J4 motor you need to use the ACE software to establish this alignment 1 Within the ACE software open the Hornet565 robot object 2 In the Configure tab click Adjust J4 Zero This will launch a utility for aligning the theta drive shaft 3 Follow the instructions in the utility Contact Adept Service for more information on this procedure Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 102 of 142 Chapter 6 Maintenance NOTE Once the theta drive shaft is installed the J4 motor and the tool flange will always rotate together so the software will know the orientation of the tool flange Replacing the Encoder Battery Pack The data stored by the encoders is protected by a 3 6 V lithium backup battery pack located in the base of the robot CAUTION Replace the battery pack only with a 3 6 V 6 8 Ah lithium battery pack Adept P N 09977 000 Battery Replacement Interval If the robot is kept in storage and not in use or if the robot is turned off no 24 VDC supply most of the time then the battery pack should be replaced every 5 years If the robot is turned on with 24 VDC supplied to the robot more than half the time then you can increase the replacement interval to 10 years If for example a robot is typically turned off only on weekends the ba
29. tie se scere ce cce d nece eee 58 Remote Man al MOde 2 2 c25d ices cnet ees Ie ilexerfiitaf usi ti ERI IQewadcielaQ tireii2uUelaeDueid 60 User Manual Auto Indication 2 2 2 2 2 eee eee eee e cece cece e eee cece cece eee cececeeeeeeceeeeees 60 User High Power On Indication 2 222522 2eieci ide edeee eee dh ded eee ee deeded eed 60 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 6 of 142 Table of Contents Remote High Power On Off Control 22 2222222 ee cece cece ee eee ee ee ee eee ss e nnn rrr 60 High Power On Ot Lamp 222 22 2s 2cccont ed dees sees one Bice e cee aiden E a EEEa Eeo ESEE 61 Remote Front Panel or User Supplied Control Panel Usage 222222222eeeeeee cece cece eeeeee 61 Remote Pendant Usage 12 25 2 3 0 9 eno eaea ene r ii Sue chocs shade ENE EEES ESE EE 62 Chapter 4 System Operation o oo ooo ooo nce cecccecceecc cece ecee es 63 4 1 Robot Status Display Panel cc ici tdccaccvedabieaceaitsde so inen e aca ooa ed a sh cppe op DA aa id us 63 4 2 Status Panel Fault OUS cooks neat peo cdtaan scena ata essa d deinen e add aane ied 64 4 3 Using the Brake Release Button 2 uciiiee t ieeetus ose eroi ideve i Rena risTi abel PU e bla tedi Ear RE 64 endis 64 Brake R lease Button lupi ddp In DU REP d ec d a s eee ne dan hehe ee 65 44 Optional Adept Front Panel P 66 4 5 Connecting Digital I O to the System 1 eeclesie ccesescbeda eicere cie ere ce peril 67 ers d P
30. to Program the Adept Hornet 565 Robot 22022022eec eee eee ee 79 Chapter 5 Options 222 00 ecc cece eee ecceecceceeeceeseeseeeees 81 5 1 Tall Frame Adapters ss hide ohh aie E RENE 81 5 2 PLE CONNECT Im 82 Configuration sesi cei eet savin eee ee eee Lee ne ee 82 Setting the Robot IP Address e accion eck Stee cond ied Se ee ee sas eee 82 Setting the Robot IP Address on the PLC 2 2222 2222222 e eee cece cece eee eee scere eeeeeeeeees 84 Using the PLC to Enable High Power 22222 2 0 cceecceeeeeeenee cece cece ne naa Tar eaea 84 5 3 SmartVision MX Industrial PC 2 2 2 222 2ccccececceecceccestcnncebedeeiciececssebeccsedeesinies 85 54 SmartController EX Motion Controller 2 2 222 222 c ceeioidcciseieeee cantik 85 55 5DIO M d le eae eR Oe dO ee ee ee Wt Te Oe aes ae Ree ee Cen een 85 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 7 of 142 Table of Contents 5 0 IO Blox T O Device TEN E 85 5 7 eAIB XBELT IO Adapter Cable goss oe re leg nance eeabecbusance saan o e EE nd 85 5 8 Cable ilet BOX c sensan ia tee Sac eee 85 lal A cC CERE 86 Installation Procedure 220 eeepc e Ra T ecR in Ne Lid dpi hechrboiecdidbiceer Esos 87 59 Intelligent Force Sensor 0cisolici eL hie se sees a tase cece dA Li E Le ae 92 510 Ball St d Locks scssi sacensties 92 Installing a Ball Stud Lock oscecnlolsedsolec0n aE o eck ele eee 93 Removing a Ball Stud Lock 2 2 2 22222222 e cece
31. 1 Robot Specifications Description Specification Work envelope 1130 mm x Z 275 mm tapers to 750 mm at Z 375 mm tapers to 410 mm at Z 425 mm Joint Range 113 to 47 Soft Stops 113 to 47 Hard Stops 114 6 to 53 Theta Range n a Weight no options 48 6 kg 107 Ib Weight in crate 116 6 257 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 126 of 142 Chapter 7 Technical Specifications 7 3 Environmental Specifications Operating Temperature 1 to 40 C 34 to 104 F Humidity 5 to 90 non condensing Shipping and Storage Temperature 10 to 60 C 14 to 140 F Humidity 75 or less non condensing 7 4 Payload Specifications Payload 1 0 kg 2 2 Ib 1 0 kg 2 2 Ib 3 0 kg 6 6 Ib 8 0 kg 17 6 Ib Torque Maximum 33 Nm Maximum rotation 360 J4 platform NOTE The fixed platform does not rotate NOTE Take care not to exceed the tool flange torque limits Excessive torque can cause permanent misalignment of the tool flange Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 127 of 142 Chapter 7 Technical Specifications 7 5 Performance Cycle Times Adept Cycle seconds 25 305 25 mm k seconds The robot tool performs continuous path straight line motions 25 mm 1 in up 305 or 700 mm 12 27 6 in over 25 mm 1 in down and back along the same path at 20 C ambient Not achievable over all paths Power
32. 2 9 Horseshoe and Spring Assembly Attaching the Theta Drive Shaft NOTE The fixed platform does not use a theta drive shaft so this section does not apply to systems with a fixed platform Each U joint has two identical ends When the theta drive shaft is shipped it will have one end of a U joint attached to each end One connects to the J4 motor drive the other connects to a shaft on the top of the J4 platform Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 31 of 142 Chapter 2 Robot Installation e Connect the top U joint to the drive shaft of the J4 motor Top U Joint The top J4 motor end of the drive shaft is labeled with ue at J4 Motor a temporary label indicating Top Remove the label i betore tS Upper Section e Connect the bottom U joint to the shaft on top of the JA of Drive Shaft platform NOTE The drive shaft is not symmetrical There is a top and a bottom Installing the drive shaft upside down will degrade system performance Note the orientation label on the drive shaft Look for a Top label on the drive shaft Lower Section To attach the free end of the U joints of Drive Shaft 1 Slide the end of the U joint over the shaft platform or J4 motor The fit will be fairly tight The hole in the side of the U joint needs to line up with S the hole in the shaft 2 Bottom U Joint at J4 Platform Platform qi US J4 Shaft Motor or Figure 2 10 U Joint 2 Screw an M6 x
33. 5 19 Removing a Ball Stud Lock Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 94 of 142 Chapter 6 Maintenance NOTE Maintenance and cleaning of user added optional equipment is the user s responsibility It is not covered in this manual NOTE When performing maintenance on the robot move any sub assemblies away from any food processing area to avoid any chance of contamination Cover or protect the food processing area 6 1 Cleaning Water Shedding Surfaces of the Hornet 565 robots have been designed to shed water This increases the likelihood that contaminants or cleaning agents will drain with a wash down procedure Wash Down Wash down cleaning is appropriate for cleaning the Hornet 565 robot Surfaces and joints have been designed with smooth internal radii for easy cleaning Table 6 1 Typical Cleaning Schedule Non raw Food Outer Arms and Ball Clean with wipes or water Studs NOTE The following cleaning actions and intervals are suggestions only Refer to HACCP guidelines to determine what is required for your installation Table 6 2 Typical Cleaning Schedule Raw Food Minimum Entire Daily Clean In Place robot Optional Platform Clean Out of Place dunk Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 95 of 142 Chapter 6 Maintenance Chemical Compatibility CAUTION Not all materials used on the Adept Hornet 565 robot are compatible with all cleaning solutio
34. Adept Hornet 565 Robot User s Guide Adept Hornet 565 Robot User s Guide P N 14608 000 Rev A July 2015 5960 Inglewood Drive Pleasanton CA 94588 USA Phone 925 245 3400 Fax 925 960 0452 adept Revierstrafe 5 44379 Dortmund Germany Phone 49 0 231 75 89 4 0 Fax 49 231 75 89 4 50 Block 5000 Ang Mo Kio Avenue 5 05 12 Techplace Il Singapore 569870 Phone 65 6755 2258 Fax 65 6755 0598 Copyright Notice The information contained herein is the property of Adept Technology Inc and shall not be reproduced in whole or in part without prior written approval of Adept Technology Inc The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology Inc The documentation is periodically reviewed and revised Adept Technology 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 Copyright O 2015 by Adept Technology Inc All rights reserved Adept the Adept logo the Adept Technology logo AdeptVision AIM Blox Bloxview FireBlox Fireview Meta Controls MetaControls Metawire Motivity Soft Machines and Visual Machines are registered trademarks of Adept Technology Inc Brain on Board is a registered trademark of Adept Technology Inc in Ge
35. Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 81 of 142 Chapter 5 Options 5 2 ePLC Connect The Hornet 565 robot can use a user supplied PLC with Adept s ePLC Connect software to control the robot motions Refer to Adept ePLC Connect 3 User s Guide Hornet 565 robots that use a PLC but do not use a SmartController EX rely on the user suppllied PLC for all digital I O Configuration The user supplied PLC and Hornet 565 robot are connected either through a shared network or via a user supplied Ethernet cable When the robot is powered on and waiting for a PLC connection the robot status panel will display its IP address two digits at a time The format will be IP oo xxx xx xx OK NOTE If you can use the robot s default IP address then you can skip the Adept ACE software installation completely Setting the Robot IP Address Configure the IP address of the Hornet 565 robot using Adept ACE software 1 Connect the PC and the robot either through a shared network or with an Ethernet cable between them 2 Start the Adept ACE software Refer to Adept ACE Software on page 44 3 Click the Detect and Configure button circled in red in the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 82 of 142 Chapter 5 Options Adept ACE AUTOMATION CONTROL ENVIRONMENT Selected Controller IP Address p 17221 12 177 gt i9 17221 12 175 SmartControlle
36. Bypass Plug standard T20 T20 Adapter Cable standard T20 K T20 Pendant option The following three items are available as an option in the Adept power supply cable kit 90565 010 AC Power Cable user supplied option 24 VDC Power Cable user supplied option 24 VDC 6 A Power Supply user supplied option Ethernet Cable PC user supplied SmartController Ethernet Cable PC user supplied option SmartVision MX S Camera and cable user supplied option The XUSR XMCP and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup C A E F G H Lg E 5 ui Las Ey Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 40 of 142 Chapter 3 System Installation WARNING Under no circumstances should you run an Adept system in production mode with all three jumpers installed This would leave the system with no E Stops Cable Installation Overview Connect eAIB XSYS cable to XSYSTEM on eAIB 2 Connect a user E Stop or Muted Safety Gate to the XUSR connector or 2a verify XUSR jumper plug is installed in XUSR connector 3 Connect Front Panel cable to optional Front Panel and XFP connector or D E 3a if using user supplied Front Panel connect Front Panel to eAIB XSYSTEM cable A E XFP See warning after table 4 Connect Pendant adapter cable to XMCP connector or 4a if no Pendant install XMCP jumper or bypass plug Gor 5 Connect user supplied ground t
37. C cable See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 90 of 142 Chapter 5 Options XSYSTEM Ethernet Ground Ports Point 24V Pin XIO XBELTIO Figure 5 14 Ground Lug Attachment 9 Hand tighten all cables to the eAIB NOTE All cables must be screwed into the eAIB 10 Attach the cable entry top cover with Roxtec frame and modules to the eAIB cable seal housing e Slide the top cover over the seal housing lip as shown in the following figure e Ensure that the gasket between the top cover and the cable seal housing is seated and that all cables are contained within the top cover e Lower the top cover onto the seal housing and secure with one screw Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 91 of 142 Chapter 5 Options Figure 5 15 Installing Cable Entry Top Cover Assembly 5 9 Intelligent Force Sensor The force sensor allows you to detect forces applied at the gripper so you can stop the robot s movement when a threshhold is passed Requires the eAIB XBELT IO Adapter cable Refer to Adept Intelligent Force Sensing System User s Guide 5 10 Ball Stud Locks Under abnormal or extreme loading conditions using very aggressive moves or in the case of a collision it is possible for the ball studs to separate from the ball joint sockets NOTE In normal use this will not happen If you are planning on extremely aggressive moves or
38. Cable Entry Top Cover Figure 5 7 Cable Entry Top Cover Assembly Figure 5 8 Bottom of Cable Entry Top Cover CF Frame 3 Adapt Roxtec modules to fit the cables that will be used by peeling out half circle strips from the modules There should be a 0 1 to 1 0 mm gap between the halves of the modules for a proper seal See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 88 of 142 Chapter 5 Options Figure 5 9 Adapting a Module to the Cable Size Checking the Gap 4 Grease the Roxtec modules using Roxtec grease See the following figure Figure 5 10 Greasing a Roxtec Module 5 Grease the inside of the CF frame where the modules will touch using Roxtec grease 6 Install each eAIB cable through its corresponding module and insert the modules into the frame See the following figure Ensure that the terminated cable ends have 10 12 in of slack See Figure 5 13 Figure 5 11 Installing Roxtec Modules into the Frame Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 89 of 142 Chapter 5 Options 7 When all of the modules are in place tighten the compression unit to 8 12 N m 6 9 ft Ibf See the following two figures There should be no visible gaps between the modules or around the cables Figure 5 13 Cable Entry Assembly with Cables 8 Attach the ground lug to GND on the eAIB The ground lug is for the cable shield of the user supplied 24 VD
39. DC supply cable to the chassis 24 VDC input connector Switch on the 200 240 VAC input supply to the chassis Switch on the 24 VDC input supply to the chassis Switch on the optional SmartController EX if you are using one Once the system has completed booting test the system for proper operation 6 5 Commissioning a System with an eAIB Commissioning a system involves synchronizing the robot with the eAIB For a new system the robot and the eAIB will have been commissioned at the factory and should not need commissioning In rare cases with a new robot with an eAIB you may need to commission the system e If the system will not power up and the robot status display shows SE you need to commission the system Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 116 of 142 Chapter 6 Maintenance e If the system will not power up in Manual mode and the robot status display shows TR you need to commission the system Safety Commissioning Utilities The Adept eAIB adds two functions from previous amplifiers that implement safety in hardware e E Stop This serves as a backup to the standard software E Stop process The system will always try to stop the robot using the software E Stop first The hardware E Stop will take over in the event of a failure of the software E Stop e Teach Restrict This limits the maximum speed of the robot when it is operated in Manual mode As with the E Stop this is a hardwa
40. IP 65 rating for the underside of the robot e Removal and submersion of the platform and outer arms designed for COP tank Cleaning agents commonly used in food processing operations See Chemical Compatibility on page 96 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 137 of 142 Chapter 8 Environmental Concerns The Hornet 565 robot protects the operating environment in the following ways e High level of surface coating adhesion prevents erosion during cleaning Lubricants are contained within multiple seals e Ball joints and springs horseshoes are designed for minimal particulate generation The theta drive shaft is designed for minimal particulate generation e All moving parts are designed so that small parts are encased within larger assemblies and are unable to contaminate the work environment Robot Base and Components The aluminum robot base and cover are coated with a white ETFE Teflon which will not flake off with repeated high pressure washings This coating is resistant to caustic and chlorinated agents has strong adherence to the metal base to resist impact and has a smooth finish that is easy to clean The gearboxes are sealed internally and sealed externally by a lip seal that is designed to meet IP 65 rating All base seal materials are designed to be compatible with caustic agents and common industrial cleaning procedures CAUTION Like most seals it is possible to prematurely d
41. Page 8 of 142 Table of Contents 74 Payload Specificati NS cos osesdes cesi eo eost ass iaoseHoro sued wobewsst ee uso I S EOE deni d 127 Payload NE 127 Bn ru 127 7 5 V urna inia To SPENDERE REDE RE RERO UAR holt 128 Cyce Times C 128 Power Consunpton l0 21212221 0 i ddsddanse edo RcRU b edo dbid denescnER ahead eed SE 128 Payload Mass vs Acceleration 222222222ceeece cece ee eee eee e eee ee eee eeeee sees an EEEE 129 Payload Inertia vs Acceleration ss a 22202 llc pepe peiequoe iced pachaeee cast E EEEE 129 7 6 Robot Mounting Frame ocvsc5 nate os soe e ele san se Se Io E Rd BIDA alee 129 Chapter 8 Environmental Concerns _ 00o 2 o oo oo ooo ce cece eee ee 137 8 1 Ambient Environment 0 2 00 20 e cece cece cece cece cece ee cecceeeeceeceeeeeecseneeees 137 82 Cleanroom Classification 2 2 22 2 2212bs2ssc2de2eeecicadensesee bli Jo ee pe co sa De e D ge S etes 137 Oo Design Factors dE 137 Robot Base and Components uuuuuuuuusiilllllllllllllllllllleIee s e Ilferrll33222222 138 Inner ATM ERN MR c 138 BallJoihis co foem cool ess At cL i ue trei en is n LUDUM tres 138 Outer rms ll lllllllllllllluillicllciccil2lc2 c2 l2l24m22222222022022 2202 22 22 2 senno 138 Spring Assemblies x2 situe dlInien in I sede Saved eibe edd eE ar iati Ab pe pictis E Sa Et 139 Platforms REC MC be aerate eh eens nk eta e
42. Software The Adept ACE Setup wizard opens 4 Follow the online instructions as you step through the installation process 5 When the installation is complete click Finish Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 44 of 142 Chapter 3 System Installation 6 After closing the Adept ACE Setup wizard click Exit on the disk menu to close the menu NOTE You will have to restart the PC after installing Adept ACE software 3 5 Robot Interface Panel XSYSTEM Ethernet Ground y Ports Point 24V Pin XIO XBELTIO Figure 3 4 Robot Interface Panel 24 VDC for connecting user supplied 24 VDC power to the robot The mating connector is provided Ground Point for connecting cable shield from user supplied 24 VDC cable 200 240 VAC for connecting 200 240 V AC single phase input power to the robot The mating connector is provided XIO DB26 high density female for user I O signals for peripheral devices This connector provides 8 outputs and 12 inputs For connector pin allocations for inputs and outputs see Using Digital I O on eAIB XIO Connector on page 69 That section also contains details on how to access these I O signals via eV XBELTIO adds a belt encoder EXPIO which supports either IO BLOX or an Intelligent Force sensor and an RS 232 interface Requires optional eAIB XBELT IO Adapter cable The belt encoder can be split for two belts with a Y adapter SmartServo
43. Task Meum MainProgram Unscheduled Programs S i Motion Groups G Ungrouped Axes amp Trends amp Data Types a Gi User Defined amp G Module Defined S amp VO Configuration 4 1756 Backplane 1756 A4 ffs 0 1756 LS5 ePLC_2_Example_No_Vision S f 1 1756 ENBT A Applications PLC t 9 ETHERNET MODULE Adept Robot Figure 5 3 Example Setting an IP Address with RS Logix The PLC should now be able to communicate with the robot Using the PLC to Enable High Power The details of enabling high power to the robot will vary depending on the software running on your PLC It RLoge St H E 1B fee tot View Seach toge Commencations Toots Window ep alee e je ile SiS vil aa a om Tea P 21 Bec pie vw l amga gt Se Precetined Monte Defined i VO Configuration 1756 Backplane 1794 44 f 0L 1756155 eC 2 Exam 9 2 1756 ENBT A Appese Figure 5 4 Example Enabling High Power with RS Logix Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 84 of 142 Chapter 5 Options In the RS Logix example double clicking Controller Tags and then setting the value of pv rbt reset fault to 1 will enable high power on the robot NOTE pv rbt reset fault is the name for a register which is fixed when downloading the PLC code example from the Adept Web site Once high power is enabled the Robot Status Panel displays ON and the amber Robot Status LED is
44. The robot base mounting tabs have spring lock Heli Coils in the M12 holes so lock washers are not needed on the M12 mounting bolts Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 26 of 142 Chapter 2 Robot Installation NOTE Check the tightness of the mounting bolts one week after initial installation and then recheck every 3 months See Checking Robot Mounting Bolts on page 98 2 7 Attaching the Outer Arms Platform and Theta Drive Shaft Joint 3 Joint 4 Robot Base Status Display Panel Inner Arm Ball Joints p S Joint 1 m NX a gg Inner Arm ut da S 3 S Motor Plug not shown i Outer Arms Platform i and Ball 4 Joints Tool Flange Figure 2 4 Major Robot Components The Adept Hornet 565 robot platform is attached to the inner arms by the outer arms NOTE Except for attaching the outer arms and theta drive shaft the platform is shipped fully assembled Aligning the Platform with the Base NOTE The fixed platform is symmetrical and can be mounted in any rotational position The tool flange must be down away from the robot body This section only applies to the J4 platform Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 27 of 142 Chapter 2 Robot Installation The rotational alignment of the platform with the base is critical to the correct operation of the robot CAUTION Incorrect alignment of the platform will result in incorrect robot performance Atta
45. ables and peripherals as shown in the preceding figure Parts and steps are covered in the following two tables The optional eAIB XBELT IO Adapter cable splits the eAIB XBELTIO port into a belt encoder lead an Intelligent Force Sensor or IO Blox lead and an RS 232 lead aesdpetum pene retos m eABASYSTEM Gabe Aseny 13923000 pandae rene Poa opin seo eerie Fardeen emm em 24 VDC 6 A Power Supply 04536 000 90565 010 or user supplied option Ethernet Cable gt eAIB user supplied eAIB XBELTIO cable 13463 000 o foption Cable Installation Overview Connect eAIB XSYSTEM cable to XSYSTEM on eAIB 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 connector C gt A Part Br E p o 3 Connect Front Panel cable to optional Front Panel and eAIB XSYSTEM cable D E XFP connector or 3a if using user supplied Front Panel connect Front Panel to eAIB XSYSTEM cable A E XFP See warning after table Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 43 of 142 Chapter 3 System Installation Connect T20 adapter cable to eAIB XSYSTEM cable XMCP connector or 4a if no 120 install XMCP jumper or T20 Adapter Cable with T20 bypass plug 5 Connect user supplied ground to robot See Grounding the Adept Robot System n a on page 52 Connect 200 240 VAC to AC Input o
46. acing Outer Arm Spring Assemblies LLiiiuuiuuuuuullllllsllslllllllls ss s nre 108 Replacing the eAIB Chassis 2421 dca to deara oe a a dace a eccps ee ied Kano SASSO 112 65 Commissioning a System with an eAIB sususuuusussssssssssssssssssses eser 116 Safety Commissioning Utilities 222 l cc ccoodsvoelcllsu deve isas sre voie ec td aco c s zd clisesgegUuge 117 E Stop Configuration Utility lt 2222 lt c2ceccs2 opheaeh oi deaddanecace cheese Me deIqlecs s a quc id DEA ADees 118 E Stop Verification Utility 2 1c oe lcu dint Sods eee n DR I De oe eee dole ded backs gigs lec 119 Teach Restrict Configuration Utility 222 220 022222 e cece eee eee eee eee ee eee sss e nnlli 119 Teach Restrict Verification Utility 22 2 2 2222220 c cece ence e eee eee eee Ires nn rmt 120 121 Chapter 7 Technical Specifications 0 0 2 123 71 Dimension Drawings 2 2 200 20 cece cece eee eee eee cence eee ele IIR eeeeeeeeeeeeeees 123 7 2 Robot Specifications 2 222402 csc en ate lcscli s eR Duce cx Ie he siete iota ies PRI RA D I d cede ees 126 7 3 Environmental Specifications 2252 25 cess sueecctal ncn RIO Red DDORIRLR Ra RI tl n seii iddee 127 ocu qc HEP 127 Shipping and Storage rioei re tareni eer RSE o isRR 83A 3 ERER E EEREN EERTE ED ARN OS REE RES 127 Adept Hornet 565 Robot User s Guide User s Guide Rev A
47. be adequately stiff to hold the robot rigidly in place while the robot platform moves around the workspace You can either use the design provided or design a custom support frame See Mounting Frame on page 23 The drawings for a sample frame are provided here starting with Mounting Frame Orthogonal View on page 131 If you choose to design a custom frame it must meet the following specifications Frame natural frequencies for stable robot operations Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 129 of 142 Chapter 7 Technical Specifications Frequency gt 25 Hz gt 40 Hz for aggressive moves or heavy payloads Mounting surfaces for the robot flanges must be within 0 75 mm 0 029 in of a flat plane If the flanges are not within this tolerance they should be shimmed CAUTION Failure to mount the robot within 0 75 mm 0 029 in of a flat plane will result in inconsistent robot motions The eAIB must be removable from the top of the frame and the inner and outer arm travel envelopes must be considered See Arm Travel Volume on page 125 The following are drawings of a frame suitable for supporting the Adept Hornet 565 robot NOTES Unless otherwise specified Material ASTM A500 Carbon Steel Grade B or Grade C permissible Remove all weld spatter and debris Continuously weld all seams and grind protruding welds to match adjacent surfaces Finish Powder coat per RAL 9003 Pure White Remove all b
48. 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 Adept Front Panel may be required See Front Panel Schematic on page 58 In this situation a pair of contacts should be wired in series with the Adept Front Panel Manual Automatic mode contacts Thus both the Adept Front Panel or the user supplied panel and the customer contacts need to be closed to allow Automatic mode WARNING Do not wire user supplied Manual Automatic contacts in parallel with the Adept Front Panel or the user supplied 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 exam
49. bot mounting tabs as a last step in the frame fabrication using a flat surface as a datum surface during the tack welding operation Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 24 of 142 Chapter 2 Robot Installation 2 6 Mounting the Robot Base Robot Orientation Adept recommends mounting the Hornet 565 robot so that the Status Display Panel faces away from the conveyor belt Although the work envelope of the robot is symmetrical this orientation gives better access to the status display It also orients the arm loading for aggressive moves across the belt This orientation places the robot World Y axis along the conveyor belt and the X axis across the belt See Mounting Dimensions on page 123 Mounting Surfaces Mounting surfaces for the robot mounting tabs must be within 0 75 mm of a flat plane CAUTION Failure to mount the Hornet 565 robot within 0 75 mm of a flat plane will result in inconsistent robot locations NOTE The base casting of the robot is aluminum and can be dented if bumped against a harder surface CAUTION Do not attempt to lift the robot from any points other than with slings as described here Mounting Procedure The Hornet 565 robot has three mounting pads Each pad has one hole with an M12 x 1 75 spring lock Heli Coil 1 Position the robot directly under the mounting frame NOTE The pallet will not fit inside most frames so the robot will need to be manually moved to the ins
50. cable With a SmartController EX Connects to the XFP connector on the SmartController Without a SmartController EX connects to the XFP branch of the eAIB XSYSTEM cable 2 System 5 V Power On LED Indicates whether or not power is connected to the robot 3 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 software restrictions on robot speed commanding no more than 250 mm sec 4 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 the optional 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 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 66 of 142 Chapter 4 System Operation 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
51. ch 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 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 Adept 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 Optional Adept Front Panel High Power Indicator on page 106 for information on changing this lamp Remote Front Panel or User Supplied Control Panel Usage Users can mount the optional Front Panel remotely by using an extension cable or by wiring a user supplied Fron
52. chment Joint 1 Figure 2 5 J4 Platform Orientation Top View Both the theta drive shaft attachment on the robot base and the platform are offset by about 2 in from the centers of the robot base and tool flange The platform should be attached so that the shaft aligns with the J4 motor between Joint 1 and Joint 3 on the robot base Joint 1 in the preceding figure should connect to motor 1 which is immediately to the right of the Status Display panel on the robot base Attaching the Outer Arms One pair of outer arms attaches between each inner arm and the platform No tools are needed e Each outer arm has a ball joint socket at each end e The inner arms and the platform have corresponding pairs of ball studs Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 28 of 142 Chapter 2 Robot Installation Figure 2 6 Inner Arm Ball Studs WARNING Pinch hazard Ball joints are spring loaded Be careful not to pinch your fingers e Outer arm pairs are shipped assembled Each pair has two springs and two horseshoes at each end See the following figure Ball Joint Socket Insert N Ball Joint Outer Arm Springs Socket Horseshoe Outer Arms gt Figure 2 7 Ball Joint Assembly CAUTION Ensure that the bearing insert is in place in the end of each outer arm Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 29 of 142 Chapter 2 Robot Installation NOTE In the following step
53. ct T20 adapter cable to eAIB XSYSTEM cable XMCP connector or if no T20 install XMCP jumper or T20 Adapter Cable with T20 bypass plug Connect user supplied ground to robot See Grounding the Adept Robot System n a on page 52 Connect 200 240 VAC to AC Input on eAIB Interface Panel secure with clamp E Connect 24 VDC to DC Input on Interface Panel Connect 24 VDC and shield ground to SmartVision MX if used See SmartVision MX user s guide for location 8 Connect Ethernet cable from PC to PLC if a PLC is used an Ethernet cable from PLC to switch if a PLC is used Connect Ethernet cable from switch to eAIB Connect Ethernet cable from SmartVision MX if used to switch Connect optional camera and cable to SmartVision MX if used NOTE A front panel can be purchased with each Hornet 565 robot system but you can choose to replace its functionality with equivalent circuits That is beyond the scope of this guide WARNING A front panel must be installed to provide an E Stop button and to enable power to the robot To operate without the Adept Front Panel the user must supply equivalent circuits Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 37 of 142 Chapter 3 System Installation Optional Cables NOTE The following cables are not covered in the steps in the preceding table XIO Breakout Cable 12 inputs Available as option 8 outputs 5 M eAIB XBELT IO Adapter Cable Available a
54. d and the other channel is opened It will also flag an error state if the channels are shorted together 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 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 58 of 142 Chapter 3 System Installation ENABLE or the Muted Safety gate If you have a specific need in this area contact Adept Customer Service 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 EN ISO 13849 operation see Figure 3 10 and the table System Instal
55. d information on safety for Adept robots It also gives resources for more information on relevant standards It ships with each robot manual and is also available from the Adept Document Library For details see Adept Document Library on page 19 1 6 Intended Use of the Robots The Adept Hornet 565 robot is intended for use in parts assembly and material handling for payloads up to 3 kg 6 6 Ib See Robot Specifications on page 126 for complete information on the robot specifications Refer to the Adept Robot Safety Guide for details on the intended use of Adept robots 1 7 Installation Overview The system installation process is summarized in the following table Also refer to System Installation on page 35 NOTE For dual robot installations see the Adept Dual Robot Configuration Procedure which is available in the Adept Document Library Table 1 1 Installation Overview Task to be Performed Reference Location If purchased mount the optional cable box Options on page 81 Mount the robot to a level stable mounting frame Mounting on page 24 Attach the robot outer arms and platform Attaching the Outer Arms on page 28 Attach the theta drive shaft for the J4 platform Attaching the Theta Drive Shaft on page 31 Install the Front Panel and Pendant if purchased System Cables eAIB Only no and Adept ACE software SmartController EX on page 35 and Adept ACE Software on page 44 Create a 24 VDC cable and connect it bet
56. d with the system but is available in the optional Power Cable kit See List of Cables and Parts on page 36 1 Locate the connector and pins shown in the preceding table 2 Use 14 16 AWG wire to create the 24 VDC cable Select the wire length to safely reach from the user supplied 24 VDC power supply to the robot base NOTE A separate 24 VDC cable is required for the optional SmartController EX That cable uses a different style of connector See the Adept SmartController EX User s Guide 3 Crimp the pins onto the wires using the crimping tool 4 Insert the pins into the connector Confirm that the 24 VDC and ground wires are in the correct terminals in the plug 5 Prepare the opposite end of the cable for connection to your user supplied 24 VDC power supply Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 47 of 142 Chapter 3 System Installation Installing 24 VDC Robot Cable 1 Connect one end of the shielded 24 VDC cable to the user supplied 24 VDC power supply See the following figure The cable shield should be connected to frame ground on the power supply e Do not turn on the 24 VDC power until instructed to do so in System Operation on page 63 2 Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the top of the robot 3 Connect the cable shield to the ground point on the interface panel Adept Hornet 565 Robot User Supplied Power Supp
57. e documents is shown in the Search Results area which opens at the bottom of the page You may need to scroll down to see it 4 Use the Description column to locate the document for the language you want and then click the corresponding Download ID number to access the Download Details page 5 On the Download Details page click Download to open or save the file 1 9 How Can I Get Help Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance with your Adept software and hardware Additionally you can access information sources on Adept s corporate website http www adept com Related Manuals This manual covers the installation operation and maintenance of an Adept Hornet 565 robot system There are additional manuals that cover programming the system and adding optional components See the following table These manuals are available on the Adept software media shipped with each system Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 18 of 142 Chapter 1 Introduction Table 1 2 Related Manuals Adept Robot Safety Guide Contains safety information for Adept robots Adept ACE User s Guide Describes the installation and use of Adept ACE Adept T20 Pendant User s Describes the use of the optional Adept T20 manual control Guide pendant Adept SmartController EX Contains complete information on the installation and User s Guide operation of the optional Adept SmartCon
58. e drive shaft is labeled with a temporary label indicating Top Remove the label before use See figure at right e Attach the bottom U joint to the shaft on top of the J4 platform To attach the free end of a U joint iSi doduds T Lower Section Slide the free end of the U joint over the J4 motor or of Drive Shaft platform shaft The fit will be fairly tight The hole in the side of the U joint needs to line up with the hole in the shaft 2 Insert one of the M6 x 20 dog point set screws 8 Bottom U Joint previously removed through the hole in the side of the U joint screw it through the shaft and into the blind at J4 Platform hole on the opposite side of the U joint The shafts are threaded the U joints are not e Use Loctite 242 e Tighten to 5 N m 3 7 ft lbf of torque The head of the set screw should be flush with the outer surface of the U joint The old drive shaft with U Joints attached needs to be returned to Adept so that it can be refurbished Contact Adept field service for instructions Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance Aligning the Platform and J4 Motor It is possible for either the motor shaft or the platform shaft to be turned manually before the theta drive shaft is connected to both If not detected the software may assume the robot s tool flange is at a different angle than it really is To ensure that the software knows
59. e sealed See Adapting a Module to the Cable Size Checking the Gap on page 89 e Roxtec grease used to assemble and seal the modules Greasing a Roxtec Module on page 89 NOTE The Roxtec CF 8 consists of a frame and integrated compression unit a wedge and bolt that compress the modules once they are assembled inside the CF frame See Cable Entry Top Cover Assembly on page 88 Tasks Measure and mark cables to establish service length 1 Install eAIB cable inlet box 2 Adapt Roxtec modules to fit cables 3 Install cables through cable entry top cover assembly 4 Attach cables to eAIB 5 Attach cable entry top cover to eAIB cable inlet box Installation Procedure 1 Measure and mark all eAIB cables at 10 12 in from the cable ends This amount of slack is needed to install the seal assembly after the connections are made to the eAIB See Cable Entry Assembly with Cables on page 90 2 Install the cable seal housing on the top of the eAIB using four M4 x 50 screws four M4 lock washers and four M4 flat washers Note that the centered M6 threaded hole must be toward the center of the robot base See the following figure right photograph Ensure that the gasket is seated between the eAIB surface and the cable seal housing Figure 5 6 Cable Seal Housing left Installed right Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 87 of 142 Chapter 5 Options Compression unit compression wedge screw
60. e voltage corresponding to the rated voltage for the basic insulation The user supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient In the industrial environment non periodic overvoltage peaks may appear on mains power supply lines as a result of power interruptions to high energy equipment such as a blown fuse on one branch in a 3 phase system This will cause high current pulses at relatively low voltage levels Take the necessary steps to prevent damage to the robot system for example by interposing a transformer See IEC 1131 4 for additional information AC Power Diagrams Note F1 is user supplied must be slow blow e 10 200 240 VAC 20A User Supplied AC Power Cable L Line N Neutral E Earth Ground Adept Hornet 565 Robot 16 200 240 VAC Figure 3 6 Typical AC Power Installation with Single Phase Supply Note F4 and F5 are user supplied must be slow blow e F5 t0 A T 200 240 VAC 3 200 240 VAC F410A User Supplied AC Power Cable E N L Li Adept Hornet L Line 1 N qe 2 565 Robot E Earth Ground 10 200 240 VAC Figure 3 7 Single Phase Load across L1 and L2 of a Three Phase Supply Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 50 of 142 Chapter 3 System Installation Details for AC Mating Connector The AC mating connector is supplied with each system It
61. ee Lee hae ena 139 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 9 of 142 Chapter 1 Introduction 1 1 Adept Hornet 565 Robots Product Description The Adept Hornet 565 robot is a three axis parallel robot The three identical axis motors control movement of the robot tool in X Y and Z directions On the four motor model a fourth motor on the robot base turns a telescoping drive shaft which provides theta rotation of the tool flange through a geared platform The Hornet 565 robot is available in two models One has a J4 platform a theta motor and theta drive shaft This provides 360 of rotation at the tool flange The other model has a fixed platform with no tool flange rotation Joint 3 Mounting Pad Joint 4 Cover Robot Base Cover Status Display Panel Inner Arm Ball Joints er 4l N Jontti v YG Y 7 Inner Arm p uda EN 1 S Motor Plug not shown Robot Base Outer Arms Platform i and Ball Joints Tool Flange Figure 1 1 Major Robot Components Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 11 of 142 Chapter 1 Introduction Adept eAIB Amplifier The Adept Hornet 565 robot uses an Adept eAIB amplifier The robot is powered and controlled using the eAIB The amplifiers and full servo control for the Adept Hornet 565 robot are contained in the eAIB which is embedded in the base of the robot The eAIB also provides the platform for run
62. em must read this guide read the Adept Robot Safety Guide and complete a training course for their responsibilities in regard to the robot e All personnel who design the robot system must read this guide read the Adept Robot Safety Guide and must comply with all local and national safety regulations for the location in which the robot is installed e The robot system must not be used for purposes other than described in Intended Use of the Robots on page 17 Contact Adept if you are not sure of the suitability for your application e 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 e Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 16 of 142 Chapter 1 Introduction 1 4 What to Do in an Emergency Press any E Stop button a red push button on a yellow background and then follow the internal procedures of your company or organization for an emergency situation If a fire occurs use CO to extinguish the fire 1 5 Additional Safety Information Adept provides other sources for more safety information The Manufacturer s Declaration of Conformity MDOC lists all standards with which each robot complies See Manufacturer s Declaration on page 18 The Adept Robot Safety Guide provides detaile
63. emoved e Apply Loctite 222 in each bolt hole not on the bolts themselves e Ensure that the Status Display panel gasket is in place between the panel and the robot body Torque the bolts to 1 1 N m 10 in Ib Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 105 of 142 Chapter 6 Maintenance 6 4 Non Periodic Maintenance Estimated Description Time of Maintenance Front Panel 30 Minutes Lamp can burn out over time Lamp 30 Minutes Excessive wear gritty environment damage from accidental impact Ball Joint 45 Minutes Plastic inserts can be replaced in case of excessive wear Inserts Preferred solution is to stock and swap extra outer arms Springs 15 Minutes Springs and horseshoes can be replaced in case of excessive and wear or accidental breakage Preferred solution is to stock and Horseshoes swap outer arms Outer 15 Minutes Broken by accidental impact Sold in pairs with springs Arms horseshoes and inserts eAIB 1 Hour Accumulated wear on electronics by excessive operations or poor line voltage Changing the Lamp in the Optional Adept Front Panel High Power Indicator The system is equipped with circuitry to detect the potentially dangerous condition of a burned out High Power indicator on the Front Panel If this lamp is burned out you cannot enable high power until the lamp has been replaced Follow this procedure to replace the High Power indicator lamp The Adept part number for the lamp
64. er EX User Supplied Safety Equipment Checks Verify that all user supplied safety equipment and E Stop circuits are installed correctly Turning on Power and Starting Adept ACE After the system installation has been verified you are ready to turn on AC and DC power to the system and start up Adept ACE 1 Turn on the 200 240 VAC power See System Installation on page 35 WARNING Make sure personnel are skilled and instructed refer to the Adept Robot Safety Guide 2 Turn on the 24 VDC power to the robot See System Installation on page 35 The Status Panel displays OK The Robot Status LED will be off 3 If you have an Adept Front Panel verify the Auto Manual switch on the Front Panel is set to Auto Mode 4 Tum on the user supplied PC and start Adept ACE e Double click the Adept ACE icon on your Windows desktop or e From the Windows Start menu bar select Start gt Programs gt Adept Technology gt Adept ACE gt Adept ACE 5 On the Adept ACE Getting Started screen e Select Create New Workspace for Selected Controller to make the connection to the controller Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 77 of 142 Chapter 4 System Operation e Select the IP address of the controller you wish to connect to or manually type in the IP address 6 Click OK You will see the message Working please wait Enabling High Power NOTE If you are controlling the robot with a PLC see Usin
65. es that fit over bearing pins on the arms This open spring assembly design allows inspection for contamination as well as wash down Platforms The Hornet 565 robot supports two types of platforms The J4 platform is electroless nickel plated aluminum The fixed platform is made of stainless steel Both platforms are designed to meet IP 67 and the basic criteria of wash down compatibility and long life Please contact your Adept representative for more information Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 139 of 142 adept 5960 Inglewood Drive Pleasanton CA 94588 P N 14608 000 Rev A 925 245 3400
66. estroy these seals by deliberate direct excessive spraying of water based agents into the sealing materials Inner Arms The inner arms are electroless nickel plated aluminum The assemblies are resistant to some caustic cleaning agents at room temperature as well as to chipping The inner arms are sealed at the robot base with a rotary V ring seal The inner arms are designed to meet IP 65 rating Ball Joints The ball studs are stainless steel The hemispherical plastic inserts are resistant to caustic agents The inserts generally produce few wear particulates The material used in the inserts is FDA compliant Lubrication of the ball joints is not needed Refer to Chemical Compatibility on page 96 Contact Adept for more information Outer Arms The outer arms are a composite assembly of carbon fiber and black anodized aluminum The interior volume of the carbon fiber tube is sealed with an internal and external continuous epoxy bond The horseshoe retaining pins are press fit into the outer arm ends with a slight interference The outer arms may be cleaned either with wash down in place on the robot or removal and tank cleaning Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 138 of 142 Chapter 8 Environmental Concerns Spring Assemblies The outer arms are attached through the positive pressure of springs that are made of electro polished stainless steel The springs attach to the arms via plastic horsesho
67. ety Settings Verify ESTOP Hardware Delay then click Next 3 Enable high power if not already enabled then click Next 4 Press an E Stop button on the Front Panel then click Next The utility will confirm that the hardware delay has been verified for this robot and display the delay times for channels A and B Teach Restrict Configuration Utility This utility sets the hardware Teach Restrict maximum speed parameter to factory specifications NOTE Ensure that the commissioning jumper is plugged into the XBELTIO jack on the eAIB before you start this procedure Procedure NOTE This procedure takes 2 or 3 minutes to complete From within the Adept ACE software Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 119 of 142 Chapter 6 Maintenance Open the robot object editor Select Configure Safety Settings Configure Teach Restrict then click Next From the Prerequisite screen click Next The wizard will go through all of the robot s motors and display messages that it is configuring Channel A and B for each It will then record the configuration and display the target times that it set Click Finish Reboot the eAIB If you are using an optional SmartController EX reboot it On some systems the SmartController EX will reboot automatically Teach Restrict Verification Utility This utility verifies that the Teach Restrict parameters are set correctly and that the hardware Teach Restric
68. fecting or being affected by the lines e Verify that any service loop or excess line does not hang down below the end effector at any platform position e Verify that excess line cannot become tangled in the outer arms or platform If end effector lines are attached directly to the bottom of the robot base to reach the end effector e Lines attached to the robot base need some form of retraction mechanism or service loop to take up the slack when the platform is near the robot base e Ensure that the lines and retraction mechanism do not apply significant force in any direction to the platform e Ensure that lines going to the robot base do not block your view of the status LED e Ensure that lines going to the robot base do not interfere with the inner arm movement User added end effector lines e Should be checked for the entire work envelope being utilized They must reach without being pulled and without impeding arm or platform movement e Cannot pull against the platform with significant force Robot performance will be affected e Must be considered as part of the payload if they add weight to the platform or outer arms e Are the user s responsibility for maintenance They are not covered in the Maintenance section of this manual Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 34 of 142 Chapter 3 System Installation 3 1 System Cables eAIB Only no SmartController EX XUSR for User
69. g the PLC to Enable High Power on page 84 After you have started the Adept ACE software and connected to the controller enable high power to the robot motors a 1 From the Adept ACE main menu click the Enable High Power icon o 2 If the High Power button on the Front Panel is blinking press and release it The optional Adept Front Panel is shown in Optional Adept Front Panel on page 66 If the button stops blinking you must Enable Power again NOTE The use of the blinking High Power button can be configured or eliminated in software Your system may not require this step This step turns on high power to the robot motors and calibrates the robot The Robot Status LED glows amber e The code on the Robot Diagnostic Panel displays ON see Robot Status Display Panel on page 63 Verifying E Stop Functions Verify that all E Stop devices are functional pendant Front Panel and user supplied Test each mushroom button safety gate light curtain etc by enabling high power and then opening the safety device The High Power push button light on the Front Panel should go out for each Aligning the Platform and J4 Motor It is possible for either the motor shaft or the platform shaft to be turned manually before the theta drive shaft is connected to both If not detected the software may assume the robot s tool flange is at a different angle than it really is To ensure that the software knows the actual rotation of the t
70. ge 96 of 142 Platform 3 Mon Robot Fans and Gear drives and Static seals Robot Mounting bolts Cable Inlet Box seals Cable Inlet Box gaskets Chapter 6 Maintenance Table 6 3 Suggested Inspection Schedule Suggested Remedy Inspect for wear around robot joints and Replace cabling if cracked or possible binding on robot worn Adjust cable position if binding Inspect inserts for excessive wear Replace worn inserts Inspect outer arms for damage caused by Replace arms if damaged possible accidental impact Replace springs and Inspect springs and horseshoes for wear horseshoes if worn or damaged Inspect platform for damage caused by Replace platform possible accidental impact Partially remove eAIB and Status Display Diagnose and or replace to inspect fans for operation non operational fans Look for lubrication leaking from gear drives See Checking Robot Gear Drives on page 98 and Checking Fan Operation Replace gear drives static seals for sanitizing wash down environments Check for good seal contact inflexible broken seals y Check tightness of bolts See Checking Tighten bolts Robot Mounting Bolts on page 98 Check for good seal contact inflexible Replace seals broken seals Check for good gasket contact inflexible Replace broken gaskets gaskets Check for water inside the display Check Replace seal for good seal contact inflexible broken seal
71. ide of the frame 2 Put nylon straps through the six slots near the three mounting pads The following figure shows two of these slots Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 25 of 142 Chapter 2 Robot Installation Mounting Pad Y gt Lifting Slots Figure 2 3 Two of Six Lifting Slots 3 Take up any slack in the straps The mechanism you use for lifting the straps will be dependent on the frame design so it is not specified here 4 Slowly lift the robot base up keeping the holes in the robot base pads and the frame pads aligned until the top surfaces of the robot base pads are touching the bottom surfaces of the frame mounting pads 5 Follow the instructions in Install Mounting Hardware that follow Install Mounting Hardware Because of the possible variability of the mounting frames mounting hardware is user supplied The bolts need to be M12 1 75 either stainless steel or zinc plated steel The threads must engage 24 mm 0 94 in of the robot base threads Heli Coil for sufficient support When mounting the robot note the following e Verify that the robot is mounted squarely before tightening the mounting bolts e Insert the bolts through the holes in the frame and into the threaded holes in the robot base mounting pads Ground the robot base to the mounting frame Refer to Grounding Robot Base to Frame on page 53 e Tighten the bolts to 61 N m 45 ft Ib NOTE
72. ify that the hardware detected the over speed condition 4 Click Next to proceed to the Manual Mode Procedure If the Automatic Mode Procedure fails you will not be allowed to proceed with the Manual Mode Manual Mode Procedure The manual mode of this verification requires the use of an Adept pendant For this verification the Front Panel keyswitch must be in Manual mode 1 From the Introduction screen click Next e Set the pendant to Joint mode e Set the pendant manual control speed to 100 2 Click Next 3 Using the pendant jog any of the robot s joints until power is disabled This indicates that the Teach Restrict function is working 4 Click Next The results of the verification will be displayed 5 Click Finish 6 Reset the Front Panel keyswitch to Auto mode Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 121 of 142 Chapter 7 Technical Specifications 7 1 Dimension Drawings Conveyor Direction _ 3x 42 84 T M12 x 1 75 ax 24 on 7244 5 0 1 19 0 2 Units are mm Section A A Figure 7 1 Mounting Dimensions Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 123 of 142 Chapter 7 Technical Specifications 747 for J4 Platform 722 for Fixed Platform Units are mm Figure 7 2 Work Envelope Side View Tool Flange The J4 platf
73. installed such that 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 Front Panel to the XSYSTEM on the eAIB or XFP port on a SmartController EX Pendant to the XSYSTEM on the eAIB or XMCP port on a SmartController EX or a loop back dongle installed XUSR to the XSYSTEM on the eAIB or XUSR port on a SmartController EX or XUSR jumper installed User supplied 200 240 V AC power to the robot 200 240 V AC connector Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 76 of 142 Chapter 4 System Operation e User supplied 24 VDC power to the robot 24 VDC connector e Ethernet cable from PLC if used to eAIB or SmartController EX if used If you are using an optional SmartController EX e User supplied 24 VDC power connected to the SmartController e User supplied ground wire installed between the SmartController and ground One end of the IEEE 1394 cable installed into a SmartServo port on the SmartController EX and the other end installed into a SmartServo port on the robot interface panel e eAIB XSYS eAIB cable between the robot interface panel XSYSTEM connector and XSYS connector on the SmartController EX and the latching screws tightened See System Installation on page 35 e Ethernet cable from PLC if used to SmartControll
74. ional laters RE gt aco act co G SDIO 1 Cenin J Caa je G p CJ Gy Ey CJ dC C lt gt Optional Mu a SmartController EX XDIO Connector XBELT Oy 12 Input signals 1001 to 1012 EXPIO 8 Output signals 0001 to 0008 eAIB XBELTIO Adapter Cable RS 232 IO Blox 1 Optional 8 Input signals 1113 to 1120 XIO Connector 3 h IO Blox 8 Output signals 0105 to 0112 12 Input signals 1097 to 1105 Device ES 8 Output signals 0097 to 0104 Figure 4 4 Connecting Digital I O to the System Table 4 5 Default Digital I O Signal Configuration Single Robot System Www me seme Controller XDIO connector Outputs 0001 0008 sDIO Module 2 1065 1096 Robot 1 XIO connector 1097 1108 For Dual Robot systems see the Adept Dual Robot Configuration Procedure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 68 of 142 Chapter 4 System Operation 4 6 Using Digital I O on eAIB XIO Connector The XIO connector on the robot interface panel offers acces
75. is 27400 29006 WARNING Lockout and tagout power before servicing WARNING The procedures and replacement of parts mentioned in this section should be performed only by trained authorized personnel The access covers on the Front Panel are not interlocked turn off and disconnect power before removing the cover 1 Turn off system power to the robot 2 Turn off power to the optional SmartController EX if you are using one Disconnect the cable between the Front Panel and the eAIB or controller Es 09 Remove the Front Panel from its mounting location 5 Remove the two screws on the back of the Front Panel Save the screws for re installation Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 106 of 142 6 10 11 12 13 14 Chapter 6 Maintenance Carefully pull the front cover away from the body of the Front Panel You will encounter some resistance as there are three plug type connectors that you need to disconnect as you pull the front cover away from the body NOTE Separate the cover from the body slowly to avoid damaging the two wires that go between the LED and the PC board inside the body Pull the front cover as straight out as possible You do not have to disconnect the wires from the PC board although you can if needed Locate the lamp body in the center of the back side of the front cover Turn the lamp body approximately 20 in either direction and then pull straight back The
76. is shipped in the Robot Accessory Kit The plug is internally labeled for the AC power connections L E N Table 3 5 AC Mating Connector Details AC Connector details AC in line power plug straight female screw terminal 10 A 250 VAC Qualtek P N 709 00 00 Digi Key P N Q217 ND NOTE The AC power cable is not supplied with the system However it is available in the optional Power Cable kit See List of Cables and Parts on page 36 Procedure for Creating 200 240 VAC Cable 1 Locate the AC mating connector shown in AC Mating Connector Details on page 51 2 Open the connector by unscrewing the screw on the shell and removing the cover 3 Loosen the two screws on the cable clamp See AC Power Mating Connector on page 52 4 Use 18 AWG wire to create the AC power cable Select the wire length to safely reach from the user supplied AC power source to the robot base 5 Strip 18 to 24 mm insulation from each of the three wires 6 Insert the wires into the connector through the removable bushing 7 Connect each wire to the correct terminal screw and tighten the screw firmly 8 Tighten the screws on the cable clamp 9 Reinstall the cover and tighten the screw to secure the connector 10 Prepare the opposite end of the cable for connection to the facility AC power source Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 51 of 142 Chapter 3 System Installation Removable Bushing Cable Clamp Line
77. ive Shaft The theta drive shaft has a U joint on each of its ends One connects to the J4 motor drive the other connects to a shaft on the top of the J4 platform e Disconnect the bottom U joint from the shaft on top of the J4 platform e Disconnect the top U joint from the drive shaft of the J4 motor To remove a U joint from a J4 motor or platform shaft 1 Unscrew the M6 x 20 dog point set screw that goes through the U joint and shaft For the top U joint use a 3 mm hex key with a 10 15 mm short leg There is not enough room at the J4 motor shaft to use a standard hex key Screw q 10 15 mm J4 Shaft TA Motor or Figure 6 1 Short 3 mm Hex Key Above U Joint Right T Platform The set screw was put in with Loctite 242 Save the set screw for installing the replacement drive shaft 2 Slide the end of the U joint off of the J4 motor or platform shaft The fit will be fairly tight Installing a Drive Shaft When the theta drive shaft is shipped it will have one end of a U oint attached to each end Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 101 of 142 Chapter 6 Maintenance NOTE The drive shaft has a top and bottom Installing it upside down will degrade system performance Look g Top U Joint for a Top label on the drive shaft H at J4 Motor e Attach the top U joint to the drive shaft of the J4 motor Upper Section of Drive Shaft The top J4 motor end of th
78. ive the inputs Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 71 of 142 Chapter 4 System Operation Typical Input Wiring Example Adept Supplied Equipment User Supplied Equipment Note all Input signals can be used for either sinking or sourcing configurations Wiring Terminal Typical User Block Input Signals equivalent circuit Part Present Sensor Signal 1097 Signal 1098 4 Feeder Empty Sensor l Part Jammed Sensor Signal 1099 e lant Read Signal 1100 Sealant Ready Sensor l Signal 1101 2 addaa Signal 1102 Bank 1 3 e Common 24V e Input Bank 1 sindu NdN Buus 10 peinBijuoo yueg GND 13 Signal 1103 e 14 Signal 1104 e 15 2 2 d Q o Es E D E T oO A S o 9 c c 5 O Q gt x lt Signal 1105 e Signal 1106 418 Signal 1107 ETE Signal 1108 18 Bank 2 Common e 10 peinByuoo z xueg sindu qNd Bunos Input Bank 2 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 XIO Output Signals The eight digital ou
79. lamp body is now free You can remove the old lamp and insert a new one Re install the lamp body by pushing it straight into the lamp housing receptacle Make sure the contacts on the lamp body are properly oriented as shown in the following figure Make sure to reconnect the wires from the LED if you disconnected them earlier Push the front cover into the body taking care to align all of the plug type connectors Verify that the wires do not get crimped as you reinstall the cover Re install the two screws on the back of the body Re install the Front Panel in its mounting Reconnect the cable between the Front Panel and the eAIB or controller Back side of front cover Wires between LED and body of Front Panel Be careful when separating front cover from body to avoid High Power On Off damaging the wires Lamp Body Figure 6 4 Lamp Body Contact Alignment Replacing a Platform CAUTION Do not overstretch the outer arm springs Separate the ball joint sockets only enough to fit them over the ball studs Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 107 of 142 Chapter 6 Maintenance NOTE Refer to Robot Installation on page 21 for details on installing the outer arms Removal is the reverse of installation 1 Remove the three pairs of outer arms from the three pairs of ball studs on the installed platform 2 For a J4 platform disconnect the theta drive shaft from the platf
80. lation on page 35 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 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 E Stop 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 57 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
81. lost requiring robot recalibration by Adept personnel 11 Connect the new battery pack to the unused connector on the battery bracket but do not disconnect the old battery pack yet There is only one way to plug in the connector Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 104 of 142 Chapter 6 Maintenance Battery Cable Cable Tie In use Battery Battery am Pack Connector Battery M Bracket Unused Battery Connector oa Status ES i Displa Diag Cable EU ua ar Connector Figure 6 3 Battery Bracket on Status Display Panel 12 Once the new battery pack is connected you can disconnect and remove the old one You will need to cut the cable tie holding the battery pack in the bracket NOTE Dispose of the battery pack in accordance with all local and national environmental regulations regarding electronic components 13 Place the new battery pack in the battery bracket and secure it and the diag cable using a cable tie e Fold any excess wiring red and black under the battery pack so that it lies between the battery pack and the V in the battery bracket e The diag cable must be cable tied to the bracket and battery pack to relieve strain on the Status Display connector NOTE In the preceding figure the diag cable has not yet been attached to the battery bracket 14 Re install the Status Display panel with the four M4 bolts previously r
82. ly 24 VDC 24V 6A User Supplied Shielded Attach shield from user Power Cable supplied cable to ground screw on robot interface 24 V 5A panel Frame Ground Attach shield from user SmartController EX supplied cables to frame Attach shield from user supplied ground on power supply Option cable to side of controller using star washer and M3 x 6 screw User Supplied Shielded Power Cable Figure 3 5 User Supplied 24 VDC Cable NOTE Adept recommends that DC power be delivered over a shielded cable with the shield connected to ground at both ends of the cable Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 48 of 142 Chapter 3 System Installation 3 7 Connecting 200 240 VAC Power to Robot WARNING Appropriately sized branch circuit protection and lockout tagout capability must be provided in accordance with the National Electrical Code and any local codes Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system Specifications for AC Power Table 3 4 Specifications for 200 240 VAC User Supplied Power Supply Auto Ranging Minimum Maximum Frequency External Circuit Nominal Operating Operating Phasing Breaker Voltage Voltage Voltage User Supplied 200 to 240 V 180 V 264 V 50 60 Hz 10 Amps 1 phase Specifications are established at nominal line voltage Low line voltage can affect
83. 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 Adept Robot Safety Guide wearing safety equipment and carrying an Adept 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 the section System Installation on page 35 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 re enabled 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 CAUTION 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 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 59 of 142 Chapter 3 System Installation Remote Manual Mode The optional Adept Front Panel provides for a Manual Mode circuit See Remote High Power On Off Control on page 60 for further details about the customer Remote Manual Mode circuitry The Adept Front Panel or a user supplied panel must
84. n upon successfully enabling high power to the robot or power cycling the 24 V supply to the robot Table 4 2 Status Panel Codes x ox MA T x 5 pA x s T mi m w emeneeAwUmn S For more information on status codes go to the Adept Document Library on the Adept website and in the Procedures FAQs and Troubleshooting section look for the Adept Status Code Summary document See Major Robot Components on page 11 for Joint locations 4 3 Using the Brake Release Button Robot Brakes The robot has a braking system which decelerates the robot in an emergency condition such as when the emergency stop circuit is open or a robot joint passes its softstop Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 64 of 142 Chapter 4 System Operation This braking system does not prevent you from moving the robot manually once the robot has stopped and high power has been disabled In addition the three inner arm motors have electromechanical brakes which are released when high power is enabled When high power is disabled the brakes engage and hold the position of the platform fixed Brake Release Button Under some circumstances you may want to manually position the platform without enabling high power For such instances a Brake Release button is located on the underside of the robot base When system power is ON pressing this button releases the brakes which allows movement of the arms and
85. n eAIB Interface Panel secure with clamp 7 Connect 24 VDC to DC Input on Interface Panel B Connect Ethernet cable from PC to eAIB Connect optional eAIB XBELTIO cable to the XBELTIO port on eAIB Connect the Y adapter cable to the eAIB XBELTIO cable Belt branch 3 4 Adept ACE Software User supplied PC The user loads the Adept ACE software onto the PC and connects it to the eAIB via an Ethernet cable Depending on the other equipment in the system there may be an Ethernet switch between the two Installing Adept ACE Software The Adept ACE disk will display a ReadMe file when inserted in your PC This contains hardware and software requirements for running Adept ACE software You install Adept ACE from the Adept Software disk Adept ACE needs Microsoft NET Framework The Adept ACE Setup Wizard scans your PC for NET and installs it automatically if it is not already installed 1 Insert the disk into the disk drive of your PC If Autoplay is enabled the Adept software disk menu is displayed If Autoplay is disabled you will need to manually start the disk NOTE The online document that describes the installation process opens in the background when you select one of software installation steps below 2 Especially if you are upgrading your Adept ACE software installation from the Adept ACE software disk menu click Read Important Information 3 From the Adept ACE software disk menu select Install the Adept ACE
86. nected devices Adept recommends a 24 VDC 6 A power supply to allow for startup current draw and load from connected user devices such as solenoids and digital I O loads If multiple robots are to be sourced from a common 24 VDC power supply increase the supply capacity by 3 A for each additional robot 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 recommended power supplies Table 3 2 Recommended 24 VDC Power Supplies ee ee cc RN JPM160PS24 24 VDC 67 A 160 W Mean Well SP 150 24 24 VDC 63 A 150 W ASM150 24 24 VDC 6 66 A 150 W Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 46 of 142 Chapter 3 System Installation 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 3 3 24 VDC Mating Connector Specs Connector Details Connector receptacle 2 position type Molex Saber 18 A 2 Pin Ground Molex P N 44441 2002 Digi Key P N WM18463 ND Pin Details Molex connector crimp terminal female 14 18 AWG E Molex P N 43375 0001 Digi Key P N WM18493 ND Recommended crimping tools Molex P N 63811 7200 Digi Key P N WM1618 ND Procedure for Creating 24 VDC Cable NOTE The 24 VDC cable is not supplie
87. nformation Installing a New eAIB Chassis 1 10 11 12 13 14 15 Carefully remove the new chassis from its packaging check it for any signs of damage and remove any foreign packing materials or debris from inside the chassis Carefully place the chassis next to the robot Using a 5 mm hex wrench connect the ground wire to the chassis Reconnect the cables you removed from their connectors on the ePMAI board and engage the securing latches Connect the white amplifier cable to the amplifier connector located on the chassis bracket Carefully insert the chassis into the robot base in the groove at the bottom of the base Tilt the chassis up and into place against the robot making sure that none of the cables get trapped or pinched and that the chassis O ring is not damaged during installation Once the chassis is in place use a 5 mm hex wrench to tighten the chassis securing screw See Figure 6 11 for details Connect the 200 240 V AC supply cable to the chassis AC input connector Connect the eAIB XSYSTEM cable to the chassis XSYSTEM connector or if you are using an optional SmartController EX connect the eAIB XSYS cable to the chassis XSYSTEM connector Connect any other cables that were connected to the chassis such as XIO RS 232 1394 or any others If you are using an optional SmartController EX connect the XSYS end of the eAIB XSYS cable to the XSYS port on the controller Connect the 24 V
88. ning Adept s eV OS and language The Adept eAIB features e On board digital I O 12 inputs 8 outputs Low EMI for use with noise sensitive equipment e No external fan for quiet operation 8 kHz servo rate to deliver low positional errors and superior path following e Sine wave commutation to lower cogging torque and improve path following Digital feed forward design to maximize efficiency torque and velocity Temperature sensors on all amplifiers and motors for maximum reliability and easy troubleshooting e Hardware based E Stop and Teach Restrict controls For improved safety relative to European standards implemented in 2012 Figure 1 2 Adept eAIB Adept Hornet 565 Robot Base The Adept Hornet 565 robot base is an aluminum casting that houses the four or three drive motors and supports the eAIB It provides three mounting pads for attaching the base to a rigid support frame The Status Display panel is mounted on the side of the robot base Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 12 of 142 Chapter 1 Introduction Inner Arms Three robot motors attach directly to the inner arms through high performance gear reducers If the robot has a theta rotation motor it is mounted at the top of the robot base The following figure shows an inner arm from a Hornet 565 robot RIA compliant hard stops limit the inner arm motion to 53 and 114 6 Ball Joints Outer Arms The inner arm motion is transmi
89. nly Turn off response time 60 usec max 28 usec typical hardware only Output voltage at inductive load turnoff I 205 A V 65 lt V lt V 45 Load 1 mH MS SM DC short circuit current limit O7A lt Lai lt 25A 4A Peak short circuit current I lt ovpk Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 73 of 142 Chapter 4 System Operation Typical Output Wiring Example Adept Supplied Equipment User Supplied Equipment Wiring Terminal Block 24 VDC Ye Signa equivalent circuit Y Typical User Loads Signa Signa S S S S Signa Signa Signa Outputs 1 8 Signa Customer AC Power Supply Signa ooo00o00 XIO Connector 26 Pin Female D Sub Figure 4 6 Typical User Wiring for XIO Output Signals XIO Breakout Cable The XIO Breakout cable is available as an option see the following figure This cable connects to the XIO connector on the eAIB and provides flying leads on the user s end for connecting input and output signals in the workcell The cable length is 5 M 16 4 ft See the following table for the cable wire chart NOTE This cable is not compatible with the XIO Termination Block Figure 4 7 Optional XIO Breakout Cable Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 74 of 142
90. nput Signals The 12 input channels are arranged in two banks of 6 Each bank is electrically isolated from the other bank and is optically isolated from the robot s ground The 6 inputs within each bank share a common source sink line The inputs are accessed through direct connection to the XIO connector see Table 4 6 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 See the eV Language User s Guide for information on digital I O programming XIO Input Specifications Table 4 8 XIO Input Specifications Operational voltage range 0 to 30 VDC OFF state voltage range 0 to 3 VDC ON state voltage range 10 to 30 VDC Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 70 of 142 Chapter 4 System Operation Typical threshold voltage V 8 VDC in Operational current range 0 to 7 5 mA OFF state current range 0 to 0 5 mA ON state current range 2 5 to 7 5 mA Impedance V nin 3 9 KQ minimum in 1n Turn on response time hardware 5 usec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time Turn off response time hardware 5 usec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time NOTE The input current specifications are provided for reference Voltage sources are typically used to dr
91. ns available Caustic The Hornet 565 robot is designed to be compatible with moderate cleaning agents commonly used in the cleaning of food processing equipment at room temperature All robot components are designed to handle daily exposure to cleaning agents Exposure may result in some discoloration of the materials but no significant material removal NOTE Anodized parts cannot be tank cleaned Highly caustic cleaning agents are not suitable for Hornet 565 robots Acidic In general acidic cleaning solutions are incompatible with the Hornet 565 robot s materials For acidic environments contact Adept 6 2 Periodic Inspection Suggested Inspection Schedule on page 97 gives a summary of the inspection procedures and guidelines on frequency NOTE The frequency of these procedures depends on the particular system its operating environment and amount of usage Use the times in the tables as guidelines and modify the schedule as needed WARNING The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons as defined in the Adept Robot Safety Guide The cover and the eAIB on the robot are not interlocked turn off and disconnect power if these have to be removed Lock out and tag out power before servicing NOTE The estimated times listed in the following table are for the inspection not the repair Adept Hornet 565 Robot User s Guide User s Guide Rev A Pa
92. nto a belt encoder lead one RS 232 lead and one lead for either IO Blox or Intelligent Force Sense System The belt encoder lead can be split into two belt encoder leads with the belt encoder Y adapter See System Cable Diagram with Belt Encoder Cables on page 42 5 8 Cable Inlet Box The addition of the cable inlet box raises the entire robot s IP rating to IP 65 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 85 of 142 Chapter 5 Options Cable Exit from Rear of Box a a m E Cty U rmm _ Figure 5 5 Cable Inlet Box Mounted on a Hornet 565 Robot NOTE The cable inlet box is not USDA compliant Drainage of wash down from the cable seal assembly does not comply with USDA requirements Overview The cable seal assembly must be mounted on the top of the robot during the robot installation process The cable seal assembly is an extra cost option and is shipped separately from the robot Components e Cable harness e eAIB Cable Seal Housing 2 gaskets 4 screws Cable Seal Housing left Installed right on page 87 e Cable Entry Top Cover assembly screw Cable Entry Top Cover Assembly on page 88 This includes the Roxtec CF 8 frame Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 86 of 142 Chapter 5 Options e 4 x 2 hole Roxtec modules These are dense foam blocks surrounding pre cut half sleeves that can be peeled away to match the diameter of the cable to b
93. o robot See robot user s guide for location n a 5a Connect user supplied ground to SmartController EX See SmartController n a EX user s guide for location 5b Connect user supplied ground to SmartVision MX if used See SmartVision n a MX user s guide for location Connect 200 240 VAC to AC Input on eAIB secure with clamp 7 Connect 24 VDC to DC Input on eAIB and SmartController EX N M 7a Connect 24 VDC to SmartVision MX if used N M Connect Ethernet cable from PC to SmartController EX Connect Ethernet cable to SmartVision MX if used 10 Connnect IEEE 1394 cable between SmartController EX and eAIB SmartServo 11 Connect optional camera and cable to SmartVision MX if used WARNING A front panel must be installed to provide an E Stop button and to enable power to the robot To operate without the Adept Front Panel the user must supply equivalent circuits Less Common Cables NOTE The following cables are not covered in the steps in the preceding table Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 41 of 142 Chapter 3 System Installation XIO Breakout Cable 12 inputs Available as option 8 outputs 5 M Y Cable for XSYS cable connections to Available as option with dual robots SmartController EX eAIB XBELT IO Adapter Cable Available as option The XIO Breakout cable is for using the I O on the eAIB See XIO Breakout Cable on page 74 The Y cable attaches at the SmartController EX XSYS connec
94. on 5 3 SmartVision MX Industrial PC The Adept SmartVision MX is a Windows 7 Embedded industrial PC designed to run Adept s ACE software It is compatible with the Adept Hornet 565 robot with or without the Adept SmartController EX motion controller For inspection applications the Adept SmartVision MX industrial PC is designed to be a plug and play vision system Using a USB or GigE camera along with Adept s PC based vision software the unit is a complete industrial vision solution providing expanded vision processing power for vision guided robotics or inspection Refer to Adept SmartVision MX User s Guide 5 4 SmartController EX Motion Controller The optional SmartController EX motion controller supports tracking more conveyors than an eAIB alone as well as other options Like the eAIB the SmartController EX uses the eV operating system It offers scalability and support for IEEE 1394 based digital I O and general motion expansion modules The SmartController EX also includes Fast Ethernet and DeviceNet Refer to Adept SmartController EX User s Guide 5 5 sDIO Module Adds 32 inputs and 32 outputs to the system This requires the optional SmartController EX motion controller Up to 4 sDIO modules can be added to a system 5 6 IO Blox I O Device Adds 8 inputs and 8 outputs per device Up to 4 devices can be used Requires the eAIB XBELT IO Adapter cable 5 7 eAIB XBELT IO Adapter Cable Splits the EXPIO port i
95. ooking through the Status Display opening Re install the Status Display panel with the four M4 bolts previously removed e Apply Loctite 222 in each bolt hole not on the bolts themselves e Ensure that the Status Display panel gasket is in place between the panel and the robot body e Torque the bolts to 1 1 N m 10 in Ib 6 3 Periodic Maintenance Table 6 5 Suggested Part Replacement Suggested Estimated Description Interval Time of Maintenance 1 Year or 30 Minutes Bushings in drive shaft are a normal wear item 5 000 hours The bushings are not field replaceable so the entire drive shaft must be replaced Backup 5 years to 15 Minutes Replacement battery pack is inserted from the side Encoder 10 years of the robot through the Status Display opening See Battery Maintenance on page 95 Pack Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 100 of 142 Chapter 6 Maintenance Replacing the Theta Drive Shaft NOTE The fixed platform Hornet 565 robot does not use a theta drive shaft so this procedure does not apply to those robots The bushings in the drive shaft are a normal wear item and need to be replaced yearly or every 5 000 hours of use Because the bushings are not field replaceable the procedure for this is to replace the entire drive shaft with a refurbished drive shaft which will have new bushings The worn drive shaft needs to be returned to Adept to be refurbished Removing the Theta Dr
96. ool flange with respect to the J4 motor you need to use the ACE software to establish this alignment 1 Within the ACE software open the Hornet565 robot object 2 In the Configure tab click Adjust J4 Zero This will launch a utility for aligning the theta drive shaft 3 Follow the instructions in the utility Contact Adept Service for more information on this procedure Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 78 of 142 Chapter 4 System Operation NOTE Once the theta drive shaft is installed the J4 motor and the tool flange will always rotate together so the software will know the orientation of the tool flange Verify Robot Motions Use the pendant if purchased to verify that the robot moves correctly Refer to the Adept T20 Pendant User s Guide for complete instructions on using the pendant The Hornet 565 robot is a parallel arm robot and as such individual joint motions are not allowed If you attempt to move a joint in Joint mode you will get an error message JOINT n OUT OF RANGE where n is the joint that you attempted to move Joints are identified in Major Robot Components on page 11 e If one joint must be moved separately release the brakes while supporting the platform and move the joint manually e If the optional pendant is not installed in the system you can move the
97. orm drive shaft See Removing the Theta Drive Shaft on page 101 for details Do not remove the top U joint which is attached to the JA motor shaft 3 Attach one pair of outer arms to each of the three pairs of ball studs on the new platform e The platform is installed flange down e Take care not to trap debris between the ball studs and their sockets 4 Fora J4 platform attach the theta drive shaft to the platform drive shaft See Installing a Drive Shaft on page 101 for details Replacing a Ball Joint Insert 1 Remove the old insert The inserts have a threaded hole in the bottom to facilitate removal Use an M4 bolt to thread into the insert and pull it out 2 Install the new insert Ensure that the insert is centered in the ball joint socket and bottomed out Replacing Outer Arm Spring Assemblies NOTE It is unlikely that you will ever need to remove the components of the outer arm spring assemblies Removing Outer Arm Springs 1 Bend the spring so that the end is 90 from normal See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 108 of 142 Chapter 6 Maintenance Figure 6 5 Removing an Outer Arm Spring Removing the first spring is the most difficult as the other spring will tend to restrict movement of the spring 2 Slip the springs off of the horseshoes See the following figure Figure 6 6 Spring with End Removed from Horseshoe Adept Hornet 565 Rob
98. orm has a tool flange that rotates relative to the platform It is gear driven attached to the theta drive shaft Ensure that the bolts used to attach end effectors engage the threads in the tool flange sufficiently The engagement needs to be between 8 and 11 mm 0 3 and 04 in SECTION A A SCALE 1 5 1 65 00 4x M6x1 0 v 11 00 Units are mm Figure 7 3 Tool Flange Dimensions Both Platforms Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 124 of 142 Chapter 7 Technical Specifications Arm Travel Volume This represents the space where any part of the arm could go This is needed for designing a supporting frame Required clearances for a flat plate are also given yp Center of Robot 3x 237 t 3x 318 l d Cutout needed in plate at 3x 226 robot mount surface height obot Mount Surface Arm travel volume n I N See CAD model for all dimensions Units are mm Figure 7 4 Arm Travel Volume Outside dimensions of plate 3x 13 50 THRU Mounting are determined by frame holes for Hornet 740 B C Flat Plate 3x 120 Units are mm Figure 7 5 Flat Plate Dimensions Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 125 of 142 Chapter 7 Technical Specifications Flat Plate Figure 7 6 Flat Plate Iso View 7 2 Robot Specifications Specifications subject to change without notice Table 7
99. ot User s Guide User s Guide Rev A Page 109 of 142 Chapter 6 Maintenance The narrowest part of the horseshoe is 90 from the groove in which the spring end normally rests 3 Repeat these steps for the remaining spring Removing Outer Arm Spring Horseshoes NOTE The only reason for removing an outer arm horseshoe is to replace one that has been damaged 1 Remove the outer arm springs from the horseshoe See the previous section Removing Outer Arm Springs on page 108 2 Cut the horseshoe with diagonal cutters Take care not to damage any part of the outer arm end 3 Remove the cut horseshoe from the outer arm pins Installing Horseshoes 1 Slip one end of the horseshoe over one of the outer arm pins See the following figure Figure 6 7 Horseshoe over One Pin 2 Pull the loose end of the horseshoe spreading it slightly and slip the end on top of the other outer arm pin The horseshoes are very stiff and do not bend easily See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 110 of 142 Chapter 6 Maintenance Figure 6 8 End of Horseshoe on Pin 3 Squeeze the horseshoe the rest of the way until it is over the pin See the following figure The horseshoe will snap into place Figure 6 9 Squeezing the Horseshoe into Position Installing Springs on a Horseshoe 1 Slip the spring onto the horseshoe at 90 from its normal position Refer to the figures in Rem
100. oving Outer Arm Springs on page 108 The narrowest part of the horseshoe is 90 from the groove in which the spring end normally rests 2 Repeat for the remaining spring Installing the last spring is the most difficult as the other spring will tend to keep the spring from moving Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 111 of 142 Chapter 6 Maintenance Replacing the eAIB Chassis Removing the eAIB Chassis CAUTION Follow appropriate ESD procedures during the removal replacement phases 1 Switch off the 24 VDC input supply to the chassis 2 Switch off the 200 240 VAC input supply to the chassis 3 Switch off the optional SmartController EX if you are using one 4 Disconnect the 24 VDC supply cable from the chassis 24 VDC input connector For the connector location see Chapter 2 5 Disconnect the 200 240 VAC supply cable from the chassis AC Input connector 6 Disconnect the eAIB XSYSTEM cable from the chassis XSYSTEM connector 7 Disconnect any other cables which may be connected to the chassis such as XIO RS 232 1394 or any others Figure 6 10 eAIB on Hornet 565 Robot Base Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 112 of 142 Chapter 6 Maintenance 8 Using a 5 mm hex wrench carefully unscrew the chassis securing screw which is shown in the following figure Note that the screw does not need to be completely removed in order to remove the chassis as thi
101. panel with the four M4 bolts previously removed e Apply Loctite 222 in each bolt hole not on the bolts themselves e Ensure that the Status Display panel gasket is in place between the panel and the robot body e Torque the bolts to 1 1 N m 10 in Ib Checking Fan Operation The motor fans are PWM controlled This check needs to be done with 24 VDC to the robot ON Verify that all fans operate Fans for J1 and J2 motors 1 Remove the eAIB See Replacing the eAIB Chassis on page 112 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 99 of 142 Chapter 6 Maintenance You do not need to disconnect the cables to the eAIB Toggle power to the eAIB Motor fans run for about 1 minute before shutting off If the robot is hot they will continue to run Verify that J1 and J2 motor fans are running by looking through the eAIB opening Re install the eAIB Installing a New eAIB Chassis on page 116 Fan for J3 motor this cannot be seen through the eAIB opening 1 Remove the four M4 hex head bolts holding the Status Display panel e Retain the bolts for re installation e These bolts were installed with Loctite 222 Remove but do not disconnect the Status Display panel Retain the Status Display panel and gasket for re installation Toggle power to the eAIB Motor fans run for about 1 minute before shutting off If the robot is hot they will continue to run Verify that the J3 motor fan is running by l
102. pecifications e Wire Size must be larger than 26 AWG Connectors must be 15 pin standard D sub male and female e Maximum cable length is 10 meters CAUTION Do not modify the cable that is attached to the pendant This could cause unpredictable behavior from the robot system Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 62 of 142 Chapter 4 System Operation 4 1 Robot Status Display Panel The robot Status Display panel is located on the side of the robot base The combined status LED high power lamp and the brake release button are on the underside of the robot base The Status Display and LED blinking pattern indicate the status of the robot Figure 4 1 Robot Status Display Panel Table 4 1 Robot Status LED Definition e ati Panel Display K Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 63 of 142 Chapter 4 System Operation 4 2 Status Panel Fault Codes The Status Display shown in Robot Status Display Panel on page 63 displays alpha numeric codes that indicate the operating status of the robot including fault codes The following table gives definitions of the fault codes These codes provide details for quickly isolating problems during troubleshooting The displayed fault code will continue to be displayed even after the fault is corrected or additional faults are recorded All displayed faults are cleared from the display and reset to a no fault conditio
103. platform Ww Status LED High power Lamp Release Button Figure 4 2 Brake Release and LED Light If this button is pressed while high power is ON high power automatically shuts down NOTE 24 Volt robot power must be ON to release the brakes CAUTION When the Brake Release button is pressed the platform and end effector may drop to the bottom of its travel To prevent possible damage to the equipment make sure that the platform is supported when releasing the brakes and verify that the end effector or other installed tooling is clear of all obstructions Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 65 of 142 Chapter 4 System Operation Remote Brake Release Feature You can also configure the XIO Input 6 2 pin 18 to act as an alternate hardware brake release input The setting is available on the Robot page in the Adept ACE software The parameter is Remote Brake Release Input When enabled True activating XIO Input 6 2 is identical to pressing the physical brake release button on the robot base The input status will still reflect in the IO register 4 4 Optional Adept Front Panel 2 Manual Auto i Mode Mode Y T gt O Figure 4 3 Adept Front Panel 1 XFP
104. ple 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 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 System Installation on page 35 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 an optional Adept 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 58 for details of the Adept Front Panel s wiring In this situation a second momentary contact for high power on off would be placed in Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 60 of 142 Chapter 3 System Installation parallel with the 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 swit
105. r Connect to i Series Cobra New Sample Application F Import contents of V memory into workspace I mmm Copyright 2006 2013 Adept Technology Inc Figure 5 1 Detect and Configure Button The IP address detection and configuration window will open The ACE software will show the IP address of any controllers it detects See the following figure To detect an unknown controller IP address re boot the desired controller now and wait for itto appear in the Controllers Detected list below When you press OK the selected controller will reboot with the new address and subnet only if no tasks are running on the controller Connect to i Series Cobra New Sample Application 17221 12 177 2552550 0 Figure 5 2 IP Addresses Detected 4 You can change the IP address and subnet mask in the Desired Address and Desired Subnet fields if needed 5 Click OK The ACE software will ask you to wait for the controller to reboot Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 83 of 142 Chapter 5 Options Setting the Robot IP Address on the PLC Using your PLC software set the IP address for the PLC to connect to on the robot MM alsje 5 ope onn 7 gisis t vier Ala E Pom REESE ES D F RUN gt f OK V BAT amp rw rr A Controller Tags amp Controller Fault Handler 3 Power Up Handler Mo General Connection Module Info 23 Tasks Type 3 8 Main
106. r s Guide User s Guide Rev A Page 13 of 142 Chapter 1 Introduction Figure 1 5 Fixed Platform Stainless Steel Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 14 of 142 Chapter 1 Introduction Platform Clocking The J4 platform which is rotational is constructed such that the clocking or rotational alignment of the platform relative to the robot base is critical This is detailed in Aligning the Platform with the Base on page 27 Platform Shipping e The platform outer arms and theta drive shaft are removed e The platform is shipped assembled as a unit You will need to connect the outer arms between the inner arms and the platform to reassemble the robot The outer arm assemblies are interchangeable For the Hornet 565 robot with the J4 platform you will also have to connect the telescoping drive shaft that connects the platform to the fourth motor on the robot base Any end effectors and their air lines and wiring are user supplied Adept SmartController EX The optional SmartController EX motion controller supports tracking more conveyors as well as other options Like the eAIB the SmartController EX uses the eV operating system It offers scalability and support for IEEE 1394 based digital I O and general motion expansion modules The SmartController EX also includes Fast Ethernet and DeviceNet SmartController EX
107. r s Guide User s Guide Rev A Page 135 of 142 Chapter 8 Environmental Concerns NOTE The optional Adept SmartController must be installed inside a NEMA 1 rated enclosure The rest of this chapter applies to the Hornet 565 robot not to the Adept SmartController The Hornet 565 robot is designed to be compatible with standard cleaning and operational needs for the handling of food products as well as less stringent requirements These design criteria impact how the environment can affect the robot operations as well as how the robot can affect the cleanliness of its operating environment 8 1 Ambient Environment The Hornet 565 robot is designed for the following operating conditions e 1 to 40 C 34 to 104 F ambient temperature At near freezing temperatures moderate robot motions should be used until the robot mechanical joints warm up Adept recommends a monitor speed of 10 or less for 10 minutes The robot system can sustain higher average throughput at lower ambient temperatures and will exhibit reduced average throughput at higher ambient temperatures e Humidity of 5 to 90 non condensing 8 2 Cleanroom Classification The Hornet 565 robot is rated for cleanroom class 1000 Please contact your Adept representative for more information 8 3 Design Factors Environmental and cleaning aspects are addressed by the following features in the Hornet 565 robot e IP 67 rating for the robot platform and outer arms e
108. re backup to software limits on robot speed If the software fails to limit the robot speed during manual operation the hardware Teach Restrict will disable power to the system These two functions are supported by four wizards e E Stop Configuration This sets the E Stop hardware delay to factory specifications e E Stop Verification This verifies that the hardware E Stop is functioning correctly e Teach Restrict Configuration This sets the hardware Teach Restrict maximum speed to factory specifications e Teach Restrict Verification This verifies that the hardware Teach Restrict is functioning correctly The initial utility screen will tell you which functions are commissioned If a function is not commissioned its verification wizard will not be displayed Any displayed verification wizard can be run at any time to ensure that its function is working properly Prerequisites e The robot must be set up and functional e Adept ACE software must be installed e If using an Adept Front Panel the keyswitch must be in Auto mode Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 117 of 142 Chapter 6 Maintenance AX Keyswitch in Auto mode Figure 6 15 Adept Front Panel e No E Stops can be activated e For Configuration E Stop and Teach Restrict the eAIB Commissioning Jumper must be plugged into the XBELTIO jack on the eAIB NOTE This is the onl
109. rmany Adept ACE Adept ePLC Connect Adept Hornet 565 Adept SmartController EX Adept SmartVision MX Adept T20 eAIB IO Blox and eV are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Created in the United States of America Table of Contents Chapter 1 Introduction osse 11 11 Adept Hornet 565 Robots Product Description usiuuuuusuuuuuuussuuussse 11 AdepteAIB Amplifier 1 222 cclcusocsielli ui ds lle se S uderco EEEa aasre ES ETa a SE Eeer SEET aei 12 Adept Hornet 565 Robot Base ocsonetoseccdacd ee enc umo oei paie peta aeaaee eiea Aone 12 Inner Arm 2 ciem eren ea a a ecu leh a a a e gal 13 Ball Joints Outer Arms 2 200 3 0 cae Fleece ee e IR ee See me oc a opu 13 d raras au So geese EE E EET ROTEN ITI 13 Adept 5martController M EX LI dekh seek ee iececdkusddc nite dd ean iar Recent 15 12 Warnings Cautions and Notes in Manual 2 2 2 2020c0ceeee cece ec eceeeeeeeeeees 15 1 3 Safety Precautions 2 2 252kec ee cocieei ects cse luseAu ape Ln sRc a honk ec SI Ino LIS alee ete 16 1 4 What to Do in an Emergency eiie iiinnecuu ci 5 oEc ei cibd Aree noo Sacer cee netoee 17 15 Additional Safety Information 1 ccnceccesessetuconiliciubesoliBe eet lo0liackiicc eddie 17 1 6 Intended Use of the Robots lisible Iedce s segue he 3g ckcP Ga elg 17 1 7 Installation Overvie
110. robot using the Robot Jog Control in the Adept ACE software For details see the Adept ACE User s Guide 4 8 Robot Motions Straight line Motion Joint interpolated motion is not possible with the Hornet 565 robot because the positions of all the joints must always be coordinated in order to maintain the connections to the moving platform Therefore for the Hornet 565 robot the eV system automatically performs a straight line motion when a joint interpolated motion instruction is encountered Containment Obstacles The work space of the robot is defined by an inclusion obstacle This is done because unlike other robots joint limits are not meaningful in defining the work space The eV software defines a cone like shape as a containment obstacle This is actually the work envelope See Work Envelope Side View on page 124 and Technical Specifications on page 123 Other obstacles can be defined within this obstacle 4 9 Learning to Program the Adept Hornet 565 Robot To learn how to use and program the robot see the Adept ACE User s Guide which provides information on robot configuration control and programming through the Adept ACE software point and click user interface For eV programming information refer to the eV user and reference guides in the Adept Document Library ADL on the Adept website For more details on the ADL see Adept Document Library on page 19 Adept Hornet 565 Robot User s Guide User s Guide Rev
111. rotect 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 Adept Robot Safety Guide for a discussion of safety issues Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 53 of 142 Chapter 3 System Installation Refer to the Adept SmartController EX User s Guide for information on connecting safety equipment into the system through the XUSR connector on the optional SmartController There is a detailed section on Emergency Stop Circuits and diagrams on recommended E Stop configurations The user supplied safety and power control equipment connects to the system through the XUSR and XFP connectors either on the eAIB XSYSTEM cable or the optional SmartController EX The XUSR connector 25 pin and XFP 15 pin connector are both female D sub connectors Refer to the following table for the XUSR pin out descriptions See Table 3 7 for the XFP pin out descriptions See the figure E Stop Circuit on XUSR and XFP Connectors on page 57 for the XUSR wiring diagram Table 3 6 Contacts Provided by the XUSR Connector MEE A XNEEMNMSg Voltage Free Contacts Provided by Customer 1 14 User E Stop CH 1 mushroom push N C contacts Shorted if NOT Used button safety gates etc 2 15 User E Stop CH 2 same as pins N C contacts Shorted if NOT Used 1 14 3 16 Line E Stop
112. s To check the J1 and J2 gear drives 1 Remove all power to the robot before starting this check Lock out and tag out AC power 2 Wait for the motors to cool before performing this check Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 98 of 142 Chapter 6 Maintenance WARNING Do not remove the encoder cable connectors from their sockets on the motors If they are removed the calibration data will be lost requiring factory recalibration 3 Remove the eAIB See Replacing the eAIB Chassis on page 112 You do not need to disconnect the cables to the eAIB 4 Check for oil inside the base of the robot e Look through the venting slots under each motor for oil leakage e Feel the bottom of the motors with your finger through the venting slots 5 Check the outside of the motors and gear drives for any signs of oil 6 Contact Adept if you find any signs of oil in these areas If you aren t going to check the operation of the motor fans 7 Re install the eAIB See Installing a New eAIB Chassis on page 116 To check the J3 gear drive 1 Remove the four M4 hex head bolts holding the Status Display panel e Retain the bolts for re installation These bolts were installed with Loctite 222 2 Remove but do not disconnect the Status Display panel Retain the Status Display panel and gasket for re installation 3 Check the outside of the motor and gear drive for any sign of oil 4 Re install the Status Display
113. s take care not to trap debris between the ball studs and their sockets NOTE The procedure for attaching outer arms is the same for both platforms 1 Attach one pair of outer arms to each inner arm a As illustrated in the following figure the outer arm assembly is most easily achieved by pivoting the two arms away from each other lengthwise This requires the least stretching of the spring to attach the ball joints b Slip one ball joint socket over the corresponding ball stud c Swing the bottom end of the outer arm pair sideways as you slip the other ball joint socket over the corresponding ball stud CAUTION Do not overstretch the outer arm springs Separate the ball joint sockets only enough to fit them over the ball studs Figure 2 8 Installing Ball Joints Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 30 of 142 Chapter 2 Robot Installation 2 Attach one pair of outer arms to each of the three pairs of ball studs on the platform a Swing the bottom end of the outer arm pair to the right as far as possible b Slip the right ball joint socket over the right ball stud Move the platform as needed to do this c Move the platform and outer arm pair to the left as you slip the left ball joint socket over the corresponding ball stud 3 Ensure that all spring hooks are fully seated in the grooves of the horseshoes as shown in the following figure Lb E E EE EE EE EE GG UU Figure
114. s option The XIO Breakout cable is for using the I O on the eAIB See XIO Breakout Cable on page 74 Cables for adding belt encoders are covered in System Cables for Systems with Belt Encoders on page 42 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 38 of 142 Chapter 3 System Installation 3 2 System Cables with SmartController EX When the optional SmartController EX is included in the system the Pendant Front Panel and XUSR connections if used must connect to the SmartController EX Adept SmartVision MX option T20 Adapter Ground Wire Gable e Bb n1 E s i T20 eres E Pendant T20 Bypass option User supplied Camera option I Adept SmartContyoller EX option t dew NB C P Jumper 5 Plug Opal 1 e ies 10 ies s Either T20 Pendant User Supplied jo S twee ee 29 T20 Bypass Plug or Ground Wire e XMCP Jumper Plug must be used XUSR for Eid User E Stop Safety Gate Muted Safety Gate Jumper plug required when not used XUSR Jumper Plug User supplied witch option Front Panel option User Supplied Ethernet to Either Front Panel or Ground Wire SmartController EX FP plug must be used eAIB Optional User supplied PLC xsYs DCP ower Q Cable Cable R from Controller XSYS Port M Ethernet from A Robot Interface Panel PC to PLC Switch or
115. s screw is captured on the chassis heat sink Figure 6 11 Securing Screw on eAIB Chassis 9 Carefully and slowly lift the chassis up see the following figure so that enough access is available to remove the internal cables The chassis can be laid flat on its cooling fins CAUTION The eAIB can damage the O ring that seals it if you are not careful Ensure that nothing scrapes against the O ring Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 113 of 142 Chapter 6 Maintenance Figure 6 12 Opening Chassis 10 Disconnect the white amplifier cable from the amplifier connector located on the chassis bracket See the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 114 of 142 Chapter 6 Maintenance ESTNE TIT T reer DEN Amplifier B NN Connector ec Figure 6 13 Connectors on Chassis and ePMAI Board 11 Carefully disconnect the INT1 INT2 ENC1 and ENC2 cables from their connectors on the ePMAI board by disengaging the securing latches 12 Using a 5 mm hex wrench disconnect and remove the ground wire from the chassis Keep the screw for reassembly later See the following figures PN 19800 000 ian Figure 6 14 Ground Screw Hole on eAIB Chassis Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 115 of 142 13 Chapter 6 Maintenance Tag the chassis with the appropriate fault diagnosis faults errors and robot serial number i
116. s 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 e 12 Inputs signals 1097 to 1108 e 8 Outputs signals 0097 to 0104 Brake Release and LED Light Table 4 6 XIO Signal Designations Inputs Pin Locations Designation GND 24 VDC Common 1 Input 1 1 Input 2 1 i Pin9 Pin 26 Input 3 1 AT v Input 4 1 Input 5 1 I 5 A OO0O00O0000 Input 6 1 GND 24 VDC A COO0O00O 00 0 oo0o0000000 11 1 N Common 2 Pin 19 i 13 14 Input 2 2 XIO 26 pin female Input 32 connector on Robot Interface Panel 15 16 Input 42 17 18 Input 52 Pin No E s C jo ae NE ra La NE Ae La He Input 6 2 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 69 of 142 Chapter 4 System Operation Table 4 7 XIO Signal Designations Outputs Pin Locations Optional I O Products These optional products are also available for use with digital I O e XIO Breakout Cable 5 meters long with flying leads on user s end See XIO Breakout Cable on page 74 for information This cable is not compatible with the XIO Termination Block e 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 Adept XIO Termination Block Installation Guide for details XIO I
117. sc EEEa ie SES aesa Tps 25 Install Mounting Hardware e etcdilbqonnl t cece ecoeaadangacdesesehelsstehedSecuaaedcscceanentet ee 26 27 Attaching the Outer Arms Platform and Theta Drive Shaft 2 22220202000 27 Aligning the Platform with the Base 2 22222222 cceee cece cece ee eee Ie ee eeeeeeeeeeeeeeees 27 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 5 of 142 Table of Contents Attaching the Outer Arms 222 2222222 cecee eee ee eee cece eee e eee cece eeee eee e 3323322 222122222222 28 Attaching the Theta Drive Shaft 05 022 oe ees sectoral ide eb irre ah eid sce sh EE endar dil aig 31 2 8 End Effectors 2000 22 ccc cece cece ccc cece cece cece eee e cece eee eee eeeeeeeeeeeeeeeeeeeeeeeees 33 Attaching an End Effector 0 022222222 ce cece cece ee eee eee cece eee eee e cler eeeeeeeeeeeeeeeeees 33 Aligning an Bnd BEHector ucc aces cnnnnhonedetgannsceteuastenede see oea E A ESSEER AEE 33 Grounding AMET 33 Accessing Vacuum 22 52 2 ouenlccocceuedu e a a onde cee ee hee steed ced g pU eee pene ceed 33 Routing End effector Lines 2 2 22 222222 ceeee cece eee cece e cence eee eee eee ee eee eeeeeeeeeeeeeeeeseees 34 Chapter 3 System Installation sss 35 3 1 System Cables eAIB Only no SmartController EX ututuuuuuuuuuuuuuuu 35 List of Cables and Parts 2 22 2 2 cece cee cece eee eee cece cece eee cece
118. t Panel control panel to the controller using the 15 pin XFP connector The Front Panel contains no active components only switches and lights Customers should be able to adapt the Front Panel s functionality into their own Front Panel design To automatically control the Front Panel s signals use relay contacts instead of switches See the figure Front Panel Schematic on page 58 for a schematic drawing of the Front Panel and see the table System Installation on page 35 for a summary of connections and pin numbers NOTE The system was evaluated by Underwriters Laboratory with an Adept Front Panel If you provide a substitute front panel the system may no longer be UL compliant Customers can build an extension cable to place the optional Adept Front Panel in a remote location The extension cable must conform to the following specifications e Wire Size must be larger than 26 AWG e Connectors must be 15 pin standard D sub male and female e Maximum cable length is 10 meters Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 61 of 142 Chapter 3 System Installation 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 s
119. t maximum speed control is working This is a two part wizard The first is run in Auto mode The second is run in Manual mode Before running this verification utility the Teach Restrict must be configured NOTE If the commissioning jumper is plugged into the XBELTIO jack on the eAIB remove it before you start this procedure Automatic Mode Procedure WARNING The robot will move during this wizard Ensure that personnel stay clear of the robot work area From within the Adept ACE software 1 2 3 Open the robot object editor Select Configure Safety Settings Verify Teach Restrict then click Next Teach a Start Position This can be any position that does not conflict with obstacles or the limits of joint movements e If the robot is already in such a position you can just click Next e Otherwise move the robot to such a position then click Next e The screen will display the number of degrees that each joint is expected to move during the verification process You can click Preview Motions on this screen to view the motions at slow speed Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 120 of 142 Chapter 6 Maintenance The default speed is 10 but you can change that speed with this screen s speed control e You can click Move to Ready to move the robot to the Ready position The robot will move each joint in succession It will generate an over speed condition for each and ver
120. to Robot cilii seo eke ee d dS eUE 46 Specifications for 24 VDC Robot and Controller Power LLsuuiuuiuuuulllllllllssssllllllsese 46 Details for 24 VDC Mating Connector 2 222222222222 e eee cece e cee eee eee eee eee eee e e rr n ni 47 Procedure for Creating 24 VDC Cable 022222200 cece cnet e eee e eee eee eeeeeeeeeeeeeeees 47 Installing 24 VDC Robot Cable clt RI ew sche ieee a se Qr ee doe eee 48 37 Connecting 200 240 VAC Power to Robot 12 2 do vencdede tesa iesstetstccebecedecievevnne 49 Specifications for AC Power 20 222222 e cece cece eee eee cece eee ess eee eeee sees eeeeeeeeeeeeeeeeees 49 Details for AC Mating Connector 2 0 2eees eiegeebeed seen Senden pede sesaeoncsbeseugne Wilt Seaeas tice sex 51 Procedure for Creating 200 240 VAC Cable 222222 cece cece cece eee eee eee eee es 51 Installing AC Power Cable to Robot 2 222222 2 ec cece eee eee cence eee eee ee lcs sn nnn nnl 52 3 8 Grounding the Adept Robot System 2 200 0 25c 22eseu dese cee a eset eee ee 52 Grounding Robot Mounted Equipment 222222222eecee cece cece ee cence ee s n nnn lll 52 Grounding Robot Base to Frame 2222222eeeeee cece eee cece c eee eee eee ceee eee eeeeeeeeeeeeeeeeeeees 53 3 9 Installing User Supplied Safety Equipment 0 20 0 2020 cece eee e ese eeee ee ees 53 Emergency Stop Circuits sesew set nce see eee eee essed est Eee eg
121. tor and splits it into two XSYS connectors This is part number 00411 000 See the Dual Robot Configuration Guide 3 3 System Cables for Systems with Belt Encoders XUSR for User E Stop Safety Gate Muted Safety Gate gt The Jumper Plug is required if neither of these is used i Od XUSR Jumper Plug XUSR Front Panel either Front Panel or User Supplied FP plug must be used FP Jumper Plug Ground Wire T20 Adapter Cable ammu u 1 amp T20 Bypass Plug XMCP Jumper Plug Either T20 Pendant T20 Bypass Plug or XMCP Jumper Plug must be used T20 Pendant option 24VDC 6A Power Supply DC Power 85 264 VAC Universal Input 200 240 VAC 10A single phase AC Power Cable to Belt Encoder 1 Bill Belt Y Splitter L Bet amp P XBELTIO Belt Force RS232 K Ap E Force EXPIO to Belt Encoder 2 Ethernet Ethernet to eAIB User Supplied PC from EG running Adept ACE Software Figure 3 3 System Cable Diagram with Belt Encoder Cables Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 42 of 142 Chapter 3 System Installation List of Cables and Parts Open the Accessory box and locate the eAIB XSYSTEM cable Connect the c
122. tputs 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 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 72 of 142 Chapter 4 System Operation 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 a direct connection to the XIO connector see XIO Signal Designations Inputs on page 69 or through the optional XIO Termination Block See the documentation supplied with the Termination Block for details XIO Output Specifications Table 4 9 XIO Output Circuit Specifications meme ae Power supply voltage range See System Installation on page 35 Operational current range D ui 700 mA per channel Total Current Limitation I 1 0 A e 40 C ambient total all channels on I 15 A 25 C ambient total ON state resistance I 0 5 A R x 0 32 Q 85 C out on I lt out Output leakage current 25 uA Turn on response time 125 usec max 80 usec typical hardware o
123. troller EX and sDIO products Adept SmartVision MX User s Instructions for use of the optional Adept SmartVision MX Guide industrial PC Adept ePLC Connect 3 User s_ Describes the installation and use of the Adept ePLC Connect Guide 3 software for using a user supplied PLC as controller Adept IO Blox User s Guide Describes the IO Blox product Adept Dual Robot Contains cable diagrams and configuration procedures for a Configuration Procedure dual robot system Adept Document Library The Adept Document Library ADL contains documentation for Adept products You can access the ADL from the Adept website Select Support Document Library from the Adept home page To go directly to the Adept Document Library type the following URL into your browser http www adept com Main KE DATA adept_search htm To locate information on a specific topic use the Document Library search engine on the ADL main page or select one of the available menu options To view a list of available product documentation use the menu links located above the search field Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 19 of 142 Chapter 2 Robot Installation 2 1 Transport and Storage This equipment must be shipped and stored within the range 10 to 60 C 14 to 140 F Humidity should be less than 75 non condensing The robot should be shipped and stored in the Adept supplied crate which is designed to prevent
124. tted to the platform through the outer arms which are connected between the inner arms and platform with precision ball joints The outer arms are carbon fiber epoxied assemblies with identical ball joint sockets at each end A bearing insert in each socket accepts the ball joint studs on the inner arms and platform and allows for approximately 60 of relative motion No ball joint lubrication is required Ball Joint Socket Insert e lt Pressed Pin NIN Ball Joint Outer Arm Springs h Socket Horseshoe Outer Arms gt Figure 1 3 Ball Joint Assembly Each pair of outer arms is held together with spring assemblies that pre tension the ball joints The outer arms can be installed and removed without tools Platforms The platform converts the motion of the Hornet 565 robot motors into Cartesian motion and for the four motor version theta rotation of the robot tool flange The fixed platform with no theta rotation is stainless steel The J4 platform has a fourth motor theta drive shaft and geared J4 platform that can rotate its tool flange 360 The platform is electroless nickel plated aluminum Both platforms have a 38 mm hole through their center for users to route air lines or electric cables to the tool flange For the J4 version of the Hornet 565 robot a stainless steel theta drive shaft attaches to a U joint at both the platform and the J4 motor on the robot Adept Hornet 565 Robot Use
125. ttery pack would need to be replaced every 10 years Battery Replacement Procedure 1 Obtain the replacement battery pack 2 Switch off the optional SmartController EX if one is being used 3 Switch off the 24 VDC input supply to the robot 4 Switch off the 200 240 VAC input supply to the robot 5 Disconnect the 24 VDC supply cable from the robot 24 VDC input connector See Robot Interface Panel on page 45 for locations of connectors 6 Disconnect the 200 240 VAC supply cable from the robot AC input connector 7 Switch off and disconnect any other power supplies connected to the robot 8 Remove the four M4 hex head bolts holding the Status Display panel e Retain the bolts for re installation e These bolts were installed with Loctite 222 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 103 of 142 Chapter 6 Maintenance Figure 6 2 Status Display Panel Face 9 Remove but do not disconnect the Status Display panel Retain the Status Display panel and gasket for re installation NOTE The battery pack is supported in a bracket that is attached to the back side of the Status Display panel with stand offs The battery pack is exposed when the Status Display panel is removed 10 The battery bracket assembly has two battery connectors Locate the unused battery connector on the battery bracket See the following figure CAUTION If battery power is removed from the robot factory calibration data may be
126. urrs and sharp edges Dimensions apply after process Interpret drawings per ANSI Y14 5 Dimensions are in mm in Tolerances mm in o place decimals 22 5 0 090 o 2 place decimals 1 5 0 060 o 8 place decimals 0 75 0 030 Angular dimensions 0 5 Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 130 of 142 Chapter 7 Technical Specifications All Structural 57 amp Members All Structural Members All Structural Members All Structural Members All Structural gt g Members Figure 7 7 Mounting Frame Orthogonal View Refer to the following table for item descriptions End Cap 5 20 Thick See detail Mounting Bracket 1 See detail Mounting Bracket 2 See detail Mounting Bracket 3 See detail Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 131 of 142 Chapter 7 Technical Specifications LL 850 5 13 80 3x 135 7 5 34 Sections shown in next figure Figure 7 8 Mounting Frame Side View 1 Sections A B C and D are shown in the following figure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 132 of 142 Chapter 7 Technical Specifications All Mounting gr 2 i Brackets ii 3xO15 i
127. utomatic Closed 6 14 Remote High Power on off momentary User must supply momentary push push button button to enable High Power to system Non voltage Free Contacts Adept Supplied 5 VDC and GND for User must supply lamp or use 1 W High Power On Off Switch Lamp 47 ohm resistor system will not operate if not present D15 Controller system 5 V power on LED 5 Optional indicator only V 20 mA See the figure Front Panel Schematic on page 58 for a schematic diagram of the Adept 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 an Adept Front Panel If you provide a substitute front panel this could void UL compliance Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 55 of 142 Chapter 3 System Installation Table 3 8 Remote Pendant Connections on the XMCP Connector 15 Pin D Sub Pendant TXD eV to Pendant TXD Pendant RXD eV to Pendant RXD No connection Shield Shield GND 24 V No connection No connection The following figure shows an E Stop diagram for the system See System Installation on page 35 for a description of the functionality of this circuit Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 56 of 142 Chapter 3 System Installation ESTOP 24 V Source XSySTEM 31 XSYSTEM 32 XFP 1 XFP 2
128. w 2 2220 222 2062 c522s5skioccbitlente as c0 ie RES eI00R2iI8 S oe aeg Daarna nnana 17 1 8 Manufacturer s Declaration oc cas okies odes asso sese esee opto desee dpbras coti Ep veh based d ene E Reap EUN 18 L9 How Can Get Help ETUR 18 Relace Manias NR a a e E ee ee eee eA 18 Adept Document Library ssssssssssslslllllslll sss sss esses ele el ll tlf lfItI23323 19 Chapter 2 Robot Installation ossssesssesuseuseees 21 2 1 Transport and Storage 3 aeocceacetonae ces Mida datae el doeser edu etu Deuda ttr Lie 21 22 Unpacking and Inspecting the Adept Equipment 2 2 020 222eeeeeeeeeeeeeeeee 21 Before Unpacking 5 etos us ipi Se et ab edad eee ele ee et BG inei edes 21 Upon Unpacking AM 21 Unpacking sserrep a teed feu haa 21 2 3 Repacking for Relocation Saco ctuscsvesncasncaetideee datas asseetenesac sau adesastecteaasenreaetindas 23 24 Environmental and Facility Requirements 2 22 2 lt 142seesec024e40see0ccd2eeesa lt ec0casne 23 225 Mounting Frame ts eset it diese Sed does teo hoses ep ddddeesdvedeccd 23 Robot to Frame Considerations 002222eeeeeeeeee ee eee eee cece eee e neces IIl e n em Ir 24 IMIGUMEIN PER ERN 24 2 6 Mounting the Robot Base Loue desc ees nested seat odas EA EREE EIE a 25 Robot Orientation RR L te do ed te ae he eee E aa a aa Ee 25 Mo nting Surfaces 2 2 ossi ediino ai e 25 Mounting Procedur 2 2222 2222 22 cece cece cece esses sone ce canes
129. ween the Procedure for Creating 24 VDC Cable robot and the user supplied 24 VDC power supply on page 47 Create a 200 240 VAC cable and connect it between Connecting 200 240 V AC Power to Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 17 of 142 Chapter 1 Introduction Task to be Performed Reference Location the robot and the facility AC power source Robot on page 49 Install user supplied safety barriers in the workcell Installing User Supplied Safety Equipment on page 53 Connect digital I O through the robot XIO connector Using Digital I O on eAIB XIO Connector on page 69 Start the system including system operation testing Starting the System for the First Time on page 76 Install optional equipment including end effectors Options on page 81 user air and electrical lines external equipment etc 1 8 Manufacturer s Declaration The Manufacturer s Declaration of Incorporation and Conformity for Adept robot systems can be found on the Adept website in the Download Center of the Support section http www adept com support downloads file search NOTE The Download Center requires that you are logged in for access If you are not logged in you will be redirected to the Adept website Login page 1 From the Download Types drop down list select Manufacturer Declarations 2 From the Product drop down list select Adept Hornet Robots category 3 Click Begin Search The list of availabl
130. x2 IEEE 1394 for connecting the IEEE 1394 cable from the robot to a controller The other robot connector can be used to connect to a second robot or another 1394 based motion axis XSYSTEM This requires either the eAIB XSYSTEM three headed cable XFP XMCP and XUSR or an eAIB XSYS cable if connecting to a SmartController EX Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 45 of 142 Chapter 3 System Installation ENET Two Ethernet ports are available One will be needed to connect to a PC running Adept ACE software 3 6 Connecting 24 VDC Power to Robot Specifications for 24 VDC Robot and Controller Power Table 3 1 VDC User Supplied Power Supply User Supplied Power Supply 24 VDC 10 150 W 6 A 21 6 V lt V 264 V Circuit Protection Output must be 300 W peak or 8 Amp in line fuse Power Cabling 1 5 1 85 mm 16 14 AWG Shield Termination Braided shield connected to ground at both ends of cable See User Supplied 24 VDC Cable on page 48 User supplied 24 VDC power supply must incorporate overload protection to limit peak power to less than 300 W or an 8 A in line fuse must be added to the 24 VDC power source In case of multiple robots on a common 24 VDC supply each robot must be fused individually NOTE Fuse information is located on the eAIB electronics The requirements for the user supplied power supply will vary depending on the configuration of the robot and con
131. y time that this jumper will be used It is part number 11901 000 and must be removed for Verification and normal operation Figure 6 16 eAIB Commissioning Jumper e An Adept pendant is required for the Teach Restrict verification E Stop Configuration Utility This utility sets the E Stop hardware delay to factory specifications NOTE Ensure that the commissioning jumper is plugged into the XBELTIO jack on the eAIB before you start this procedure Adept Hornet 565 Robot User s Guide User s Guide Rev A Page 118 of 142 Chapter 6 Maintenance Procedure From within the Adept ACE software 1 Open the robot object editor 2 Select Configure Safety Settings Configure ESTOP Hardware Delay then click Next This procedure will configure Channel A and then Channel B It will then report the delay that it set for each 3 Reboot the eAIB 4 f you are using an optional SmartController EX reboot it On some systems the SmartController EX will reboot automatically E Stop Verification Utility This utility verifies that the hardware E Stop parameters are set correctly and that the hardware E Stop is working The hardware E Stop must have already been configured for this wizard to run NOTE If the commissioning jumper is plugged into the XBELTIO jack on the eAIB remove it before you start this procedure Procedure From within the Adept ACE software 1 Open the robot object editor 2 Select Configure Saf

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