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Adept 1850/1850XP Palletizer Robot User`s Guide

1. Alarm Corrective Display name Operating status Cause measure Overload If the code comes on Faulty PC board Replace the servo when system power amplifier is turned on but before the program is started If the code comes on The motor is Review the load while the motor isin operated over the operation rated torque The holding Ensure that the brake is not brake releases released when the amps are enabled The code comes on Wire broken ina Repair the after the motor is phase of the wiring operated for a while motor main The motor revolves circuit wire but delivers less than the rated torque Comes on even Faulty PC board Replace the servo though the motor is amplifier operating below the rated torque Amplifier If the code comes on Faulty Replace the servo overheating when system power temperature amplifier is turned on but sensor PC board before the program is started Comes on while the The ambient Lower the motor is in operation temperature of temperature the servo below 55 C amplifier exceeds 55 C Heat generation Replace the servo due to a servo amplifier amplifier fault Adept 1850 1850XP Palletizer Robot User s Guide Rev A 53 Chapter 5 Operation Table 5 3 Amplifier Fault Alarm Codes Continued Alarm Corrective Display name Operating status Cause meas
2. Lubrication marks Grease fitting HE Plugs gt Figure 6 7 1850XP Linear Guides Move the Z axis to align the lubrication marks on the column with the marks on the robot arm as shown in Figure 6 7 Switch off the power Remove the upper and lower rubber plugs from both the left and right faces of the robot to expose the grease fittings If the robot has only one opening on each side move the Z axis until it aligns with the top mark first then the lower mark sec ond Inject grease into the four grease fittings using the grease gun Reinsert the rubber plugs Switch on the power and move the Z axis up and down several times to distribute the grease on the guides Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance Lubricating 1850XP J oints 1 2 and 4 Lubricate the Joint 1 A axis Joint 2 B axis and Joint 4 W axis every two years Grease Optimol Longtime PD O Nihon Parkarising See Table 6 6 for acceptable equivalent Tools Grease gun 5 mm hex wrench Allen wrench Grease fitting for aie Upper cover M5 x 12L 11pcs x JE Grease fitting for j B axis gear x EM Grease fitting for W axis gear Fi Figure 6 8 1850XP J oint 1 2 and 4 Grease Fittings
3. Figure 2 4 1850 and 1850XP Arm Motion Envelope CAUTION The range of robot arm motion overlaps the position of the Z axis column Therefore it is possible for the robot arm to strike the Z axis column It is the User s responsibility to program robot motion to prevent the robot arm from striking the Z axis column One way to prevent the robot arm from striking the Z axis column is to define new soft stops for Joint 1 and or Joint 2 In this case and any other time it becomes necessary to limit the travel of one or more of the joints within the normal working envelope define new softstops using the SPEC utility program formerly CONFIG_R supplied with the system Refer to the V 11 x Release Notes and the Instructions for Adept Utility Programs 14 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Performance Specifications 2 3 RobotPerformance Specifications Table 2 1 lists the performance specifications for the Adept 1850 Palletizer Robot Table 2 2 lists the performance specifications for the Adept 1850XP Palletizer Robot All specifica tions are subject to change without notice Table 2 1 Adept 1850 Robot Performance Specifications Reach Maximum radial 1 850 mm 72 8 in Minimum radial 500 mm 19 7 in Vertical clearance bottom of base to end effector flange 522 mm 20 6 in Vertical Stroke Z direct
4. Sensor error If the code comes on when system power is turned on but before the program is started Faulty motor encoder Faulty servo Replace the motor Replace the Comes on after the motor moves slightly amplifier servo amplifier Absoluteencoder Check the wiring serial and encoder communication power supply error Faulty motor Replace the encoder sensor Absoluteencoder Check the wiring serial and encoder communication power supply error Adept 1850 1850XP Palletizer Robot User s Guide Rev A 55 Chapter 5 Operation Table 5 3 Amplifier Fault Alarm Codes Continued Alarm Corrective Display name Operating status Cause measure Main power If the code comes on Faulty PC board Replace the servo supply drop when system power amplifier is turned on but before the program is started Comes on after the The power Bring the power main power supply is supply voltage is supply voltage turned on too low within specs The rectifier is Replace the servo broken amplifier Comes on while the Input power Bring the power motor is in operation supply variation supply voltage too large within specs Faulty PC board Replace the servo amplifier Phase If the code comes on Faulty PC board Replace the servo missing when system power amplifier from the is turned on but main power bef
5. 1 Move the Z axis down to bring the robot arm to a convenient working height Switch off the power 2 Remove the screws securing the Joint 2 upper cover Remove the cover to expose the Joint 2 grease fitting 3 Using the grease gun inject grease into the Joint 1 Joint 2 and Joint 4 grease fit tings shown in Figure 6 8 4 Reinstall the Joint 2 upper cover 5 Switch on the power and exercise Joint 1 Joint 2 and Joint 4 several times to dis tribute the grease in the joints Adept 1850 1850XP Palletizer Robot User s Guide Rev A 75 Chapter 6 Maintenance Inspecting the 1850XP J oint 3 Belt Inspect the Joint 3 Z axis belt every six months Tools 4 5 6 and 8 mm hex wrenches Allen wrenches 19 mm open end wrench Push pull gauge Scale Push pull gauge S Detection Bar HE 0 MT a 6 M6 x 12L 2 M6 x 25L 4 M8 x 12L y 7 M10x35L 8 M5 x 10L Figure 6 9 1850XP J oint 3 Belt Access 8 M10 x 100L 1 Move the Z axis down to the lower end of the envelope Switch off the power 2 Remove the M6 x 25L bolts holding the bellows in place and pull down the bel lows 3 Remove the M5 x10L bolts holding the top cover in place and remove the top
6. 5 Softstops description 47 specifications 48 U Unpacking and inspection 27 xcix Chapter cce adept technology inc 150 Rose Orchard Way San J ose CA 95134 00764 00030 Rev A 408 432 0888
7. 10 Contact Adept Technology or your service provider for encoder recalibration 1850 Encoder Battery Layout Z B Z B A A Ww i Battery Connectors Battery Assemblies 1850XP Encoder Battery Layout Battery Assemblies Battery Connectors Figure 6 14 1850 and 1850XP Enc oder Battery Panel and Connectors Adept 1850 1850XP Palletizer Robot User s Guide Rev A 83 Dimension Drawings A 1 RobotDimensions zsumnnuunnuu nn nun nun nn nn nn nn nn nn nn nn nun 86 A 2 Control Unit Dimensions sunnunummnun nun nn nun nn nn nn nn nun nun 90 A 3 Tool Hange DimensionsS 00 ccee eee e eee 91 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 85 Appendix A Dimension Drawings A 1 Robot Dimensions R70 70 850 R115 h 1000 160 R160 1 ua _ 116 5 i 6 d a E 725 e T rta ro Y i 80 20 20 nu 660 All dimensions in mm 380 350 i 7 700 d Figure A 1 1850 Dimensions Top View 86 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Dimensions R97 75 97 75 850 150 R155 d i 240 L 1000 Y 134 40 Y Y 4 i 240 i 800 240 Y 4 240 un Y f 40 All dimensions in mm F
8. 122 2 Se re le ia 44 VME Font Panel VEB sess catas a a ra NR 45 Joint Out of limit Indicators ooooooooccorcr eee eens 49 AMP FAULT RESETand ZAXIS BRAKE RELEASE Buttons 0 51 1850 Chain Lubrication Ports 0 0 cece tee 65 1850 Joint 3 ZAxis RACK een tenes 66 1850 LINC AN GUIDES vio a ee ete ae eee ie 67 1850 J oint 1 2 and 4 Grease FittingS 0 cece eee 68 1850XP Chain Lubrication Ports sasaaa ee 71 1850XP J oint 3 ZAxis Ball Screw 1 rennen nennen 72 1850XP Linear GuldeS u Sve whee ws WR een ye Rae Ses wae ee ee 74 1850XP Joint 1 2 and 4 Grease FittingS 0 eee eee 75 1850XP Joint 3 Belt ACCESS een tenes 76 1850XP 6int 3 Belt Tetis sacos e EXER a ewe Wile a ewe PR a ae 77 1850XP Joint 2 Belt ACCESS teen eens 78 T850XP Joint 2 Belt les vo EP Pee eed LE a eee 79 Encoder Battery Low Indicationson the Amplifier Display 82 1850 and 1850XP Encoder Battery Panel and Connectors 83 1850 Dimensions Top View ssseeee I eh 86 1850XP Dimensions Top View ssseeee m III n 87 Adept 1850 1850XP Palletizer Robot User s Guide Rev A V Table of Contents Figure A 3 Figure A 4 Figure A 5 Figure A 6 Figure A 7 Figure B 1 Table 2 1 Table 2 2 Table 3 1 Table 4 1 Table 5 1 Table 5 2 Table 5 3 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 vi 1850 Dimensions Side View 0 0 20
9. CPU error Turn off the control power supply then turn it on again If the same error occurs again replace the servo amplifier Adept 1850 1850XP Palletizer Robot User s Guide Rev A 59 Maintenance 6 1 Introductioi 2 2212001229 a ee ee 62 Power Settings During Maintenance sssusa 0 cee eee 62 6 2 1850 Periodic MaintenanCe occoocccccc eee 63 1850 Maintenance Schedule 0 cee tee 63 1850 Mounting Bolts 0 cee ete 64 1850 Mounting Plate 0 cect tees 64 Lubricating the 1850Joint3 Chain 0 0 cee eee 65 Lubricating the 1850J oint 3 Rack 0 eee 66 Lubricating the 1850J oint 3 LM Guides 0 0 ee 67 Lubricating 1850Joints 1 2 and 4 anaana anaana 68 6 3 1850XP Periodic Maintenance oocoocooccconcn nun nun 69 1850XP Maintenance Schedule ooooococococorr 69 1850XP Mounting Bolts cubas a ana ee a 70 1850XP Mounting Plate o oococooocorrrrr tte 70 Lubricating the 1850XP Joint 3 Chain llli 71 Lubricating the 1850XP Joint 3 Ball Screw 2 ee 72 Lubricating the 1850XP Joint 3 LM Guide 0 0 eee eee 74 Lubricating 1850XP J oints 1 2 and 4 oooococcocococrr 75 Inspecting the 1850XP J oint 3 Belt 2 cee ee 76 Inspecting the 1850XP J oint 2 Belt luana 0 2 eee 78 6 4 Compatible Lubricant Information oococcccocc nun nun 80 6 5 Replacing the Control UnitAirFil
10. contact is possible during high speed operation The hard stops are designed to withstand large forces without damaging the robot CAUTION The hardstops must not be modified in any way or damage to the robot could occur Table 5 1 1850 and 1850XP Softstop and Hardstop Specs Default Softstop Maximum Softstop Hardstop approximate Joint 1 110 110 116 Joint 2 150 150 155 Joint 3 0 mm and 2 000 mm 0 mm and 2 000 mm 60 mm and 2 060 mm Joint 4 180 360 N A no hardstops 48 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Joint Out Of Limits 5 6 Joint Out Of Limits If any joint moves beyond a softstop but does not trip a limit switch the robot stops immediately The program cannot resume until the joint is moved back within limits You can move the joint back within limits by using the manual con trol pendant MCP e If Joint 1 or 2 trips a limit switch or if high power will not enable you must move the joint back within limits manually before you can enable high power e If Joint 3 trips a limit switch the Z brake must be released and then the joint must be moved back within limits manually When any joint softstop is exceeded or joint limit switch is activated the Adept MV con troller automatically shuts off High Power and applies the Z axis brake The joint that has gone out of limits is indicated by a lighted fault light on the motion board VMI of the A
11. robot joint 1 1100 9 E i 1100 i i 1250 layer 4 ES i 1000 layer 3 b 750 layer 2 E 500 E es 4 layer 1 ES ED yi on t 250 Pallet Conveyor 500 Figure B 1 1850 1850XP Palletizer Robot Performance Simulation Adept 1850 1850XP Palletizer Robot User s Guide Rev A 95 Adept User s Manual Comment Form We have provided this form to allow you to make comments about this manual to point out any mistakes you may find or to offer suggestions about information you want to see added to the manual We review and revise user s manuals on a regular basis and any comments or feedback you send us will be given serious consideration Thank you for your input NAME DATE COMPANY ADDRESS PHONE MANUAL TITLE PART NUMBER and REV level COMMENTS Adept 1850 1850XP Palletizer Robot User s Guide Rev A 97 Index A Air supply to quill 40 B Brake release button 51 Brakes releasing for manual movement 51 H Hardstops description 48 specifications 48 J Joint motion Joint 4 13 L Lefty configuration 13 limit switch 48 Limiting joint travel hardstops 48 softstops 47 M Maintenance schedule 62 63 69 77 79 Modifications acceptable 6 unacceptable 6 R Righty configuration 13 Robot joint locations 10 S Safety
12. 5 The next step is to run the calibration routine according to the instructions in the next section Adept 1850 1850XP Palletizer Robot User s Guide Rev A 45 Chapter 5 Operation 5 3 Calibration 46 Introduction The Adept 1850 and 1850XP Palletizers use absolute encoders on each joint These encod ers function as standard incremental encoders during normal operation of the robot but during calibration they may be queried for their absolute position This feature allows the robot to bypass the traditional homing methods used by most Adept robot systems The absolute encoders use on board electronics that track the encoder count even when controller power is turned off When controller power is not on the encoders are powered by batteries located in the base of the robot When the controller is first booted the encoder count is read and then used to set the position of each joint The interface between the encoders and the Adept MV controller is a Robot Signature Card RSC located in the base of the robot The RSC provides two primary functions it communicates directly to the encoders and passes the joint positions back to the control ler and it holds calibration and robot identification data in an EEPROM Calibration Procedure V Version 11 1 Calibrate an 1850 1850XP Palletizer Robot running V version 11 1 by executing a vt pro gram The program file is present in the root directory of the hard drive C and is
13. 88 1850XP Dimensions Side View sslsessesee sh 89 1850 1850XP Control Unit Dimensions lisse 90 1850 Tool Flange Dimensions oococcocco eee 91 1850XP Tool Flange Dimensions oocoocooocorcr tees 92 1850 1850XP Palletizer Robot Performance Simulation 95 List of Tables Adept 1850 Robot Performance SpecificationS o ooooooo 15 Adept 1850XP Robot Performance Specifications oo o 16 Anchorand Mounting Bolt Specificati0nS 0ooooooommoo 23 User Electrical and Air Line Connector Specifications 40 1850 and 1850XP Softstop and Hardstop Specs 0c eee eee 48 Amplifier Status Display l l III 52 Amplifier Fault Alarm Codes 0 00 00 0 cece eere 53 Power Settings During Maintenance 00 cece 62 Recommended 1850 Preventive Maintenance Schedule 63 Recommended 1850XP Preventive Maintenance Schedule 69 1850XP J oint 3 Belt Tension Specifications 00 c eee eee 77 1850XP J oint 2 Belt Tension Specifications 002 c eee eee 79 Compatible Lubne ants uu os irme keen e Hana 80 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Introduction 1 1 How This Manual lsOMganized 0coocococococcn nn nn nnn 2 12 Related ManualS coococcocccc nnn nhanh ana 2 Standard ManualS o ooooocooocorn nen 2 Other Adept Product Manuals 0 000 cette 3
14. Multemp No 1 General Optimol LongTime PD O Nihon Parkarising Compatible products Alvania EP RO Shell Oil Epinoc APO Nippon Oil Cosmo Olpus 100 Cosmo Compatible products Teresso 100 Exxon Panorl 100 General DTE Oil Heavy Mobil Mori Speed Grease No 2 Sumitomo Compatible products Beacon Q2 Exxon MobilPlex Special Mobil Diamond Multi Purpose Grease M Misubishi 80 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Replacing the Control Unit Air Filters 6 5 Replacing the Contol Unit Air Filters The 1850 1850XP Control Unit has air filters on the MV Controller and on the rear door of the cabinet that should be inspected regularly and cleaned at the first sign of dust or dirt buildup The inspection schedule depends on the conditions that the controller experi ences MV Contoller Air Filter s The MV 8 Controller uses one filter and the MV 19 uses two The air filter s are located behind the grill panel below the controller modules For instructions See the Fan Filter Inspection and Cleaning section in the Adept MV Controller User s Guide Contol Unit Rear Door Air Filters The air supply to the 1850 1850XP Control Unit is filtered through two air filters located behind the upper and lower grills on the rear door of the cabinet The inspection and cleaning procedure is the same for both filters 1 Make sure that no program is running then turn off the Control Unit at the SYS TEM POWER switch on t
15. auto loaded into system memory when the control unit is booted The calibration program is contained in a file named CALIB V2 A copy of the program is also located on the operat ing system diskettes in the root directory Execute the calibration program by typing EXECUTE 1 a calib at the V operating system prompt When calibration is complete the monitor displays the dot prompt The system is ready for operation One LED on the front of each Adept MV controller module will also light up The robot can only be calibrated when robot high power is off High power is automati cally disabled when the calibration program is executed After the calibration program has executed robot high power can be enabled and the robot can be moved under pro gram control NOTE The normal V CALIBRATE monitor command is disabled for palletizers running V version 11 1 If this command is executed it will give the error message Robot not calibrated V Version 11 2 and Higher Calibrate an 1850 1850XP Palletizer Robot running V version 11 2 or higher by executing the normal CALIBRATE monitor command Refer to the V Operating System Reference Guide Adept 1850 1850XP Palletizer Robot User s Guide Rev A Programming and Running the 1850 System When calibration is complete the monitor displays the dot prompt The system is ready for operation One LED on the front of each Adept MV controller module will also light
16. by a structural engineer or a similarly quali fied professional Adept Technology Inc cannot accept any responsibility for damage due to improper installation Procedure to Install Mounting Plate Adept recommends that the robot be installed onto a mounting plate and that the mount ing plate be installed into a concrete floor of your facility with anchor bolts This is a brief outline of the steps to install the plate Refer to the drawings on the following pages for details 1 Usea steel base at least 32 mm 1 25 in thick according to the dimensions in Figure 3 1 2 Make the mounting base level 3 Use anchor bolts to secure the plate to the floor as shown in Figure 3 3 NOTE Poor or improper installation of the mounting plate may affect system performance Mounting Plate Dimensions The mounting plate should be steel at least 32 mm 1 25 in thick Figure 3 1 shows the dimensions for the 1850 mounting plate Figure 3 2 shows the dimensions for the 1850XP mounting plate Bolts The mounting plate is secured to the floor by eight anchor bolts with flat washers and lock washers The robot is secured to the mounting plate by mounting bolts with washers and lock washers 1850 six bolts 1850XP eight bolts The anchor bolts and mounting bolts must meet or exceed the following specifications Table 3 1 Anchor and Mounting Bolt Specifications Standard Size Specification Torque Metric M20 x P2 5 ISO Pro
17. eon a A Se Be aah are ae ke oe eeu e 7 Outside Continental United StatesorEurope 7 Adept Bulletin Board Service nn nn lll nn 8 2 Descnptll h uote e Rh RAR ae kg eek bad 9 2 1 Intoduction 2 2 2 o 10 2 2 RobotDescription lll ls 10 Join Motlons x ooo mo ROUX XR RR RR Roe XXX e RO 11 OMNES 4 46 tots rer OF nune Peo muse UNIS MR VR URP an ses 12 Jont e x ox ox c a a ee X X ox x03 13 J OIDIt Boyds o exei b un he bnt duo D Pre CR esito eee LP at fr a 13 ONE sean eR Aste duce e eda UT ORAL Ser RU EE I a e ea TUR 13 Working Envelope rns 14 2 3 Robot Performance Specifications 15 Optionsand Accessories 16 2 4 Control UnitDescription lll ls ss 17 AG BOWGE ud actu v A AR IA os uoo ego dut a 18 Control UnitIntemalLayout cr 18 Adept 1850 1850XP Palletizer Robot User s Guide Rev A i Table of Contents POWEerRack u a armen wi ot AO eae ee a 19 Adept MV Controller 20 00 0202 ee 19 User Installed Additions 20 3 Robot Installati0N o 21 3 1 Conditions for Robot Installation 22 Facility Requirements ors 22 Power Requirements 2 2 2 2 2 5 2 2 52 22 32 Installing the Mounting Plate 23 Procedure to Install Mounting Plate 23 Mounting Pla
18. link Travel of Joint 2 is limited by software to a total of 300 This motion can be likened to an elbow capable of acting in either a left or right hand configu ration See Figure 2 3 The 1850 1850XP Palletizer Robot is capable of attaining a given location utilizing either a right hand RIGHTY or left hand LEFTY configuration However when Vt moves the arm to a location it must sometimes make assumptions about which configuration to use While this generally produces the result desired by the Programmer sometimes the sys tem assumption may differ from the Programmer s expectations In those cases the Pro grammer must specify within the program RIGHTY or LEFTY operation NOTE For further information concerning right and left hand configuration refer to the V Language User s Guide and V Language Reference Guide RIGHTY Figure 2 3 Joint 2 Motion and LEFTY RIGHTY Configurations Joint 3 Joint3 is also referred to as the Z axis Joint 3 provides vertical movement of the entire arm mechanism with a stroke of 78 7 inches 2000 mm Joint 4 Joint 4 is also referred to as the wrist and as the W axis Joint 4 provides rotation of the quill over a range of 360 This motion is similar to that of the human hand involved in tightening a bolt or unscrewing a bottle cap Adept 1850 1850XP Palletizer Robot User s Guide Rev A 13 Chapter 2 Description Working Envelope
19. m A RO E Cre E Lesen eo Sedo RR 43 5 1 Preparing For StartUp 2 sls s 44 5 2 Starting the Sytem uaaa llle s 44 ii Adept 1850 1850XP Palletizer Robot User s Guide Rev A Table of Contents 5 3 Calibration opo xo a ee Pe a ae tl X Introduction o e ae an Inm de AA Nob cack de Se nee NUN de Pa 38 Calibration Procedure rss VEVersonclll ose x 2 Woo aa XR Bee V Version 11 2 and Higher nn nn 5 4 Programming and Running the 1850 System 5 5 Joint Travel 4 4 4 fe al Pha aw aa ara a Pa eaa o A HA a e EMI SWIERE S eur ms a xe wee cde eee imum wed eg Hard Stop sis is u tei es qM RB E IE Rueda M d agas 5 6 J oint Out Of mits lll ls Joint4 Outoflimits 2 2 2 2 2 2 525 Jointlor2Outoflimits 2 2 2 2 2 2 5 Joint3Outoflimits 2 a k a ala a a 5 7 Amplifier Status and Fault Messages s 6 Maintenance 000 00 sh 6 1 Introduction s s s s Power Settings During Maintenance 6 2 1850 Periodic Maintenance 04 1850 Maintenance Schedule 1850 Mounting Bolts 2 les 1850 Mounting Plate 2 llle Lubricating the 1850Joint3Chain 0 Lubricating the 1850Joint3Rack 04 Lubricating the 1850Joint3LM Guides Lubricating 1850Joints1 2 and4 04 4 6 3 1
20. s Guide Concepts and strategies for programming the AdeptVision VME system See also the optional Adept Vision Reference Guide AdeptMotion VME User s Guide Installation configuration and tuning of an AdeptMotion VME system AdeptForce VME User s Guide Installation operation and programming of the AdeptForce VME product Manual Control Pendant User s Guide Basic use and programming of the Manual Control Pendant Optional V Developer s Manuals If you will be programming yi applications you should order the optional Vt devel oper s manuals first three in the list below These manuals contain a complete descrip tion of the commands instructions functions and other features available in the vt language and operating system These manuals are essential for advanced applications programming If you will be programming vision applications you should order the Adept Vision Reference Guide in addition to the V developer s manuals Manual Material Covered V Operating System Reference Guide Descriptions of the V operating system commands known as monitor commands V Language User s Guide V is a complete high level language as well as an operating system This manual covers programming principles for creating vt programs V Language Reference Guide A complete description of the keywords in the basic V language system Adept Vision Reference Guide Descriptions of the additional V keyword
21. up The robot can only be calibrated when robot high power is off High power is automati cally disabled when the calibration program is executed After the calibration program has executed robot high power can be enabled and the robot can be moved under pro gram control Programming and Running the 1850 System 5 4 5 5 The V Operating System User s Guide has information on basic operation of the V Operat ing System Also refer to the Instructions for Adept Utility Programs for information on using the Adept utility programs For programming information refer to the following optional manuals e V Language User s Guide e V Language Reference Guide e V Operating System Reference Guide Joint Travel The joint travel is limited by software limits limit switches and hardware limits The pro grammable software limits are known as softstops the fixed hardware limits are referred to as hardstops CAUTION The range of robot arm motion overlaps the position of the Z axis column See Figure 2 4 Therefore it is possible for the robot arm to strike the Z axis column It is the User s responsibility to program robot motion to prevent the robot arm from striking the Z axis column One way to prevent the robot arm from striking the Z axis column is to define new soft stops for joint 1 and or joint 2 In this case and any other time it becomes necessary to limit the travel of one or more of the joints within the nor
22. 50 1850XP Palletizer Robot User s Guide Rev A Control Unit Description Power Rack The power rack containing the four amplifiers is mounted in the control unit below the Adept MV controller The 1850 and the 1850XP power racks are different The amplifiers receive control signals from the Adept MV Controller and in turn provide the amplified power signals to drive the robot motors An LED display on each amplifier visible when you open the control unit front door displays the operational status of the amplifier See Adept MV Contoller The Adept 1850 1850XP Control Unit contains an Adept MV 8 or MV 19 controller The MV 8 controller shown in Figure 2 7 is an 8 slot chassis The MV 19 controller is a 19 slot chassis for more complex applications The MV controller contains the various VME mod ules that control the robot system and run the vt Operating System and Programming Language See the Adept Controller User s Guide for details on the MV controllers 030 SIO VGB VIS VMI DIO DES Zw eOe gt Bee gt Ce d Figure 2 7 Adept MV 8 Controller Adept 1850 1850XP Palletizer Robot User s Guide Rev A 19 Chapter 2 Description User Inst
23. 850XP Periodic Maintenance 1850XP Maintenance Schedule 1850XP Mounting Bolts less 1850XP Mounting Plate res Lubricating the 1850XP Joint3Chain Lubricating the 1850XP Joint 3 Ball Screw Lubricating the 1850XP Joint 3LM Guide Lubricating 1850XPJoints1 2 and4 Inspecting the 1850XP J oint 3 Belt 0 Inspecting the 1850XP J oint 2 Belt ooa a aaa a 6 4 Compatible Lubricant Infommation 6 5 Replacing the Control Unit Air Alters MV Controller Air Filtes a a aa a a Control Unit Rear Door Air Filters 6 6 Replacing the EncoderBatteries 048 Adept 1850 1850XP Palletizer Robot User s Guide Rev A iii Table of Contents A Dimension Drawings 2 4 85 A lRobotDimensions 2 2 2 2 2 2 2 5 86 A 2 Control Unit Dimensions 0 0 00004 90 A 3 Tool Hange Dimensions ls eae 91 B Palletizer Performance e nn nn n n mrs Benchmark 93 B 1 Performance Simulation 94 iv Adept 1850 1850XP Palletizer Robot User s Guide Rev A Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 4 1 Figur
24. Adept 1850 1850XP Palletizer Robot User s Guide car Adept 1850 1850XP Palletizer Robot User s Guide 00764 00030 Rev A March 1995 Coli 150 Rose Orchard Way San Jose CA 95134 USA Phone 408 432 0888 Fax 408 432 8707 ee Otto Hahn Strasse 23 44227 Dortmund Germany Phone 0231 75 89 40 Fax 0231 75 89 450 a 11 Voie la Cardon 91126 Palaiseau France Phone 1 69 19 16 16 Fax 1 69 32 04 62 1 2 Aza Nakahara Mitsuya Cho Toyohashi Aichi Ken 441 31 Japan 0532 65 2391 Fax 0532 65 2390 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 This manual is periodically reviewed and revised Adept Technology Inc assumes no responsibility for any errors or omissions in this document Critical evaluation of this manual by the user is welcomed Your comments assist us in preparation of future documentation A form is provided at the back of the book for submitting your comments Copyright 1995 by Adept Technology Inc All rights reserved The Adept logo is a registered trademark of Adept Technolog
25. Controller User s Guide for controller and pendant operating instructions All physical connections between the 1850 1850XP Palletizer Robot and the Adept 1850 1850XP Control Unit are located on the robot connection panel at the rear of the robot base In addition user air lines and signal lines can be connected at the robot connection panel Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Description J oint Motions Figure 2 1 shows the joints of the 1850 1850XP Palletizer Robot Joint 1 A axis o o S weil E da A Joint 4 Joint 2 W axis B axis Joint 3 Z axis Y Figure 2 1 Robot oint and Axis Diagram Adept 1850 1850XP Palletizer Robot User s Guide Rev A 11 12 Chapter 2 Description Joint1 Joint 1 is also referred to as the shoulder and as the A axis Joint 1 is the pivot point and provides the rotational movement between the column and the inner link Travel of the inner link is limited by software to 220 See Figure 2 2 110 110 Figure 2 2 Joint 1 Motion Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Description J oint 2 Joint 2 is also referred to as the elbow and as the B axis Joint 2 is the pivot point between the inner link and the outer link Outer link travel is limited by hardstops located on top of the inner
26. MW o Terminal O O O Q Monitor 1850XP Robot Connection Panel Figure 4 2 1850XP Robot and 1850XP Control Unit Connection Panels Adept 1850 1850XP Palletizer Robot User s Guide Rev A 39 Chapter 4 Control Unit Installation 4 4 User Connections on Robot User Electrical Lines The I O connector on the robot connection panel is provided for user electrical lines This connector is wired directly to a connector on the top of the outer link These connectors can be used to run user electrical signals from the back panel through the robot and up to the outer link See Table 4 1 and Figure 4 3 User Air Lines The AIR 1 and AIR 2 connectors 10 mm diameter on the robot connection panel are pro vided for user vacuum and pneumatic lines These air lines run through the robot up to a pair of matching connectors on the top of the outer link See Table 4 1 and Figure 4 3 Table 4 1 User Hectrical and Air Line Connector Specific ations Item Name Type Maker Adept Part Number 1 Service connector JMSP2524F DDK 25186 10240 2 Connector JMR2524M DDK N A 3 Connector JMR2524F DDK N A 4 Service connector JMSP2524M DDK 25181 10240 5 Air fitting KQE10 00 SMC N A The item numbers refer to the callout numbers in Figure 4 3 Figure 4 3 shows the user electrical and air connectors The callout numbers refer to the ite
27. Optional V DevelopersManuals 0 0000 cece tee 3 1 3 Notes Cautions and Wamings lise nn nnnm 4 TA Safet a UERBO 4 System Safeguard Sito ese eta dose tros kde e oe tet B Mew et 5 Equipment Safety suas sei oy Pe eR ew Ese a See AA A AA 5 L5 Robot Modifications rssessee eser hh nh nan 6 Acceptable ModificatiONS oooooooocoorrrrrra eh 6 Unacceptable ModificatiONS ooooooocorronnnorr nn 6 L6 How Can I Get Help ooccoccocccc nun nn h hanh nan 7 Within the Continental United States 0 0 eee 7 Seirvice Call amp inet te ARRIERE ARR ESAE ales RR S RA 7 Application Questions ooooooocoocrrrrr eB 7 Applications Intemet E Mail Address 00 0c eens 7 Training Information 00 cee tee 7 Within EUFOB 552 2 80 42 bee ae Pe ond a pel Pee as te ed 7 Outside Continental United StatesorEurope nananana 7 Adept Bulletin Board Service 0 cc eects 8 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1 Chapter 1 Introduction 1 1 How This Manual Is Organized This manual provides general installation operation and maintenance information for the Adept 1850 and 1850XP Palletizer Robots also referred to as a Selective Compliance Assembly Robot Arm or SCARA 1 2 Related Manuals Adept products come with a set of documentation that is defined by the products you have ordered In addition there are optional
28. Palletizer Robot User s Guide Rev A 91 Appendix A Dimension Drawings 2120 6 M8 depth 12 every 60 ao tum All dimensions in mm Figure A 7 1850XP Tool Hange Dimensions 92 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Palletizer Performance Benchmark B 1 Performance SimulatiON 0cccoccccccccc Adept 1850 1850XP Palletizer Robot User s Guide Rev A 93 Appendix B Palletizer Performance Benchmark B l Performance Simulation 94 The performance specifications for the 1850 1850XP Palletizer Robot listed in Table 2 1 and Table 2 2 were calculated according to the configuration shown in Figure B 1 The following factors apply to the specifications and the simulation The robot picks up the workpieces boxes from the conveyor and stacks them on the pallet The boxes weigh 30 kg each The pallet is loaded eight boxes per layer four layers deep The simulation does not include any time for gripper motion Joint 3 motion follows the following heights above floor level for each layer Layer 1 500mm Layer 2 750mm Layer 3 1000 mm Layer 4 1250 mm Adept 1850 1850XP Palletizer Robot User s Guide Rev A Performance Simulation Workpiece weight 30 kg 250 E nl Conveyor i 275 gt 550 4 1500 All dimensions in mm 4300 Pallet Center of
29. Standard for Industrial Robot Systems Safety Requirements published by the RIA in conjunction with the American National Standards Institute ANSI The publication ANSI RIA R15 06 1986 contains guidelines for robot system installation safeguards maintenance testing start up and operator training The document is available from American National Standards Institute 1430 Broadway New York NY 10018 This Guide assumes that the User has successfully completed an Adept Training Course and has a basic working knowledge of the Adept system The User should provide the necessary additional training for ALL personnel working within or around the workcell Adept 1850 1850XP Palletizer Robot User s Guide Rev A Safety System Safeguards Safeguards should be an integral part of robot workcell design installation Operator training and operating procedures Adept systems are computer controlled and may activate remote devices under program control at times or along paths not anticipated by personnel It is critical that safeguards be in place to prevent personnel from entering the workcell whenever equipment power is present WARNING Entering the workcell when either the HIGH POWER or the PROGRAM RUNNING light on the Adept 1850 1850XP Control Unit is on could result in severe injury Adept Technology highly recommends the use of workcell safety features such as light curtains safety gates or safety floor mats to prevent access to th
30. TA F Force applied at point F 3 4 to 3 7 kef L Belt deflection at point L Approximately 3 3 mm 0 125 in W Belt width 21mm S Span 216 6 mm T Tension 54 4 to 59 2 kef f Force applied at point f 2 1 to 2 3 kef I Bar deflection at point Approximately 5 4 mm 0 2 in Adept 1850 1850XP Palletizer Robot User s Guide Rev A 77 Chapter 6 Maintenance Inspecting the 1850XP J oint 2 Belt Inspect the Joint 2 B axis belt every six months Tools 4 5 6 and 8 mm hex wrenches Allen wrenches 19 mm open end wrench Push pull gauge Scale Push pull gauge 2 M5 x 12L i Upper cover SS nin E T H Figure 6 11 1850XP J oint 2 Belt Access 1 Move the Z axis down to bring the robot arm to a convenient working height Switch off the power 2 Remove the screws securing the Joint 2 upper cover Remove the cover to expose the belt 3 Use the push pull gauge to pull the belt at point E Apply 2 7 kgf of pulling force as shown in Figure 6 11 and Figure 6 12 4 While applying the force measure belt deflection at point L The correct belt deflection is approximately 6 6 mm 78 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance 5 If the measured deflection is not cor
31. The mounting plate must remain level to maintain the accurate operation of the robot Check that the mounting plate is level one week after robot operation begins and then at six month intervals 70 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance Lubricating the 1850XP J oint 3 Chain Lubricate the Joint 3 Z axis chain once a week Oil Tools Cosmo Olpus 100 Cosmo See Table 6 6 for acceptable equivalent 5 mm hex wrench Allen wrench Oil brush Oil can Lubrication ports M6 x 20L Sprocket bolts Chain Bellows Brush oil here Figure 6 5 1850XP Chain Lubrication Ports CAUTION Do not lubricate the chain with grease Move the Z axis down near the lower end of the envelope Switch off the power Remove the bolts holding the bellows in place and pull down the bellows to expose the chain Brush oil onto the visible parts of the chain Inject oil into the two chain lubrica tion ports shown in Figure 6 5 Pull up the bellows and reinstall the bolts Turn the power back on and exercise the Z axis several times to distribute the oil Adept 1850 1850XP Palletizer Robot User s Guide Rev A 71 Chapter 6 Maintenance Lubricating the 1850XP J oint 3 Ball Screw Lubricate the Joint 3 Z axis rack monthly Grease Multemp SRL Kyodo Yushi See Table 6 6 for acceptable equivalent Tools 5 mm hex wrench Allen wre
32. Unplugged or breaker circuits You can turn high power off in either of the following ways Type in the shutdown command on the monitor according to local usage Push in the EMERGENCY STOP button on the VFP Turn system power off by turning the SYSTEM POWER switch on the VFP to the OFF 0 position Turn the main system breaker off by turning it to the OFF 0 position 62 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850 Periodic Maintenance 6 2 1850 Periodic Maintenance This section describes the maintenance procedures required to keep the 1850 Palletizer Robot operating properly See 1850XP Periodic Maintenance on page 69 for 1850XP periodic maintenance 1850 M aintenance Schedule See Table 6 2 for a summary of the preventive maintenance procedures and some rough guidelines on frequency Table 6 2 Recommended 1850 Preventive Maintenance Schedule Interval Item Comment Daily before 1 Confirm that each axis moves operation smoothly without vibration 2 Confirm that no abnormal sound Occurs as each axis moves 3 Confirm that all bolts and nuts are secure and have not worked loose including all cable connections between robot and controller 4 Confirm that Emergency Stop works correctly Weekly Lubricate Joint 3 Z axis chain Cosmo Olpus 100 See page 65 Three 1 Grease Joint 3 Z axis rack Mori Speed Grease months See page 66 2 Grea
33. al O O O O Monitor 1850 Robot Connection Panel Figure 4 1 1850 Robotand 1850 Control Unit Connection Panels 38 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing Cables Between Robot and Control Unit Installing Cables Between the 1850XP Robot and 1850XP Control Unit The 1850XP system uses seven cables between the control unit and the robot Four motor cables labeled M A M B M Z and M W Two encoder cables labeled EN A Z and EN B W One signal cable labeled RSC Install the motor cables the encoder cables and the RSC signal cable between the1850XP robot and the 1850XP control unit Each cable is labeled at both ends to match the labeled connectors on the robot and control unit connection panels see Figure 4 2 1 Connect the motor cables to the matching connectors on the robot and control unit connection panels One end of each cable mates with the matching robot con nector and the other end mates with the connector on the control unit The 1850XP motor cables and connectors are labeled MA MB MZ and MW 2 Connect the two encoder cables to the EN AZ and EN BW connectors on the robot and control unit connection panels 3 Connect the RSC signal cable to the RSC connector on the robot and control unit connection panels 1850XPControl Unit Connection Panel RSC MA MZ ENAZ C C Keyboard a PR Pointer PWR MB E EN B W 1
34. alled Additions Additional user installed components can be installed inside the 1850 Control Unit in the 7U 311 mm 12 25 vertical dimension space below the amplifiers The Rear Option Panel above the Connector Panel on the rear of the Control Unit cabinet is provided for the user to install connectors for user installed components see Figure 2 5 The cable saddles on the cross member above the Rear Option Panel are provided for user installed wiring 20 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Installation 3 1 Conditions for Robot Installation lesen nnn nnn 22 Facility Requirements 00 ct nn 22 Power RequirementS 0 00 c cee ttt 22 3 2 Installing the Mounting Plate 00cces cece eee eee 23 Procedure to Install Mounting Plate 0 cc eee eee 23 Mounting Plate Dimensions 0 00 c rennen nn 23 BOWS e bor Weed Rue RHET ME eal eid eS ie ee 23 Mounting Plate Installation 0 0c cece 26 3 3 Unpacking and Inspecting the Robot 00ccceceeee eee o 27 Before Unpacking 2 angian oa ge hee ee ee ERPS Ex 27 After UNPaACKINGin pvt un epu en a Mitre we els Ste ee REA 27 Repacking forRelocation 0 cece tes 27 Removing the Robot from the Crate 2222er nennen nn 28 Raising the Robotto Vertical lusu 0 eee 28 3 4 Installing the Robot useeseeseee nnn nnm hn ann 31 Procedure to Install Robot sssssleeseeeee n
35. alletizer Robot User s Guide Rev A 7 Chapter 1 Introduction Adept Bulletin Board Service Adept maintains a computer bulletin board service for Adept customers Adept posts application hints and utilities to this bulletin board and users may post their own hints and application notes There is no charge for access to the bulletin board You will of course incur normal long distance phone charges for the call to the BBS The BBS number is 203 264 5590 The first time you call you will be able to set up an account right from the BBS If you have any questions call 800 232 3378 and ask about the BBS 8 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Desc nption 2 1 InttOductiOn 1 cee eee 10 2 2 RobotDeschipti0N 0occococcco 10 Joint MOTIONS i ne ne mme AON cde et A mpl RR woe 11 Joint l c mx mega mam eg eR RR Rm DEG mr ERO 12 JOH 25 0 cere enel eL X eI e bM ER Ra IRSE 13 Joint 3 224244 oka weds move 6x mI exem OR E EG 13 Ip MET 13 Working Envelope oocoocococr nennen en 14 2 3 Robot Performance SpecificatiONS 0oooooooomocornn o 15 Optionsand Accessories lislsllsesees tas 16 2 4 Control Unit Description 0occoocccco nnnm 17 AG Power votas AE rede Ses TED ees eee eee 18 Control Unit Intemal Layout oooooococococron 18 Power Rack se dee GI oed y exa kn E 19 Adept MV Contmller ooooooocooccoo ne 19 User Installed Additions lille RI 20 Ad
36. amage Adept 1850 1850XP Palletizer Robot User s Guide Rev A 31 Chapter 3 Robot Installation Mounting Hole Dimensions for Robot Base Adept 1850 Top View 55 116 Y Y 4 2 tf i y 295 725 1 a 295 Lj pl EE 80 20 All dimensions in mm gt 350 350 gt 700 Figure 3 6 Adept 1850 Mounting Hole Dimensions 32 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing the Robot 134 40 800 240 gt ja 240 40 8 D24 All dimensions in mm 800 Figure 3 7 Adept 1850XP Mounting Hole Dimensions Removing Counterbalance Lock Screws 1 After the robot is securely mounted remove the counterbalance lock screw from each side of the robot See Figure 3 5 2 Remove the two screws holding the access cover plate located below the counter balance lock screw 3 Install the access cover plate over the lock screw hole CAUTION Use only supplied hardware to install the access cover plate over the lock screw hole Longer fasteners will interfere with the movement of the counter balance machinery during operation Adept 1850 1850XP Palletizer Robot User s Guide Rev A 33 Control Unit Installation 4 1 Conditions for Control Unit Installation eee 36 Facility Requirements o nosne nsi cece eee eee rn 36 4 2 Installing the Con
37. ation 0 00055 Repeatability X Y plane 10 3 mm 40 012 in Joint 3 vertical Z 0 3 mm 40 012 in Joint 4 rotational 3 0 5 Joint Speed maximum Joint 1 140 sec Joint 2 140 sec Joint 3 1 500 mm sec 59 in sec Joint 4 225 sec Weight Robot without options 2 400 kg 5 300 Ib A See Appendix B for information on Performance Simulation Options and Accessories The following options can be used with both models of the 1850 1850XP Palletizer Robot e AdeptVision VME e AdeptMotion VME e PalletWare 16 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Control Unit Description 2 4 Control Unit Description Controller Window VME Front Panel VFP Optional Manual Control Fe Pendant The Adept 1850 1850XP Control Unit runs the control program supplies amplified power signals to the robot motors and receives the feedback signals from the position encoders of the robot The control unit cabinet contains the following component assem blies The Adept MV Controller MV 8 or MV 19 The power rack The VME Front Panel VFP The control unit connector panel Incoming AC power connections are installed at the lower left corner of the connector panel The control unit and its components are cooled by a fan mounted on the rear door The incoming and outgoing air streams are cleaned by reusable filters mounted in the rear door For the dimensions of the Ad
38. axis ball screw Marutemp SRL See page 71 Three months Grease the Joint 3 Z axis LM guide Multemp SRL See page 74 Six months 1 Confirm that the mounting plate is See page 70 level 2 Confirm that Joint 3 Z axis See page 70 mounting bolt torque is correct 3 Confirm that Joint 3 Z axis timing See page 76 belt tension is correct 4 Confirm that Joint 2 B axis timing See page 78 belt tension is correct Two years Grease Joint 1 A axis Joint 2 B axis Optimol Longtime PD O and Joint 4 W axis gears See page 75 NOTE The frequency of periodic maintenance procedures will depend on the particular system its operating environment and amount of usage Use the intervals in Table 6 2 as guidelines and modify the schedule as needed CAUTION Using improper lubrication products on the Adept 1850XP can cause damage to the robot Be sure to use the recommended lubricants for each lubrication procedure See Table 6 6 for compatible lubricants Contact Adept Customer Service if you have any questions Adept 1850 1850XP Palletizer Robot User s Guide Rev A 69 Chapter 6 Maintenance 1850XP Mounting Bolts The 1850 robot is secured to the mounting plate by eight bolts with washers and lock washers Torque metric bolts to 3800 kgfcm Torque SAE bolts to 275 ft lb Check the torque on these bolts one week after robot operation begins and then at six month inter vals 1850XP Mounting Plate
39. bles between the control unit and its peripherals For details see Install ing the Control Unit on page 36 d Any cables from user installed accessories to the robot or control unit 2 Ifno Manual Control Pendant MCP is installed make sure that the jumper is installed on the PENDANT connector on the VME Front Panel VFP 3 Make sure the rear door and front door are latched closed 5 2 Starting the System Start the system as follows 1 Turn on the monitor 2 Supply power to the system by turning the main system breaker on the rear of the Control Unit to the ON position Figure 5 1 Main System Breaker 44 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Starting the System 3 On the VME Front Panel VFP turn the SYSTEM POWER switch to the ON 1 position This initiates the boot up sequence LAMP TEST PROGRAM HIGH PENDANT REMOVE RUNNING POWER TERMINAL O O O PENDANT NETWORK SYSTEM PROGRAM PENDANT START go POWER O OQ E S 7 Q9 Figure 5 2 VME Front Panel VFP EMERGENCY STOP 4 Wait while the boot up sequence runs its course During the sequence which takes one to two minutes you will see messages on the monitor showing the progress and the indicator lights on the MV Controller blink in a random pattern When the sequence is complete the indicator lights stop blinking Also the moni tor displays the dot prompt with the cursor blinking
40. bottom of the robot to be used if the system is ever relocated CAUTION The 1850 1850XP Palletizer Robot must be bolted to the mounting plate and the mounting plate bolted to the floor before the lifting shackles are removed If the unmounted Adept 1850 1850XP is fully extended it may fall and cause substantial damage Repacking for Relocation If you relocate the robot reverse the installation procedures described in this section Reuse the transport brackets The original shipping container is not reusable Package the robot for relocation in new material equivalent to the original Follow all safety notes used for installation Improper packaging for shipment will void your warranty Adept 1850 1850XP Palletizer Robot User s Guide Rev A 27 Chapter 3 Robot Installation Removing the Robot from the Crate The load points of the robot are located at either end of the shipping crate pallet It is rec ommended that the shipping crate be lifted from both ends WARNING The following procedures are only guidelines for unpacking and installing the robot If you are not familiar with handling large indus trial equipment you should hire professional riggers to install the robot Depending on your installation site there may be different methods of handling the robot than we provide here Adept Technology Inc cannot accept responsibility for damage or injury due to improper handling or installation 1 Remove the screws and unlat
41. cation marks Grease fitting behind A rubber plug Side View Front View Figure 6 3 1850 Linear Guides 1 Move the Z axis to align the upper lubrication mark on the column with the mark on the robot arm as shown in Figure 6 3 Switch off the power 2 Remove the rubber plugs from both the left and right sides of the robot as shown in Figure 6 3 to expose the grease fittings 3 Inject grease into the grease fittings on both sides of the robot using the grease gun Reinsert the rubber plugs Adept 1850 1850XP Palletizer Robot User s Guide Rev A 67 Chapter 6 Maintenance 68 4 Switch on the power and move the Z axis to align the lower lubrication mark on the column with the mark on the robot arm Switch off the power 5 Remove the rubber plugs from both the left and right sides of the robot 6 Inject grease into the grease fittings on both sides of the robot using the grease gun Reinsert the rubber plugs 7 Switch on the power and move the Z axis up and down several times to distribute the grease on the guides Lubricating 1850 J oints 1 2 and 4 Replace the Joint 1 A axis Joint 2 B axis and Joint 4 W axis grease every 20 000 hours of operation Grease Optimol Longtime PD O Nihon Parkarising See Table 6 6 for acceptable equivalent Tools Grease gun Grease fitting for y Joint 1 A axis gear Grease fitting f
42. ch the fasteners as necessary to remove the sides and top from the shipping crate The robot should be left resting upon the bottom pal let of the shipping crate 2 Carefully cut away the vapor seal bag if installed from around the robot Remove any additional straps holding down the robot 3 Install lifting shackles and or chains capable of supporting the weight of the robot onto the transport brackets at the top and bottom of the robot CAUTION The robot must be lifted by either the eye bolts located on top of the robot or by the transport brackets 4 Lift the robot out of the shipping crate and set it down on its transport brackets Raising the Robotto Vertical 1 Move the robot to the installation site 2 Remove the lifting equipment from the top and bottom transport brackets Install lifting equipment on the top hook bolts see Figure 3 5 WARNING Due to the shifting center of gravity the robot can swing as it is being lifted to vertical The installer should take steps to maintain control of the bottom of the robot 3 Taking care to maintain control of the bottom of the robot carefully lift the robot to vertical using the hookbolts 28 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Unpacking and Inspecting the Robot 4 Without reaching under the supported weight of the robot place two large wood supports under the bottom of the robot so the bottom transport bracket can be removed Lower the robot ont
43. cover 76 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance Remove the M8 x12L bolts holding the back cover in place and remove the back cover Use the push pull gauge to push against the inspection bar Apply 2 1 to 2 3 kgf of pushing force to the bar at point f as shown in Figure 6 9 and Figure 6 10 While applying the force measure deflection in either of two ways a Measure belt deflection at point L The correct belt deflection is approxi mately 3 3 mm b Measure inspection bar deflection at point l The correct bar deflection is approximately 5 4 mm If the measured deflection is not correct the belt must be replaced and the joint encoders recalibrated Inspect the belt for excessive wear or deterioration If the back of the belt or any teeth are cracked the belt is swollen or any teeth are worn half their width or more the belt must be replaced and the joint encoders recalibrated Inspect the pulleys for excessive wear or deterioration If any pulley teeth are worn 1 0 mm or more the pulley must be replaced and the joint encoders recali brated 10 Contact Adept Technology or your service provider for belt replacement and reca libration Detection bar F Figure 6 10 1850XP J oint 3 Belt Test Table 6 4 1850XP J oint 3 Belt Tension Specific ations Item Specification Type of belt 8M 800 21 UNIT
44. dept MV controller as shown in Figure 5 3 NOTE Other faults in addition to a joint out of limits can also cause these indicators to light VMI E Care Joint 1 fault FE Win Joint 2 fault A EA Joint 3 fault A QA Joint 4 fault ER Cer digo Cee Figure 5 3 Joint Out of limit Indic ators Adept 1850 1850XP Palletizer Robot User s Guide Rev A 49 Chapter 5 Operation J oint 4 Out of Limits Joint 4 has softstops but no limit switches If Joint 4 goes out of limits 1 Use the MCP to bring it back within limits 2 After making sure that no one is in the robot operating area restart the program WARNING Make sure that no one is in the robot operating area before restarting the program J oint 1 or 2 Out of Limits If Joint 1 or Joint 2 goes out of limits 1 Make sure that the amber High Power light is off 2 Manually push the joint back within the allowed limits 3 After making sure that no one is in the robot operating area restart the program WARNING Make sure that no one is in the robot operating area before restarting the program 50 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Joint Out Of Limits J oint 3 Out of Limits WARNING C SAMP LANE ROBOT MAY MOVE UNEXPECTELY WHEN RESET RELEASE BRAKE RELEASES Figure 5 4 AMP FAULT RESET and Z AXIS BRAKE RELEASE Buttons If Joint 3 goes out of limits two or more people must w
45. e 4 2 Figure 4 3 Figure 4 4 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure A 1 Figure A 2 Table of Contents List of Figures RobotJoint and AxisDiagram 2 cece 11 Joint1Motion ooococcoo hh rr 12 Joint 2 Motion and LEFTY RIGHTY Configurati0NS ooooooooooo 13 1850 and 1850XP Arm Motion Envelope 000 nennen nenn 14 Adept 1850 1850XP Control Unit liliis eere 17 Adept 1850 1850XP Control Unit Intemal Layout o o ooooooooooo 18 Adept MV 8 Controller uer ee a ERR ee Meu 19 1850 Mounting Plates s a ias a EVER A WE Weed a eles Wate A EAE 24 1850XP Mounting Plate ooooocooocoocrrrr nennen 25 Anchor Bolt Details wiry cise Ba See ee UR A ees 26 Top View Showing Transport Bracket 0 0 0 cece ete 29 Upright Robot with Transport Brackets nne seen 30 Adept 1850 Mounting Hole Dimensions 000 cece eee 32 Adept 1850XP Mounting Hole Dimensions 000 0s eee eee 33 1850 Robot and 1850 Control Unit Connection Panels 38 1850XP Robot and 1850XP Control Unit Connection Panels 39 User Line Connme CEOTS soe eh exten ces Pe ene Bs es Wa Se ee 40 Control Unit Digital I O Terminal Strip 0 0 cece eee 41 Main System Breaker vc
46. e 5 2 and 5 3 describe the amplifier status and fault codes If an amp fault occurs 1 Press the AMP FAULT RESET button momentary contact switch to turn the amps back on see below for exceptions The AMP FAULT RESET button is located inside the front of the Control Unit next to the Z AXIS BRAKE RELEASE button above the MV controller 2 Restart the program There are four faults that cannot be reset by the AMP FAULT RESET switch They are 8 F P and no lights System power must be turned off and on again to clear the fault assuming the fault cause has been removed Table 5 2 Amplifier Status Display Displa Explanation of Status play P The control power supply is active Low power is ON high power is OFE High power is ON but amps are not enabled This occurs when the robot is not calibrated High power is ON and amps are enabled Rotates in form of the figure 8 The encoder battery for this motor is low See Replacing the Encoder Batteries on page 82 52 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Amplifier Status and Fault Messages Many of the corrective measures listed in Table 5 3 are beyond the scope of this manual Each of these measures is identified by an asterisk Call Adept Technology or your ser vice provider to perform these corrective measures Table 5 3 Amplifier Fault Alarm Codes
47. e od TE here i al ojo pl A IUA lo o Y lo o lo o i C D Lower gt La bellows lo Ojo M i o Figure 6 2 1850J oint 3 Z Axis Rack 1 Move the Z axis down near the lower end of the envelope Switch off the power 2 Remove the M6 x 20L bolts holding the upper bellows in place and pull down the upper bellows to expose the upper part of the rack 3 Brush grease evenly onto the upper part of the rack Apply the grease evenly approximately 1 mm 1 16 in thick 4 Pull up the bellows and reinstall the bolts 5 Remove the M6 x 20L bolts holding the lower bellows in place and pull down the lower bellows 66 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850 Periodic Maintenance 6 Switch on the power and move the Z axis up near the top of the envelope Switch off the power 7 Brush grease evenly onto the lower part of the rack Apply the grease evenly approximately 1 mm 1 16 in thick 8 Pull up the bellows and reinstall the bolts 9 Turn the power back on and move the Z axis up and down several times to dis tribute the grease on the rack Lubricating the 1850 J oint 3 LM Guides Lubricate the Joint 3 Z axis linear motion LM guide every three months Grease Multemp SRL Kyodo Yushi See Table 6 6 for acceptable equivalent Tools Grease gun HSP 1 Yamada Yuki Lubri
48. e rear of the control unit Adept 1850 1850XP Palletizer Robot User s Guide Rev A 41 5 1 Preparing For StartUp cece eee eee 44 5 2 Starting the SySteM ococcccoccc 44 5 3 Calibrati0N 0ooooccooooc aa a 46 Introduction ied ie a ed we SE wed x Sea RUE bee Ow 46 Calibration Procedure 0 ec eae 46 V Version TLL oo eee eens 46 V Version 11 2 and Higher 0 0 c eee eee 46 5 4 Programming and Running the 1850 System i leeren 47 5 5 Joint Tavel iici ccc cece eee hh hh hh hh hh hm 47 OOPS ici ri Tier A IRA Eel 47 LIMIT SWIC RES ian EE ceri ree E REA IURE pe ox e 48 Haidstops vc moyran Serra uw da tere tie yet ere tee Need 48 5 6 Joint Out Of Limits 0 0 cee 49 Joint 4A Outof EINS en an 50 Joint 1 or2 Out of mits llle nh 50 Jont Out of HMS cae Ot ad oe taal en wher me en SAL Back 51 5 7 Amplifier Status and FaulEMessages eee n nn n nn nnn 52 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 43 Chapter 5 Operation 5 1 Preparing For Start Up Before turning the system on 1 Make sure that all system connections are installed correctly System connections include the following a Power cord from the AC power source to the control unit For details see Installing the Control Unit on page 36 b Cables between the robot and the control unit For details see Installing Cables Between Robot and Control Unit on page 37 c Ca
49. e workcell while power is present Adept controller systems have various control features which may aid the user in constructing system safeguards including Emergency stop circuitry Digital input and output lines The emergency power off circuitry in the MV controller is capable of switching external power systems as well as detecting intrusion signals from safety barriers Equipment Safety All personnel must observe sound safety practices during the operation and testing of all electrically powered equipment To avoid injury or damage to equipment always remove power by disconnecting the AC power cord from the source BEFORE attempting ANY repair or upgrade activity WARNING DO NOT remove or replace any assemblies subassemblies Printed Circuit Assemblies PCAs or components with primary power present To avoid possible personnel injury or equipment damage always remove power BEFORE attempting repair or upgrade procedures Adept 1850 1850XP Palletizer Robot User s Guide Rev A 5 Chapter 1 Introduction 1 5 Robot Modifications It is often necessary to make modifications to Adept robots to successfully integrate them into a workcell Unfortunately many seemingly simple modifications can either cause a robot failure or reduce the robot s performance reliability or lifetime Acceptable Modifications In general the following robot modifications will not cause any problems but may affect robot performance A
50. ed States Adept Technology maintains a Customer Service Center at its headquarters in San Jose CA The phone numbers are Service Calls 800 232 3378 24 hours per day 7 days a week 408 433 9462 FAX NOTE When calling with a controller related question please have the serial number of the MV controller and the serial number of the robot The serial numbers can be determined by using the ID command See the V Operating System User s Guide Application Questions 800 232 3378 Monday to Friday 6 00 am to 6 00 pm Pacific time 408 434 6248 FAX Applications Intemet E Mail Address If you have access to the Internet you can send applications questions by e mail to applications adept com This method also enables you to attach a file such as a portion of vt program code to your message Training Information For information regarding Adept Training Courses in the USA please call 408 434 5024 Within Europe Adept Technology maintains a Customer Service Center in Dortmund Germany The phone numbers are 49 231 75 89 40 from within Europe Monday to Friday 8 00 am to 5 00 PM 49 231 75 89 450 FAX Outside Continental United States or Europe For service calls application questions and training information call the Adept Customer Service Center in San Jose California USA 1 408 434 5000 1 408 433 9462 FAX service requests 1 408 434 6248 FAX application questions Adept 1850 1850XP P
51. enn 31 Mounting Hole Dimensions for Robot Base 0 cee ees 32 Removing Counterbalance LOCK SCEWS 6 ees 33 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 21 Chapter 3 Robot Installation 3 1 Conditions for Robot Installation 22 Facility Requirements The site for the 1850 1850XP Palletizer Robot installation must meet the following condi tions Surrounding temperature 0 to 40 C 32 to 104 F Surrounding humidity 35 to 90 non condensing No dust or smoke No ignitable or corrosive materials Non combustible and non corrosive atmosphere e No vibration Easy access to robot and control unit for service and repair Robot and control unit within reach of the connecting cables Standard cables are 7 m 23 ft Power Requirements The 1850 1850XP Palletizer Robot system requires the following power Three phase 220VAC 10 40 Amps minimum No electrical noise on power lines Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing the Mounting Plate 3 2 Installing the Mounting Plate The robot must be installed in a safe and secure manner by professionals familiar with the structural engineering principles related to the installation of large industrial equipment The information on the following pages can be used as a guide to help you install your robot WARNING The customer must have the installation plan for the selected site verified to be adequate
52. ept 1850 1850XP Control Unit see Appendix A Main System Breaker Upper Air Filter Lower Air Filter Rear Option Panel Connector O O OON O Panel p x ox x omo mm T Ur Figure 2 5 Adept 1850 1850XP Control Unit Adept 1850 1850XP Palletizer Robot User s Guide Rev A 17 Chapter 2 Description AC Power The Adept 1850 1850XP Control Unit is shipped with an AC power cord without termi nations The AC power cord is installed through the PWR access port in the connection panel on the rear of the control unit Control Unit Intemal Layout Figure 2 6 shows the layout inside the front of the control unit NOTE The front and rear doors on the control unit have locks that can be opened with a key that is supplied in the accessories kit Amp Fault Reset and I Z Axis Brake Release Panel Falla O Adept MV 19 Controller q FTD OU A ODDO Power Rack Containing a Amplifiers m m Figure 2 6 Adept 1850 1850XP Control Unit Intemal Layout 18 Adept 18
53. ept 1850 1850XP Palletizer Robot User s Guide Rev A 9 Chapter 2 Description 2 1 Intoduction 2 2 The Adept 1850 1850XP robot system consists of an 1850 or 1850XP Palletizer Robot con trolled and driven by an 1850 Control Unit specific to that system Section 2 2 describes the 1850 and the 1850XP robots Section 2 3 describes the Control Unit Robot Desc ription 10 The 1850 1850XP Palletizer Robot is a high payload four axis SCARA robot designed for heavy duty palletizing material handling packaging and assembly tasks Joints 1 2 and 4 are rotational and Joint 3 is translational Figure 2 1 shows the robot joint locations See Figure 2 4 for the operating envelope and Table 2 1 and for specifications The 1850XP is a faster higher payload version of the 1850 The characteristics of the 1850 and the 1850XP are alike but not identical The 1850XP has a greater maximum payload and faster cycle times In this manual the difference between the two models is specifi cally noted where appropriate The 1850 1850XP Palletizer Robot is designed to interface with the Adept MV controller inside of the 1850 Control Unit All control and operation of the 1850 1850XP Palletizer Robot is programmed and performed through the MV controller The optional Operator s or Programmer s Pendant is required for manually teaching robot locations Additionally it can serve as the sole operator interface to the system Refer to the Adept MV
54. eriodic Maintenance Lubricating the 1850 J oint 3 Chain Lubricate the Joint 3 Z axis chain once a week Oil Tools Cosmo Olpus 100 Cosmo See Table 6 6 for acceptable equivalent 5 mm hex wrench Allen wrench Oil brush Oil can mw V Y ports bu S M6 x 20L bolts Sprocket Brush Chain oil here d le Bellows Figure 6 1 1850 Chain Lubrication Ports CAUTION Do not lubricate the chain with grease Move the Z axis down to the lower end of the envelope Switch off the power Remove the bolts holding the bellows in place and pull down the bellows to expose the chain Brush oil onto the visible parts of the chain Inject oil into the two chain lubrica tion ports shown in Figure 6 1 Pull up the bellows and reinstall the bolts Turn the power back on and exercise the Z axis several times to distribute the oil Adept 1850 1850XP Palletizer Robot User s Guide Rev A 65 Chapter 6 Maintenance Lubricating the 1850 J oint 3 Rack Lubricate the Joint 3 Z axis rack every three months Grease Mori Speed Grease No 2 Sumitomo See Table 6 6 for acceptable equivalent Tools 5 mm hex wrench Allen wrench Oil brush Upper bellows Rack gear En O Brush TUR greas
55. esponsibility of the user to install the AC power plug in compliance with local regulations Connect the AC power cord from the back of the control unit to an AC power source with the following specifications 220VAC 10 50 60 Hz 40 Amps minimum MV Controller Peripherals Connect the monitor and keyboard according to these instructions 1 Connect the monitor AC power cord to an appropriate voltage source NOTE If a graphics board is not ordered as part of the Adept MV controller install a Wyse terminal instead of a monitor Connect the terminal at the Pointer Terminal connector on the control unit connection panel Refer to the Adept MV Controller User s Guide for details 2 Connect the monitor signal cable to the monitor connector on the right hand side of the control unit connection panel See Figure 4 1 or Figure 4 2 3 Connect the double connector keyboard cable to the Keyboard and Pointer con nectors on the control unit connection panel See Figure 4 1 or Figure 4 2 The Adept MV controller is mounted inside the control unit Refer to the Adept MV Con troller User s Guide for details about the monitor and about third party peripherals 36 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing Cables Between Robot and Control Unit 4 3 Installing Cables Between Robot and Control Unit WARNING The cables must be installed properly Each cable must be connected only to the connectors on the robot and cont
56. for mounting the mounting plate to the floor as shown in Figure 3 3 17 0 Nut and Washer P d NEN Anchor Bolt M20 x 315L 60 32 Plate 300 Mortar Y All dimensions in mm See text for SAE equivalent bolt 80 Figure 3 3 Anchor Bolt Detail WARNING The customer must ensure that this mounting plan will be adequate for the actual condition and structure of the floor at the intended installation site 26 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Unpacking and Inspecting the Robot 3 3 Unpacking and Inspecting the Robot Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit Pay special attention to tilt and shock indication labels if they are present on the exteriors of the con tainers If any damage is indicated request that the carrier s agent be present at the time the container is unpacked After Unpacking Compare the actual items received not just the packing slip with your equipment pur chase order and verify that you received everything you ordered Inspect each item for external damage as it is removed from its container If any damage is evident contact Adept Retain all containers and packaging materials These items will be necessary to settle damage claims or to relocate the robot Retain the control unit packing material and the transport brackets for the top and
57. he VFP Remove the grill by pulling straight out from the door You may have to pry up one edge of the grill using a screwdriver Remove the air filter and inspect it for dust and dirt If the filter is dirty clean it using compressed air If the filter is clogged or unusable for any reason order a new filter The upper smaller filter is Adept part number 92200 00180 The lower larger filter is Adept part number 92200 00070 Insert the cleaned or new air filter and slide the grill over it Install the grill with the air inlets downward not upward Adept 1850 1850XP Palletizer Robot User s Guide Rev A 81 Chapter 6 Maintenance 6 6 Replacing the Enc oder Battenes 82 The position of each robot joint is measured by an absolute encoder and stored on the Robot Signature Card RSC When controller power is off the position data is maintained by four batteries one for each encoder The encoder batteries have three conditions OK low battery battery failure When an encoder battery is low but has not failed the robot can still operate The encoder batteries should be replaced as soon as any low battery warning is displayed Replace the batteries with new lithium batteries ER6 3 6V The system displays three warnings when the voltage of an encoder battery begins to go low A low battery is indicated by a Low Battery message on the monitor during the calibration program A low battery is indicated by a
58. igure A 2 1850XP Dimensions Top View Adept 1850 1850XP Palletizer Robot User s Guide Rev A 87 Appendix A Dimension Drawings n 581 Y 400 55 i 60 L A A 766 82 5 rot A 3344 3284 2000 ER E Y A 518 Y Y Y All dimensions in mm Figure A 3 1850 Dimensions Side View 88 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Robot Dimensions 280 4115 ol o A A 4 P 543 994 5 L mm iu JM 276 nu 3478 3407 2000 In i o y 412 5 400 45 1 Y Y Y All dimensions in mm Figure A 4 1850XP Dimensions Side View Adept 1850 1850XP Palletizer Robot User s Guide Rev A 89 Appendix A Dimension Drawings A 2 Control Unit Dimensions 559 00 800 00 1503 50 Y 00 I 100 00 el Front View Dimensions in mm Side View Figure A 5 1850 1850XP Control Unit Dimensions 90 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Tool Flange Dimensions A 3 Tool Hange Dimensions 2100 6 M8 depth 15 every 60 Pe eS 2 6H7 depth 8 All dimensions in mm Figure A 6 1850 Tool Hange Dimensions Adept 1850 1850XP
59. inued Alarm Corrective Display name Operating status Cause measure Regenerative Comes on when the Faulty PC board Replace the servo error control power amplifier supply is ON Comes on after the Faulty Replace the servo main power supply is regenerative amplifier turned on transistor Comes on during e The load inertia Correct the operation is too large load inertia within specs Deceleration is Make the too large deceleration time longer Memory Comes on after the Faulty PC Replace the servo error main powersupplyis board amplifier turned on Memory IC failure Battery Comes on after the The battery Replace the voltage drop main powersupplyis voltage is low battery turned on 58 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Amplifier Status and Fault Messages Table 5 3 Amplifier Fault Alarm Codes Continued Alarm Corrective Display name Operating status Cause measure CPU error Remains OFF after The 5V power Replace the servo the control power supply is low amplifier supply is turned on Faulty PC board Replace the servo amplifier CPU failure Turn off the No control power indication supply then turn it on again If the same error occurs again replace the servo amplifier Goes off during The 5V power Replace the servo operation supply is low amplifier
60. ion Joint 3 2 000 mm 78 7 in Joint Rotation Joint 1 220 Joint 2 300 Joint 4 360 nominal 720 maximum Payload Including end effector 70 kg 154 Ib Inertia Load Maximum 7 8 kg m 26 700 Ib in Cycle Time 700 cycles hour Resolution Joint 1 0 00044 Joint 2 0 00055 Joint 3 vertical Z 0 0037 mm 0 00014 in Joint 4 tool rotation 0 00055 Repeatability X Y plane 10 3 mm 40 012 in Joint 3 vertical Z 0 3 mm 40 012 in Joint 4 rotational 3 0 5 Joint Speed maximum Joint 1 120 sec Joint 2 160 sec Joint 3 1 000 mm sec 39 4 in sec Joint 4 225 sec Weight Robot without options 1 800 kg 4 000 Ib a See Appendix B for information on Performance Simulation Adept 1850 1850XP Palletizer Robot User s Guide Rev A Chapter 2 Description Table 2 2 Adept 1850XP Robot Performance Specifications Reach Maximum radial 1 850 mm 72 8 in Minimum radial 500 mm 19 7 in Vertical clearance bottom of base to end effector flange 412 5 mm 16 2 in Vertical Stroke Z direction Joint 3 2 000 mm 78 7 in Joint Rotation Joint 1 220 Joint 2 300 Joint 4 360 nominal 720 maximum Payload Including end effector 150 kg 330 Ib Inertia Load Maximum 13 7 kg m 46 900 Ib in Cycle Time 1 000 cycles hour Resolution Joint 1 0 00044 Joint 2 0 00035 Joint 3 vertical Z 0 0049 mm 0 00019 in Joint 4 tool rot
61. m numbers in Table 4 1 li User Signal Lines 20 wires Robot Connection Top of Outer Link Panel User Air Lines one of two Figure 4 3 User Line Connectors 40 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Control Unit Digital I O 45 Control Unit Digital I O The Digital I O terminal strip shown in Figure 4 4 is provided for user Digital I O to the Adept MV controller The I O terminal strip is located inside the rear of the control unit This terminal strip connects directly to the Digital I O connector on the SIO module in the Adept MV controller The connectors on the I O terminal strip correspond by number to the pinouts listed in Table 6 5 in the Adept MV Controller User s Guide Note that pins 41 43 and 42 44 are connected together by jumper wires These jumpers should be replaced by user installed E stop circuitry as described in the Adept MV Control ler User s Guide Control Unit Rear View with Door Open S o6 93 00000000000000000 pl Jo 00000000000000000 OO000000000000000 oo Digital I O Terminal Strip Removable Rear Option Panel can be used to route user wiring into control unit il Figure 4 4 Contol Unit Digital I O Terminal Strip WARNING Always turn off power to the control unit before attempting to install Digital I O wiring inside th
62. mal working envelope define new softstops using the SPEC utility program formerly CONFIG R supplied with the system Refer to the V Release Notes and the Instructions for Adept Utility Programs Softstops The MV controller uses softstops to define the limits of robot movement under program control or under operator control using a manual control pendant If a robot joint travels beyond a softstop the MV controller automatically shuts off high power and activates the Z axis brake stopping the robot Furthermore the Adept MV controller will not allow high power to be turned on while any joint is beyond its softstop Adept 1850 1850XP Palletizer Robot User s Guide Rev A 47 Chapter 5 Operation Limit Switc hes In most cases joint travel will not go beyond the softstops However exceeding softstops is possible if a programming or other error occurs during high speed operation In this case limit switches are installed just beyond the softstop positions If joint 1 2 or 3 not joint 4 trips a limit switch the MV controller automatically shuts off HIGH POWER and activates the Z axis brake If this situation occurs use the Z AXIS BRAKE RELEASE BUT TON and manually move the arm back within the softstop limits Hardstops The hardstops for each joint are fixed mechanical stops beyond the softstops and the limit switches In most cases the softstop and the limit switch will prevent joint travel from con tacting a hardstop however
63. manuals available if you are going to be pro gramming the Adept system This manual refers to both the standard and optional manu als The following sections give a brief description of the contents and organization of the Adept documentation set Standard Manuals In addition to this 1850 1850XP Palletizer Robot User s Guide the following manuals are shipped with the system Manual Material Covered Adept MV Controller User s Guide This manual details the installation configuration and maintenance of your Adept MV controller V Operating System User s Guide A description of the vr operating system This manual describes loading storing and executing programs Instructions for Adept Utility Programs Adept provides a series of programs for configuring and calibrating various features of your Adept system This manual describes these utility programs V Version 11 X Release Notes Describes changes to V The Release Notes are updated as each version of V is released 2 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Related Manuals Other Adept Product Manuals When you order AdeptVision VME AdeptMotion VME AdeptForce VME or any AIM software product you will receive manuals that cover those products Also optional hardware such as the Manual Control Pendant will come with a manual A partial list is shown below Manual Material Covered Adept Vision VME User
64. nch Oil brush Ball screw M60 x 20L bolts Upper bellows Ball screw M60 x 20L bolts Lower bellows Figure 6 6 1850XP J oint 3 Z Axis Ball Screw 1 Move the Z axis down near the lower end of the envelope Switch off the power 2 Remove the bolts holding the upper bellows in place and pull down the upper bellows to expose the upper part of the ball screw 72 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance Brush grease evenly onto the upper part of the ball screw Apply the grease approximately 1 mm 1 16 in thick Pull up the bellows and reinstall the bolts Remove the M6 x 20L bolts holding the lower bellows in place and pull down the lower bellows Switch on the power and move the Z axis up near the top of the envelope Switch off the power Brush grease evenly onto the lower part of the ball screw Apply the grease approximately 1 mm 1 16 in thick Pull up the bellows and reinstall the bolts Turn the power back on and exercise the Z axis several times to distribute the grease Adept 1850 1850XP Palletizer Robot User s Guide Rev A 73 Chapter 6 Maintenance Lubricating the 1850XP J oint 3 LM Guide Lubricate the Joint 3 Z axis linear motion LM guide every three months Grease Tools 74 Multemp SRL Kyodo Yushi See Table 6 6 for acceptable equivalent Grease gun
65. o the wooden supports 5 Unbolt the two transport brackets and remove them from the robot Hook bolts 2 of 4 Robot with all axes Top transport D turned inside for transport bracket ae O Figure 3 4 Top View Showing Transport Bracket Adept 1850 1850XP Palletizer Robot User s Guide Rev A 29 Chapter 3 Robot Installation Vertical hook e ge Hook bolt M20 Ko DN b Top transport bracket LS Counterbalance lock screw one on each side EAS EL Bottom transport bracket Figure 3 5 Upright Robot with Transport Brackets 30 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing the Robot 3 4 Installing the Robot Procedure to Install Robot 1 Za Raise the robot and move it into position over the mounting plate Lower the robot onto the plate Install the M20 x P2 5 mm mounting bolts through the robot base and into the threaded holes in the plate Use six bolts for the 1850 or eight bolts for the 1850XP Tighten the mounting bolts See Table 3 1 for torque specifications Remove the lifting equipment Save both brackets and related hardware for future moves CAUTION The 1850 1850XP Palletizer Robot must be bolted to the mounting plate and the mounting plate bolted to the floor before the lifting shackles are removed If the an unmounted Adept 1850 1850XP is fully extended it may fall and cause substantial d
66. or Joint 2 B axis gear Grease fitting for Joint 4 W axis gear Figure 6 4 1850J oint 1 2 and 4 Grease Fittings 1 Move the Z axis down to bring the robot arm to a convenient working height Switch off the power 2 Using the grease gun inject grease into the Joint 1 Joint 2 and Joint 4 grease fit tings shown in Figure 6 4 3 Switch on the power and exercise Joint 1 Joint 2 and Joint 4 several times to dis tribute the grease in the joints Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850XP Periodic Maintenance 6 3 1850XP Periodic Maintenance This section describes the preventive maintenance procedures that are required to keep the 1850 XP Palletizer Robot operating properly 1850XP Maintenance Schedule See Table 6 2 for a summary of the preventive maintenance procedures and some rough guidelines on frequency Table 6 3 Recommended 1850XP Preventive Maintenance Schedule Interval Item Comment Daily before 1 Confirm that each axis moves operation smoothly without vibration 2 Confirm that no abnormal sound occurs as each axis moves 3 Confirm that all bolts and nuts are secure and have not worked loose including all cable connections between robot and controller 4 Confirm that Emergency Stop works correctly Weekly Lubricate Joint 3 Z axis chain Cosmo Olpus 100 Cosmo See page 71 Monthly Grease Joint 3 Z
67. ore the program supply is started Comes on after the The 3 phase Correct the main power supply is power supply power supply turned on has a phase missing Insufficient Correct the tightening of wiring input terminal 56 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Amplifier Status and Fault Messages Table 5 3 Amplifier Fault Alarm Codes Continued Alarm Corrective Display name Operating status Cause measure Velocity Comes on after the Faulty PC board Replace the servo control error main power supply is amplifier turned on Comes on with servo The motor Replace the ON oscillates servo amplifier vibrates Replace the motor Comes on when a e Wire broken in Correct the velocity command is motor wiring entered Motor encoder signal error External Comes on after the Faulty PC board Replace the servo overheating main power supply is amplifier turned on The H1 and H2 Correct the terminals are wiring open Servo Comes on after the Faulty PC Replace the servo processor main power supply is board amplifier error turned on The 5V power supply is low Faulty servo Replace the servo processor amplifier The 5V power supply is low Adept 1850 1850XP Palletizer Robot User s Guide Rev A 57 Chapter 5 Operation Table 5 3 Amplifier Fault Alarm Codes Cont
68. ork together to move the joint back within limits as follows 1 Make sure that the amber HIGH POWER light is off 2 One person must push and hold the Z AXIS BRAKE RELEASE button throughout the operation The Z AXIS BRAKE RELEASE button is located inside the front of the Control Unit next to the AMP FAULT RESET button above the MV controller WARNING The robot may move unexpectedly when the Z axis brake is released Because of the internal counterbalance with a heavy payload the robot arm might move down with a light payload the arm might move up 3 One or more people must manually move the robot arm back inside the allowed joint range The arm is heavy and its vertical position is affected by the internal counter balance weight inside the main column It might take two or more people to move the arm 4 After making sure that no one is in the robot operating area restart the program WARNING Make sure that no one is in the robot operating area before restarting the program Adept 1850 1850XP Palletizer Robot User s Guide Rev A 51 Chapter 5 Operation 5 7 Amplifier Status and Fault Messages The four amplifiers are located in the Control Unit below the MV controller The LED dis play near the top of each amp gives the operational status of the amp Open the front door of the Control Unit to see the front of the amps If the system turns off and you can t enable power the problem could be caused by an amp fault Tabl
69. perty Class 8 8 3800 kgfcm SAE 3 4 10 UNC SAE Grade 5 275 ft lb Adept 1850 1850XP Palletizer Robot User s Guide Rev A 23 Chapter 3 Robot Installation 1500 8 228 For Bey anchor bolts 50 t A A 565 700 Y A 1500 rov 295 Y A 295 700 Y A 345 ry Y Y 50 50 4 C30 gt gt 6 M20 x P2 5 330 330 For mounting y E 1850 robot 660 50 gt gt lt 50 gt 700 700 All dimensions in mm See text for SAE equivalent anchor and robot mounting bolts Figure 3 1 1850 Mounting Plate 24 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Installing the Mounting Plate 1500 8 28 For anchor bolts 50 Y A Em 565 700 gt 240 1500 gt 4 240 a 700 240 215 Fs Y i 50 4 C30 8 M20 x P2 5 I m For mounting 250 one 1850XP robot 50 gt 760 gt lt 50 700 700 All dimensions in mm See text for SAE equivalent anchor and robot mounting bolts Figure 3 2 1850XP Mounting Plate Adept 1850 1850XP Palletizer Robot User s Guide Rev A 25 Chapter 3 Robot Installation Mounting Plate Installation The floor under the mounting plate must be level stable and continuous Install the anchor bolts
70. rect the belt must be replaced and the joint encoders recalibrated 6 Inspect the belt for excessive wear or deterioration If the back of the belt or any teeth are cracked the belt is swollen or any teeth are worn half their width or more the belt must be replaced and the joint encoders recalibrated 7 Inspect the pulleys for excessive wear or deterioration If any pulley teeth are worn 1 0 mm or more the pulley must be replaced and the joint encoders recali brated 8 Contact Adept Technology or your service provider for belt replacement and encoder recalibration Figure 6 12 1850XP J oint 2 Belt Test Table 6 5 1850XP J oint 2 Belt Tension Specific ations Item Specification Type of belt 420 8M 30 UNITTA F Force applied at point F 2 7 kgf L Belt deflection at point L 6 6 mm 0 26 in W Belt width 30mm S Span 420 mm T Tension 35 kgf Adept 1850 1850XP Palletizer Robot User s Guide Rev A 79 Chapter 6 Maintenance 6 4 Compatible Lubricant Information The compatible products in the table below can be substituted for the lubricants called out in the procedures in Section 6 2 and Section 6 3 Table 6 6 Compatible Lubricants Brand Vendor Marutemp SRL Lithium grease Kyodo Yushi Compatible products Beacon 325 Exxon MobilGrease 22 Mobil MobilTemp SHC100 Mobil Zemico Grease
71. rol unit panels that have the same label as the cable If a cable is installed incorrectly the motions of the robot will be unpredictable and uncontrolled possibly resulting in serious damage and injury Installing Cables Between the 1850 Robot and 1850 Control Unit The 1850 system uses five cables between the control unit and the robot Two motor cables labeled M A Z and M B W Two encoder cables labeled EN A Z and EN B W One signal cable labeled RSC Install the motor cables the encoder cables and the RSC signal cable between the 1850 robot and the 1850 control unit Each cable is labeled at both ends to match the labeled connectors on the robot and control unit connection panels See Figure 4 1 1 Connect the motor cables to the matching connectors on the robot and control unit connection panels One end of each cable mates with the matching robot con nector and the other end mates with the connector on the control unit The 1850 motor cables and connectors are labeled M A Z and M B W 2 Connect the two encoder cables to the EN AZ and EN BW connectors on the robot and control unit connection panels 3 Connect the RSC signal cable to the RSC connector on the robot and control unit connection panels Adept 1850 1850XP Palletizer Robot User s Guide Rev A 37 Chapter 4 Control Unit Installation 1850 Control Unit Connection Panel ENAZ G O OO O Keyboard Ife i Pointer mE MB ENBW Termin
72. s available with AdeptVision VME option Adept 1850 1850XP Palletizer Robot User s Guide Rev A 3 Chapter 1 Introduction L3 Notes Cautions and Wamings 14 There are three levels of special notation used in this equipment manual In descending order of importance they are WARNING If the actions indicated in a WARNING are not complied with injury or major equipment damage could result A Warning statement will typically describe the potential hazard its possible effect and the measures that must be taken to reduce the hazard CAUTION If the action specified in the CAUTION is not complied with damage to your equipment could result NOTE A NOTE provides supplementary information emphasizes a point or procedure or gives a tip for easier operation Safety The 1850 1850XP Palletizer Robot may move at high speed and exert considerable force Like all mechanical systems and most industrial equipment it must be treated with respect by both the User and the Operator NOTE This manual follows Robotic Industries Association RIA definitions of User as the responsible person or company and Operator as a person who starts stops or monitors robot or workcell operation This User s Guide should be read by ALL personnel who operate or maintain 1850 1850XP Palletizer Robot systems or who work within or near the workcell We also recommend that you read the American National
73. se the Joint 3 Z axis LM Multemp SRL guides See page 67 Six months 1 Confirm that the mounting plateis See page 64 level 2 Confirm that the mounting bolts are See page 64 torqued correctly 20 000 hours Grease Joint 1 A axis Joint 2 Baxis Optimol Longtime PD O and Joint 4 W axis gears See page 68 NOTE The frequency of periodic maintenance procedures will depend on the particular system its operating environment and amount of usage Use the intervals in Table 6 2 as guidelines and modify the schedule as needed CAUTION Using improper lubricants on the Adept 1850 can cause damage to the robot Be sure to use the recommended lubricants for each lubrication procedure See Table 6 6 for compatible lubricants Contact Adept Customer Service if you have any questions Adept 1850 1850XP Palletizer Robot User s Guide Rev A 63 Chapter 6 Maintenance 1850 Mounting Bolts The 1850 robot is secured to the mounting plate by six bolts with washers and lock wash ers Torque metric bolts to 3800 kgfcm Torque SAE bolts to 275 ft lb Check the torque on these bolts one week after robot operation begins and then at six month intervals 1850 Mounting Plate The mounting plate must remain level to maintain the accurate operation of the robot Check that the mounting plate is level one week after robot operation begins and then at six month intervals 64 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 1850 P
74. te Dimensions cll 04 23 BOWS se vd edu Ave Ab b vh va dasha a vate os Bs S 98 tuus vt We 23 Mounting Plate Installation 26 3 3 Unpacking and Inspecting the Robot 27 Before Unpacking o au ou vom Ros Sos ee gm M a 27 After UN pPaGKING x4 co sr eh ou eA ele dede odd ruo ae 8 27 Repacking for Relocation 0 ee 27 Removing the Robot from the Crate 04 28 Raising the Robot to Vertical 28 3 4 Installing the Robot non nn 31 Procedure to InstallRobot 000 2004 31 Mounting Hole Dimensions for Robot Base 32 Removing Counterbalance LockScrews 33 4 Control Unit Installation 35 4 1 Conditions for Control Unit Installation 36 Facility Requirements 2 nn nn 36 42 Installing the Control Unit 36 Connecting AC Power m aa a a a 36 MV Controller Peripherals rns 36 4 3 Installing Cables Between Robotand Control Unit 37 Installing Cables Between the 1850 Robot and 1850 Control Unit 37 Instaling Cables Between the 1850XP Robot and 1850XP Control Unit 39 4 4 UserConnectionsonRobot 0084 40 UserElecticallines 4 o o 40 USSTAMUNES a a fw O AAA A ae A 40 4 5 Control UnitDigitall O 41 5 Operabon 0 63
75. ters ille ee 81 MV ControllerAirFilter s llle BB BIB 81 Control Unit Rear Door Air Filters llle 81 6 6 Replacing the EncoderBatieries lieri 82 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 61 Chapter 6 Maintenance 6 1 Introduction This chapter is divided into four parts Section 6 2 1850 Periodic Maintenance describes the maintenance procedures for the 1850 robot Section 6 3 1850XP Periodic Maintenance describes the maintenance procedures for the 1850XP robot Section 6 4 Replacing the Control Unit Air Filters describes how to replace the air filters in the Control Unit Section 6 5 Replacing the Encoder Batteries describes how to replace the encoder batteries in the robot Power Settings During Maintenance When performing maintenance procedures disable power according to the following table Table 6 1 Power Settings During Maintenance y Main System AC Power Maintenance Procedure High Power System Power Breaker Cable Lubrication procedures OFF ON 1 ON Plugged in Encoder battery replacement OFF ON 1 ON Plugged in Air filter replacement OFF OFF 0 ON Plugged in Connecting and disconnecting OFF OFF 0 ON Plugged in the cables from the Control Unit to the robot Repairing the robot OFF OFF 0 ON Plugged in Working in the rear of the OFF OFF 0 OFF Plugged in Control Unit Working on the power supply OFF OFF 0 OFF
76. the letter U on the LED display of the affected amplifier See Figure 6 13 A low battery is also indicated by a dot in the lower right corner of the LED dis play of the affected amplifier See Figure 6 13 The dot is displayed in addition to any other status or fault indication that may be displayed on the display Figure 6 13 Encoder Battery Low Indications on the Amplifier Display When actual battery failure occurs the robot cannot function until the battery is replaced Battery failure is indicated by a Battery Failure error message on the monitor during the calibration program NOTE If one battery has to be replaced Adept recommends replacing all four batteries at the same time 1 Turn off the high power to the robot If the robot is not calibrated run the calibration program See Section 5 3 Record robot joint positions Remove the battery panel shown in Figure 6 14 Qr qme iy ho Replace the battery assemblies NOTE The joint position data is protected for the brief time required to replace the batteries 6 Run the calibration program See Section 5 3 7 Compare the robot joint positions to the positions recorded in step 1 8 If the joint positions are identical within 0 01 resume normal operations Adept 1850 1850XP Palletizer Robot User s Guide Rev A Replacing the Encoder Batteries 9 If the joint positions are not identical the joint encoders must be recalibrated
77. trol Unit Lille nnn nmn nmn 36 Connecting AG Powers ves x vs eue Tur c Ge ee 36 MV ControllerPeripheralS oooooococcrrro nennen nn 36 4 3 Installing Cables Between Robotand Control Unit 37 Installing Cables Between the 1850 Robot and 1850 Control Unit 37 Installing Cables Between the 1850XP Robot and 1850XP Control Unit 39 4 4 UserConnectionsonRobot ooccoocoo nn nnn nnn 40 UserElectricallineS o oooooooocrorcra RR IRI 40 User Ar ENG ur prete oe ere ale Eee a wad aped te p aene Dodo e nes 40 4 5 Control Unit Digital I O 0ooooooooooorrna nnm mnn 41 Adept 1850 1850XP Palletizer Robot User s Guide Rev A 35 Chapter 4 Control Unit Installation 4 1 Conditions for Control Unit Installation Facility Requirements The site for the Adept 1850 1850XP Control Unit installation must meet the following conditions Surrounding temperature 0 to 40 C 32 to 104 F Surrounding humidity 35 to 90 non condensing No dust or smoke No ignitable or corrosive materials Non combustible and non corrosive atmosphere No vibration Must have easy access to robot and control unit for service and repair Robot and control unit within reach of the connecting cables The standard cable is 7 m 23 ft 4 2 Installing the Control Unit Connecting AC Power The Adept 1850 1850XP Control Unit is shipped with an AC power cord without termi nations It is the r
78. ttaching tooling utility boxes solenoid packs vacuum pumps screwdrivers cameras lighting etc to the inner link outer link or column Attaching hoses pneumatic lines or cables to the robot These should be designed so they do not restrict joint motion or cause robot motion errors Modifying robot access covers as long as adequate protection is provided after the modification Covers can be modified as long as modifications long screws etc do not extend inside the robot Unacceptable Modifications If not done properly the modifications listed below will damage the robot reduce system reliability or shorten the life of the robot CAUTION Making any of the modifications listed in this section will void the warranty of any components that Adept determines were damaged due to the modification Please contact Adept Customer Service before attempting any of the following modifications to determine if they can be made without causing problems Modifying any of the robot harnesses or robot to control unit cables Modifying any drive system components Modifying including drilling or cutting any robot casting Modifying any robot electrical component or PC board other than those explicitly stated in the robot user s guide Routing additional hoses air lines or wires through the robot Adept 1850 1850XP Palletizer Robot User s Guide Rev A How Can I Get Help L6 How Can GetHelp Within the Continental Unit
79. ure Over voltage If the code comes on Faulty PC board Replace the servo when system power amplifier is turned on but before the program is started Comes on some time The input Bring the power after the main power power supply supply voltage supply is turned on voltage is too within specs high The power supply waveform is distorted Comes on while the The load inertia Reduce the load motor is in operation is too large inertia below the specification Over If the code comes on Faulty PC Replace the velocity when system power board servo amplifier is turned on but before the program Faulty motor Replace the is started encoder servo motor Comes on while the The velocity Change the motor is in operation command is too velocity large command Faulty motor Replace the encoder motor 54 Adept 1850 1850XP Palletizer Robot User s Guide Rev A Amplifier Status and Fault Messages Table 5 3 Amplifier Fault Alarm Codes Continued Alarm Corrective Display name Operating status Cause measure Control If the code comes on The input power Correct the power when system power supply is below voltage supply error is turned on but 170 V before the program is started The 15 V power Replace the servo is abnormal amplifier Comes on while the motor is in operation Input power supply variation too large Bring the power supply voltage within specs
80. y Inc Adept AdeptOne AdeptThree PackOne HyperDrive A Series S Series Adept MC Adept CC Adept IC Adept OC Adept MV AdeptNet AdeptNFS AdeptFTP AdeptVision AdeptMotion AIM VisionWare AIM MotionWare AIM PalletWare AdeptForce AIM and V are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Printed in the United States of America Table of Contents 1 Introduc Hon 4 20052 02 sl Rr bs PR 1 1 1 How This Manual Is Organized 0 4 2 1 2 Related Manuals 2 Standard Manuals Enno 2 Other Adept Product Manuals a lll ss 3 OptionalV DevelopersManuals 0004 3 1 3 Notes Cautions and Wamings 4 14 Safety cit 92220 idi el hot 2b de ato te ae a 4 System Safeguards 2 2 2 2 2 2 2 2 252 52 5 5 Equipment Safety c n 5 15 RobotModifications lll lll ss 6 Acceptable Modifications nn nn 6 Unacceptable Modifications 4s 6 L6 HowCanlGetHelp 7 Within the Continental United States ls s 7 Service Call a io 2 ox kok oso xo woo XGA b UR RS 7 Application Questions 2 2 200048 7 Applications Intemet E Mail Address 7 Training Information 2 0 2 0 0 20 2 7 Within Euro PG oou

Adept 1850/1850XP Palletizer Robot User`s Guide

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