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AdeptOne-XL/AdeptThree-XL Robot Instruction Handbook

1. Figure 11 5 Adept XL Camera Bracket Mounting Pattern 246 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Dimension Drawings Tool Flange Dimensions of the Adept XL Robots Side View 10 16 mm 0 40 in 8 88mm 0 35 in 45 Ts Pw E J U s j i 25 38 4 mm lt 1 5 in gt 1 5 mm 0 06 in 941 145 mm 4 14 mm 1 62 in 0 16 in Y 60 0 mm 2 4 in lke WD 63 0 mm 2 5 in 17 68 mm Bottom View 0 696 in 6 0 0 013 mm B i 0 000 mm 2 N 24 13 mm 6 35 mm 0 95 in 0 250 in 0 2362 in 0 0005 in 0 0000 in 889 mm 0 35 in S 4 Y Y o f 4 Section A A 17 68 mm 0 696 in 7 11 mm 0 280 in Y 50 0 mm f 1 9685 in M3 0 5 mm 0 20 in Ground Wire Attachment Point 4X M6 v 7 62 mm 0 30 in Figure 11 6 Adept XL Robot Tool Flange Dimensions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 247 Chapter 11 Technical Specifications Dimensions of the Adept MV 10 and Adept MV 5 Controllers 215 9 mm 8 5 in
2. 477 7 mm 18 8 in 5 Bi D i EE 15 0 mm 4 0 6 in Note 1 Allow 25 mm 1 in minimum at top and bottom for air intake and exhaust 57 4 mm 16 0 mm 2 3 in 0 6 in 286 7 mm 11 3 in E E Ey U Note 2 Allow 75 mm 3 in minimum at front for power cord and signal cable clearance Figure 11 7 Adept MV 10 and Adept MV 5 Controller Dimensions 248 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Dimension Drawings Dimensions of the Adept PA 4 Power Chassis 290 mm 11 4 in Top View 290 mm le ss 216mm g WN 8 5 in 11 4 in ry e eje eje eje e e eje eje eje e q A Al A A 479 mm 18 9 in 136 mm 5 4 in 1 a f mm S 2 Front View 0 7 in Side View Figure 11 8 Adept PA 4 Power Chassis Dimensions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 249 Chapter 11 Technical Specifications Dimensions of the Controller Interface Panel CIP T To a g 119 38 mm MCP RS ZA 4 70 in a 132 08 mm Q 5 20 in 67 56
3. Adept XL Robot To Earth Ground User Supplied Ground Wire for Robot P Typical Power Distribution Rail User Supplied Earth Equipment Cabinet Ground Ground Point Figure 5 13 Adept XL Robot System Grounding Diagram 110 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Security Panel Functions 5 2 Security Panel Functions The Security Panel Checks for faults in the safety system prior to power up in Manual mode cyclic checking Removes power from the robot if the Teach Restrict sensors in the robot and power chassis detect excessive speed and or acceleration while the robot is in Manual mode Interlocks with the Category B safety circuitry in the Adept MV controller Indicates to the Adept MV controller the source of emergency stop conditions The emergency stop circuitry has two independent channels and is constructed so that no single failure can cause a loss of the safety function and that any latent failures can be detected before power is applied the definition of Category 3 operation Redundant connections are provided on the Security Panel for customer E Stop safety barriers See Category 3 Emergency Stop Circu
4. Figure 7 7 User Connections in the Adept XL Robot Gripper Solenoid Drivers The 24 VDC IC drivers are located on a PC board under the joint 1 cover Each driver is designed to handle a 24 VDC solenoid or motor at a nominal 75 mA each The total current drawn from all four drivers must not exceed 300 mA If you do not use the Adept solenoid valve option you may connect to these drivers using a 9 pin D Sub male connector See Table 7 4 for the connector pins and signal names and Figure 7 5 for location of the connector Table 7 4 Pin Assignment on 9 Pin Connector J240 for Gripper Solenoid Signals Pin Number Signal Name 1 Sig 3001 24 VDC 75 mA max 6 Common 2 Sig 3002 24 VDC 75 mA max 7 Common 4 Sig 3003 24 VDC 75 mA max 9 Common 3 Sig 3004 24 VDC 75 mA max 8 Common 5 Not used 148 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Robot Camera Bracket Kit 7 4 Adept XL Robot Camera Bracket Kit Introduction The Adept XL Robot Camera Bracket Kit P N 95000 00100 provides a convenient way of mounting cameras to the outer link of the robot The kit consists of the following e Two camera plates e Two camera brackets e One camera mount slide bracket e One camera mount channel e MAX 12 mm screws e Mdstainless steel flat washers e M5X 12 mm screws Tools Required e M4 Allen wrench e NO Allen wrench
5. sens 239 Installing Amplifier Modules nen 239 10 10 Spare Parts List MV 5 MV 10 ooooocccoocco eee 240 10 11 Spare Parts List PA 4 Amplifier ChassisS 0oooooooooooo 241 10 12 Spare Parts List Adept XL Robot 2 0 eee 241 11 technical SDCCHICGHONS 3 as 243 11 1 Robot Dimension Drawings 0 0 cece RII 243 AN 244 Customer External Equipment Mounting Area sess 245 Dimensions of the Camera Bracket Mounting Pattern 246 Tool Flange Dimensions of the Adept XL Robots 0 0 cee 247 Dimensions of the Adept MV 10 and Adept MV 5 Controllers 248 Dimensions of the Adept PA 4 Power Chassis 0 0 0000 esses 249 Dimensions of the Controller Interface Panel CIP 00 ee 250 Dimensions of the MMSP Security Panel 0 0 0 00 eee ees 251 Dimensions of the Controller and PA 4 Mounting Brackets 252 Dimensions of the Manual Control Pendant MCP saaa aaae 253 Dimensions of the MCP Cradle ss nn 254 112 Joint Motions 2 cose a Rm ek ee bh ru RUE Dee ee Ee 255 AdeptOne XL Robot Working Envelope aaua ees 255 AdeptThree XL Robot Working Envelope 0 00 aa 256 JO cus Mr oM eet M etes Oona teeta OA 256 Non 258 Joint otic a ctae ptas epe s tage Ens tates ent Gti ee tae eas 258 JOYA stre tette E t dO A I ie e Ro Prid Rt PER SA Aie or dad 259 11 3 AdeptOne XL Robot Specifications oooooooocorrrrnmmoo o 260 11 4 AdepiThree X
6. Adept XL Robot To Earth Ground Figure 4 20 Adept XL Robot Ground Point 94 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 5 1 MMSP Installation and Configuration The emergency stop system of the Manual Mode Safety Package MMSP has several interconnected components see Figure 5 1 The Security Panel controls the Category 3 E Stop system It works together with the AUTO MANUAL operating mode key switch on the CIP Installation of the MMSP Option Before beginning this installation you should have completed all the steps in Chapter 3 and the steps in Chapter 4 through section 4 7 Adept recommends mounting the Security Panel in the same enclosure as the Adept MV controller or in a separate protected enclosure that fulfills the requirements detailed in Table 2 2 on page 47 See Figure 11 10 on page 251 for the dimensions of Security Panel Figure 5 2 shows the Security Panel and its associated components On the left side of the Control Rail X1 is the Category 3 E Stop board with the terminals for the connections of customer supplied safety equipment and digital I O signals On the right side is the Teach Restrict Interface TRI Board The lower DIN rail is the Power Rail X2 containing the external 24VDC power supply the contactors and the circuit breaker for the power chassis AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 95 Chapter 5 MMSP Installation and Configuration
7. gt EXI gt Commissioning Tests gt Accelerometer gt B Amp Voltage Restrict CIP Switches and Buttons gt MCP E STOP Functions gt Brake Holding Force gt Accelerometer Diagnostic gt B Amp Diagnostic gt CIP Diagnostic OANHDOBWNHEH Oo ll V Enter Selection In order to mark the robot as commissioned option 1 must be selected Adept strongly recommends however that the individual options be tested first starting with option 2 This will allow you the operator to become familiar with the tests and procedures before attempting to commission the robot The other options can also be selected individually to test a component that has failed a test After testing the individual component option 1 must be selected again The system is marked commissioned only after all tests pass In some tests the system recognizes the result of the test on its own Other tests require the operator to type a N or Y to indicate the result of the test N indicates no Y indicates yes NOTE Pressing the Enter key without entering Y or N is interpreted as no Accelerometer Test WARNING The user must remain outside the robot workcell with all safety barriers closed while conducting these tests Failure to observe this warning could cause serious injury The accelerometer is tested to ensure that it is operational The MANUAL AUTO and NETWORK key switches are checked by SAFE UTL If a switc
8. Short Fault indicates that an over current in the motor leads has been detected o9 Amplifier Control connector the EJI to Amp cable connec tors are installed here Teach Restrict connector the Teach Restrict to B Amp cable is installed here Motor Power Output connector the Arm Power cable is installed here Figure 4 3 Dual B Amplifier 68 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Joining an Adept PA 4 Power Chassis to an Adept MV Controller 4 1 Mounting the Adept MV Controller and Power Chassis NOTE The Adept MV controller must be installed in a suitable enclosure that provides the environment temperature etc specified in Table 2 2 Robot System Operating Environment Requirements on page 47 and complies with applicable local and national regulations The enclosure must also provide a power disconnect with a method for user service personnel to lock the power in the OFF position This is required for safety including national and international standards such as OSHA Lockout Tagout USA EC 204 1 EN 60204 1 WARNING Failure to provide and use a suitable disconnect device could cause death or injury to personnel Joining an Adept PA 4 Power Chassis to an Adept MV Controller The Adept PA 4 power chassis can be joined to an Adept MV controller using the brackets and screws supplied in the accessory kit Join the chassis a
9. EJl to Amp Cable Controller OOOO 8888 n 355 A Power Chassis Teach Restrict to B Amp Cable cod Gp CIP to AWC Cable JAWC Arm Power Cable If arm m AUX ESTOP JSIO to Cat3 E Stop Cable CIP JMMSP to Cat3 E Stop Cable MCP to CIP Panel Cable User 1 1 0 Security Panel User 2 User to E Stop Teach Restrict Cable 96 Security Panel gt Adept XL Robot S Arm Signal Cable Power Cord From PA 4 Chassis MMSP i OPTION User Supplied 3 phase Power Cord Figure 5 1 Components of a Category 3 E Stop System AdeptOne XL AdeptThree XL Robot Instruction Ha
10. See Figure 7 9 on page 151 and Figure 7 10 on page 152 for allowable mounting hole positions Unacceptable Modifications The modifications listed below may damage the robot reduce system safety and reliability or shorten the life of the robot CAUTION Making any of the modifications outlined below will void the warranty of any components that Adept determines were damaged due to the modification You must contact Adept Customer Service if you are considering any of the following modifications Modifying any of the robot harnesses or robot to controller cables Modifying any drive system components except as noted in Chapter 7 Modifying including drilling or cutting any robot casting is prohibited with the exception of the access covers for joint 1 and joint 2 and the quill cover see Figure 7 9 on page 151 and Figure 7 10 on page 152 Modifying any robot electrical component or printed circuit board Routing additional hoses air lines or wires through the robot Modifications that compromise EMC performance including shielding modifications to cables 1 7 Transport Always use adequate equipment to transport and lift Adept products See Chapter 2 for more information on transporting lifting and installing WARNING Do not remain under the robot while it is transported AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 37 Chapter 1 Safety 1 8 8 Safety Requirements for Additiona
11. Install EJI to Amp Cable Here d AMPLIFIER 4 yi BELT ENCODER S Install Arm Signal Cable Here ARM SIGNAL e Figure 4 15 Robot to EJI Cable Installation AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 85 Chapter 4 Adept MV Controller Installation Connecting the Adept MV Controller to the Power Chassis The EJI to Amp cable connects the controller to the power chassis This cable assembly has a single plug on one end for the EJI and four plugs on the other end for the amplifiers 1 Connect the cable end with the 50 pin connector to the connector marked Amplifier Signal on the EJI board see Figure 4 15 2 Connect the cable end with four plugs in the following pattern a Connect the plug labeled Amplifier Crtl 1 to the Control Signal connector on A amp 1 Tighten the two captive screws securely b Connect the plug labeled Amplifier Crtl 2 to the Control Signal connector on A amp 2 Tighten the two captive screws securely c Connect the plug labeled Amplifier Crtl 3 to the B1 Control Signal connector on the B amp Tighten the two captive screws securely d Connect the plug labeled Amplifier Crtl 4 to the B2 Control Signal connector on the B amp Tighten the two captive screws securely 3 Verify that all connectors are secure fully inserted and installed in the correct location WARNING Verify that a
12. Table 1 7 Partial List of Worldwide Robot and Machinery Safety Standards International USA Canada Europe Title of Standard ISO 10218 EN 775 Manipulating Industrial Robots Safety ANSI RIA CAN CSA Industrial Robots and Robot Systems R15 06 7434 94 Safety Requirements EN 292 Safety of Machinery Basic Concepts General Principles for Design EN 954 1 Safety Related Parts of Control Systems General Principles for Design EN 1050 Safety of Machinery Risk Assessment Applicable US standards include ANSI RIA R15 06 Applicable European standards include EN 775 EN 954 and EN 1050 Applicable international standards include ISO 10218 Adept has performed a risk assessment for this product based on the intended applications of the robot For normal operation AUTO mode user supplied interlocked guarding must be installed to prevent anybody entering the workcell while High Power is on The risk assessment for teaching this product depends on the application In many applications the programmer will need to enter the robot workcell while High Power is enabled to teach robot locations Other applications can be designed so that the programmer does not have to enter the work envelope while High Power is on Examples of alternative methods of programming include 1 Programming from outside the safety barrier 2 Programming with High Power off using brake release button 3 Copying p
13. 0 0 cc eee eee 31 1 3 Risk Assessment ima a A ad 33 1 4 Risk Assessment Category l ooococccco eee 34 Installations Not Requiring Programmer to Enter Workcell 34 Installations Requiring Programmer to Enter Workcell 35 1 5 Intended Use of the Robots ooooocococo eee 35 1 6 Robot Modifications 0 eee 37 Acceptable Modifications sds 9i aden a a Qa ek BE 37 Unacceptable Modifications lisse e 37 1 7 Transport asse om RR RR eee ee ROS A RR ot 37 1 8 Safety Requirements for Additional Equipment 38 1 9 Sound EMISSIONS consa ed eren e e t doe e we a Pn ona dee 38 1 10 Thermal Hazard iii oor ERR ets 38 1 11 Working Areas 52er RR RERO IRR ERR ee ee 38 1 12 Qualification of Personnel 0 cc eee eee 39 1 13 Safety Equipment for Operators 0 0 ce eee 40 1 14 Protection Against Unauthorized Operation ooooooomo 40 1 15 Safety Aspects While Performing Maintenance 40 1 16 Risks That Cannot Be Avoided 00 40 For Systems with MMSP Option ossaa sse 40 For Systems Without MMSP Option sasaaa asaan eee ees 41 1 17 What to Do in an Emergency Situati0N ooocooocoooooomo 41 1 18 How Can Get Help oocoocccco eee eens 41 1 19 Related Manuals 000 ccc eee teens 42 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 9 Table of Conte
14. 0 ccceccecceceececeuess 125 6 1 Graphical User Interface Using the VGB Board oooooooooo 126 Installation Procedo uua estere e o eo ER oe cre 126 6 2 Text Based Interface Using a Terminal 00 cece eee eee 128 Recommended Terminal for Text Based SysteMS 6 00 ees 128 Installation Procedure 5s sse a dece ea d reca 128 6 3 Graphical Interface Using AdeptWindows PC oooooocooooooo 129 Installing the AdeptWindows Software ies 129 Setting Up the TCP IP Interface Ethernet Connection 130 Connecting One PC and One Controller liess 134 7 Optional Equipment Installation 137 7 1 User Signal and Solenoid Driver Lines oooooomommmmmomo 137 USERT T THROUGH USER 294 ai A de e een 137 7 2 Adept XL Joint 5 Wiring llle 141 7 3 Adept XL Robot Solenoid Kit 0 0 cc eee 141 TOONS ROQUE ac te cece Pte Ate A catenins aa 141 Installation Procedure icon it re EX OE OE E ena 141 Install the 24 Volt Valve Assembly lise 141 Test4Ahe Gcripper Valves wisn kA wn vd SER a Ee hee Oa ett Rcs 147 Compressed Air Lines In the Adept XL Robot 148 Gripper Solenoid Drivers iiis 148 7 4 Adept XL Robot Camera Bracket Kit o oooooooooomomo 149 TOUCH di scher oe uA ees to emet tt s 149 Tools RECURS Gi ov A We ceo eo hts d a ee E ote aN 149 STANTON TIMMS 200 ets Rete betonen PES Eie e CR 1
15. AC Line fuse at Power 5 AT 250V IEC 127 style Entry board 5x20mm NOTE The T suffix indicates the fuse response time a 5 AT fuse rating specifies a 5 amp slow blow type Spare Fuses in Sliding Fuses Compartment F1 and F2 y Fuse Holder c Rz yA lt 2 E me oj E Side View of Fuse Holder Figure 10 6 Adept MV Controller Fuse Holder AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 233 Chapter 10 Maintenance 10 7 Special Maintenance for Adept XL IP 54 Robot Rotary Seal Assemblies The joint 1 drive tube rotary seal assembly used on the Adept XL IP 54 Robot is composed of a V ring Nitrile rubber seal that is in contact with the machined upper base cover The seal has a clamp that secures the seal to the joint 1 drive tube and acts as a shield against water and dust intrusion This rotary seal assembly is lubricated at the factory with an O ring lubricant During the initial wear in period some dry seal particles or seal wear particles mixed with grease may extrude from the seal to cover interface The seal should be checked every three months for signs of excessive wear or breakdown of the nitrile rubber Fixed Seals The removable access covers are sealed with custom Nitrile rubber gaskets If these seals degrade or become worn due to physical abuse chemical attack etc they should be repaired or replaced immediately Please contact Adept Cus
16. During system bootup the red SF OK and ES HPE LEDs are lit and the red HD LAN LED blinks After system bootup the SF OK LED should show green If the ES HPE LED shows red the E Stop circuit is open During compact flash reads and writes the HD LAN LED pulses red When the AWC is active on an Ethernet network the HD LAN LED pulses green See Table 8 1 LED Status Indicators on page 183 for details on the LEDs labeled 1 3 Two RS232 ports and one RS422 485 port see the Adept MV Controller User s Guide for pin descriptions and locations Ethernet connector Shielded RJ45 receptacle that supports 10 BaseT communications see the Adept MV Controller User s Guide and the AdeptNet User s Guide Controller Interface Panel CIP connector that accepts a standard 50 pin SCSI cable that routes signals and information to the CIP Note that the CIP does not communicate in SCSI format see sections 4 2 through 4 5 for basic installation details See the Adept MV Controller User s Guide for complete details Figure 4 1 AWC System Processor Board 66 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C A Amplifier Module Overview A Amplifier Module Overview The A amplifier module is a plug in module that contains the circuitry and amplifying components to drive the joint 1 or joint 2 motor in an Adept XL robot In this type of robot system there are two A amplifier modules in the Adept PA 4 power chassis The A amp mo
17. lise 167 Remote High Power Control oo eens 167 Remote High Power On Off Lamp ene 168 Connecting the System Power Switch to the CIP eee 169 Manual Mode Safety Package MMSP Connector saaana aaa 171 Remote User Panel Connections lisse 172 Remote MCP Connections viii da e tae ru 172 Remote E Stop Circuit seen 172 Remote Enable Switch Connections iili sess 172 7 11 Connecting User Supplied Digital I O Equipment 173 JSIO CONMSCION autre tute ata oh eR Maen ack oda et 173 REACT Input Signals 1001 fto 1012 174 Fast Input Signals 1001 to 1004 0 oo coco eene 174 Qutput Signals o aee De ERE YR Bee ae es a eee 175 7 12 Extended Digital I O Signals lsllllllses leslie 177 8 Verifying the System Installation oo oooooo 179 8 1 Installation Check List 0 0 0 eee 179 Mechanical CHECKS ih se rto ete e etr ape Der a 179 AC Power to the Adept Components Checks sess 179 Board and Cable Installation Checks eee 180 Cable Connection Summary All Systems ee 180 Cable Connection Summary MMSP SysteMms o 181 User Supplied Safety Equipment on JUSER and JSIO Connector Checks 181 E Stop Button and Switch Checks isse 181 8 2 Applying Power to the Adept Control SysteM o ooooooooo o 182 LED Status Indicators on the AWC cee 183 8 3 Checks After Applying Power 00 eee 183 8 4
18. Chapter 11 Technical Specifications Dimensions of the Controller and PA 4 Mounting Brackets 266 mm 10 47 in e eje 6 6 e 3 o A Amp A Amp B Amp B Amp a eje Ena eje g o C o o e eje eje eje ello e ele ele ele e o o Power Chassis With Mounting Brackets Installed 481 mm 18 94 in CA CE CE Ce Ce Ce fe 18 5 eTe 91e 916 e 040 sio VGB ws ua foo 1 os Fo somo o e eje e e eje se O poo 89 38 n dE QD AAAA At or ES aig o X w ety Ule a 8 e Ole f o aaa vov EN ay M vov S pv x v o T UT e eje ojo 9e E o e eje eje eje e Ai ede e 9 lle E DODOM 2 JI Controller and Power Chassis With Mounting Brackets Installed 3 2 mm 0 13 in 22 2 mm i 0 87 in ry 133 35 mm 5 25 in Y ry 479 mm 18 8 in 146 05 mm 5 75 in Y 133 35 mm 5 25 in 6 8 mm 0 27 in 4x Y ry 8 56 mm 0 34 in Y 33 1 mm 1 30 in 1
19. In joint state directions are sent from the MCP to move individual robot joints In free state selected joints of the robot are freed from servo control so they can be moved by hand AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Moving a Robot or Motion Device With the MCP Mode Control Buttons The mode control buttons Figure 9 11 change the state being used to move the robot switch control of the robot between the MCP and application programs and enable High Power when necessary Figure 9 11 Mode Control Buttons Emergency Stop Button The emergency stop button will stop program execution and turn off High Power If your robot is equipped with brakes they will be activated COMP PWR Button If High Power is enabled the COMP PWR button selects computer mode If the system is in AUTO mode and High Power is disabled the COMP PWR button enables High Power and selects computer mode In computer mode an executing program or the system terminal has control of the robot After you press the COMP PWR button to enable High Power the High Power lamp begins blinking and the LCD prompts you to press the High Power button You must press this button within the allowed time this time is programmable or High Power will not be enabled If the system is in Manual mode and you press the COMP PWR button to enable High Power you need to take the following actions e release the MCP enable switch press and
20. San Jose CA 95134 408 432 0888 00862 00100 Rev C
21. 252 Manual Control Pendant MCP Dimensions sees 253 MGCP Cradle DIMENSIONS s x m bo tetas eR etr e eR 254 AdeptOne XL Robot Working Envelope sss eese 255 AdeptThree XL Robot Working Envelope 0 ee 256 Adeptone XLJointzT Motion i itr ott oe tte et ort e et teret 257 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 21 List of Figures Figure 11 17 AdeptThree XL Joint 1 MOTION oo es 257 Figure 11 18 AdeptOne XL Joint 2 LEFTY RIGHTY Configurations o ooommm eee 258 Figure 11 19 AdeptThree XL Joint 2 LEFTY RIGHTY Configurations isses 258 Figure 11 20 AdeptOne XL Joint 3 and Joint 4 Motions 1 6 eee 259 Figure 11 21 AdeptThree XL Joint 3 and Joint 4 Motions 6 0 6 6c 259 Figure 11 22 Harting Connector Pin Out oo en 265 Figure A 1 Adept XL Cleanroom Features sssaaa saaran raaa 270 Figure A 2 Z Stroke and Payload oooococcoccco tes 275 22 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 1 5 Table 1 6 Table 1 7 Table 1 8 Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 4 1 Table 4 2 Table 4 3 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 5 7 Table 5 8 Table 5 9 Table 5 10 Table 5 11 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 Table 7 7 Table 7 8 Table 7 9 List of Tables Adept Hardware and Software Compatibility for MMSP Sys
22. Conditions d utilisation et d installations L quipement doit tre install et utilis en respectant scrupuleusement les instructions du manuel Manuel d utilisation du robot AdeptOne AdeptThree XL En particulier les barri res de s curit doivent tre concues et install es pour fournir un niveau de s curit de cat gorie 3 conforme la norme EN 954 Si la syst me fournis par Adept conf rent selon la norme EN954 un niveau de s curit de cat gorie 1 L ensemble robotis doit comporter une enceinte de s curit non fournie par Adept sectionnant l alimentation 380V du ch ssis d alimentation des variateurs PA 4 lors de l intrusion d une personne alors que le robot est asservi L apprentissage des positions doit se faire de l ext rieur de cette enceinte de s curit ou lorsque le robot est hors asservissement L ensemble ne doit comporter que les cartes enfichables ou accessoires list s dans les tableaux 1 ou 2 Si des accessoires list s dans le tableau 2 sont install s l utilisateur devra apr s installation v rifier la conformit avec les directives EMC Cette d claration ne s applique que sur les produits Adept dont les num ros de r f rence sont sp cifiquement list s dans cette d claration Les modifications suivantes sont susceptibles d annuler la conformit des quipements avec les directives de s curit a moins que de nouveaux tests ne soient effectu s Modifications non autoris es des q
23. Example 1 4 kg payload mounted to end effector joint 2 at 0 and all other joints stationary AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Precautions and Required Safeguards maximum possible projectile energy 1 2 4 kg 17 1 m s 584 J 431 ft lb Example 2 6 kg payload mounted to elbow Joint 2 maximum possible projectile energy 1 2 6 kg 10 7 m s 343 J 253 ft lb Additional Safety Information The standards and regulations listed in this handbook contain additional guidelines for robot system installation safeguarding maintenance testing start up and operator training The table below lists some sources for the various standards Table 1 5 Sources for International Standards and Directives BSI British Standards Institute Sales Department Linford Wood Milton Keynes MK14 6LE United Kingdom Phone 0181 996 7000 Fax 0181 996 7001 http www bsi org uk Beuth Verlag GmbH 10722 Berlin Germany Phone 030 26 01 22 60 Fax 03026 01 1260 http www din de en beuth Beuth html TEC International Electrotechnical Commission Rue de Varembe 3 PO Box 131 CH 1211 Geneva 20 Switzerland Phone 41 22 919 0211 Fax 41 22 919 0300 http www iec ch American National Standards Institute ANSI 11 West 42nd Street 13th Floor New York NY 10036 USA Phone 212 642 4900 Fax 212 398 0023 http www ansi org Document Center Inc 1504 Industrial Way
24. Hold the SPEED BAR then press and release the STEP button While continuing to hold the SPEED BAR press and release the STEP button B Amp Tripped as expected Joint 4 is tested in the same manner as joint 3 Press the CLR ERR button on the pendant the following is then displayed B Amp Voltage Restrict test passes Press ENTER to continue Press ENTER to continue with the next test or return to the main menu CIP Switch and Button Test The CIP High Power button and lamp are tested to ensure that they are operational You are asked to test the MANUAL AUTO and NETWORK keyswitches by changing their position The following messages are displayed eR CDP TEST ex Keyswitch test Switch the MANUAL AUTO keyswitch to AUTO and press ENTER As the keyswitch position is changed the program verifies the state If the test fails the main menu is displayed If the test passes the High Power state test is performed and the following messages are displayed HIGH POWER state test Press and hold the HIGH POWER button on the CIP Release the HIGH POWER button As the High Power button is pressed the program verifies its state If the test fails the main menu is displayed If the test passes the High Power enable test is performed and the following messages are displayed HIGH POWER Enable test Press ENTER then press and release the HIGH POWER button w
25. It is critical that safeguards be in place to prevent personnel from entering the workcell whenever equipment power is present The robot system integrator or end user must ensure that adequate safeguards safety barriers light curtains safety gates safety floor mats etc will be installed The robot workcell must be designed according to the applicable local and national standards see section 1 8 on page 38 The safe distance to the robot depends on the height of the safety fence The height and the distance of the safety fence from the robot must ensure that personnel cannot reach the danger zone of the robot see section 1 8 on page 38 The Adept control system has features that aid the user in constructing system safeguards including customer emergency stop circuitry and digital input and output lines The emergency power off circuitry is capable of switching external power systems and can be interfaced to the appropriate user supplied safeguards See Chapter 5 for information on safe and effective use of the robot AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 29 Chapter 1 Safety 30 Impact and Trapping Points Impact Trapping Pinch Points Figure 1 4 Adept XL Robot Impact and Trapping Point Hazards Adept robots are capable of moving at high speeds If a person is struck by a robot impacted or trapped pinched death or serious injury could occur Robot configuration joint speed joint
26. Unit 9 Belmont CA 94002 USA Phone 415 591 7600 Fax 415 591 7617 http www doccenter com AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 31 Chapter 1 Safety 32 Table 1 5 Sources for International Standards and Directives Continued Global Engineering Documents 15 Inverness Way East Englewood CO 80112 USA Phone 800 854 7179 Fax 303 397 2740 http global ihs com Robotic Industries Association RIA 900 Victors Way PO Box 3724 Ann Arbor MI 48106 USA Phone 313 994 6088 Fax 313 994 3338 http www robotics org Table 1 6 Other Standards Related Organizations American Electronics Association AEA Europe 40 rue des Drapiers 1050 Brussels Belgium Phone 011 32 502 7015 Fax 011 32 2 502 6734 http webl aeanet org homepage europe council html http www aeanet org AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Risk Assessment 1 3 Risk Assessment Without special safeguards connected to its control system the Adept XL robot could inflict serious injury to an operator working within its work envelope Safety standards in several countries require that appropriate safety equipment be installed as part of the system Table 1 7 lists some of the safety standards that affect industrial robots This is not a complete list You must comply with all applicable local and national standards for where the robot is installed
27. dust tight and protection against water splashing The Adept XL robot product line with the IP 54 option includes the following upgrades e Corrosion resistant external fasteners Joint 1 drive tube sealing hardware Joint 2 labyrinth sealing design Gasketed access covers for the quill Joint 2 encoder and inner and outer link covers Blower attachment fitting sealing arrangement at the robot s base e Stainless steel tool flange When configured with the IP 54 Option the Adept XL robot product line meets the dust and water protection requirements as defined in IEC 529 Degrees of protection provided by enclosures IP Code IP 54 Adept XL Robot The standard Adept XL robot which has an IP 20 rating can be upgraded to an IP 54 protection class with the IP 54 hardware upgrade kit see Table A 2 on page 274 To achieve the IP 54 rating the kit provides custom gaskets for the quill cover joint 1 upper cover joint 2 upper cover and joint 2 lower cover a multipurpose joint 1 drive tube dynamic seal and deflector blower attachment fitting lower base baffle plate and corrosion resistant fasteners All gaskets and seals are made from Nitrile rubber which provide excellent sealing capabilities and wear resistance CAUTION Damage or removal of any one of these upgrades can lead to reduction in IP protection level damage to the robot system or damage to customer hardware AdeptOne XL AdeptThree XL Robot Instruct
28. 30 1001 2000 Ib in2 5866 10264 kg cm 4 55 2001 3500 Ib in 102650 14663 kg cm 5 85 3500 5000 Ib in AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 155 Chapter 7 Optional Equipment Installation 7 7 DeviceNet Communication Link DeviceNet is a communications link that connects industrial I O devices to a message packeting network All devices connect to the same backbone cable eliminating the need for individual wiring for each I O point Adept incorporates the following DeviceNet ready hardware in the Adept XL robot Female connector for the robot tower Micro style 12 mm thread DIN female connector see Figure 7 11 on page 157 Male Micro style 12 mm thread DIN connector at the robot base A nonstandard DeviceNet cable consisting of two shielded twisted pairs that connect the above connectors Adept considers this cabling to be a drop line with a maximum total length of 6 meters and therefore uses the following wire sizes DeviceNet nte Adept thin cable Power pairs 24 22 Signal pairs 28 24 This means that total current on the power pairs must be limited to 2A instead of the standard 3A in a DeviceNet trunk line Because this is intended to be a DeviceNet drop line with a maximum of 6 meters 16 5 feet the full data rate should be achievable However Adept has only tested the internal cable at 125k baud See Adept MV Controller User s
29. 4 Adept MV Controller Installation Power Cord From 19 mm 3 4 in Power Chassis Shrink Tubing i m d Blue Wire Figure 4 19 Insulating Blue Wire in Power Cord 380 415 VAC 4 10 Connecting AC Power to the Adept PA 4 Power Chassis 92 For systems without the MMSP option power is connected directly to the power chassis For systems with the MMSP option power is connected through the security panel The following sections detail connection of a system without the MMSP option See Chapter 5 for details on installing power to an MMSP equipped system The Adept PA 4 power chassis is shipped from the factory configured for either 380 415VAC or 200 240VAC operation depending on your sales order A voltage setting label is located on the front of the chassis below the circuit breaker The voltage setting is also shown on the ID label on the side of the chassis Verify that the setting matches your facility power before installation This chassis is designed for 3 phase operation only If you need to change the AC voltage setting from 380 415 VAC to 200 240VAC see section 4 9 WARNING Electrical hazard Verify the voltage settings are correct before turning on power Operating the Adept PA 4 power chassis with incorrect voltage settings can cause damage or injury Connecting the Power Chassis AC Power Cord to AC Supply Non MMSP System The user end of the cord is unterminated Connect each conductor of the pow
30. 4 13 Cable Installation Without MMSP Option AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C System Cable Lengths System Cable Lengths Table 4 1 System Cable Lengths Cable Length Arm Power and Arm Signal Standard 5 m 16 5 ft Optional 8 m 26 3 ft and 15 m 49 3 ft EJI to Amp MV 10 1 m 3 ft JSIO to Cat3 ESTOP MMSP Option 3 0 m 10 ft CIP to Cat3 ESTOP MMSP Option 3 0 m 10 ft User to ESTOP Teach Restrict 1 8 m 6 ft MMSP Option Teach Restrict to B Amp 1 8 m 6 ft MMSP Option Controller Interface Panel CIP to AWC 2 m 6 5 ft PA 4 Power Cord 2 9 m 9 5 ft Adept MV Power Cord 3 m 10 ft MCP Cable 1 6 m 5 4 ft Connecting the Robot to the Power Chassis The cable between the robot and power chassis is called the Arm Power cable The robot end of the cable has a large rectangular Harting connector with four slotted screws The opposite end of the cable has three separate square 9 pin connectors that go to the power chassis 1 2 see Figure 4 14 on page 84 The fourth connector is not used Connect the Harting connector of the Arm Power cable to the Arm Power interface on the back plate of the robot Verify that an O ring gasket is in place to seal the Harting connector to the electrical bulkhead Tighten the four captive screws securely Make sure that there is at least 254 mm 10 in behind the electrical bulkhead for cab
31. 5 4 on page 100 Table 5 1 AC Power Cord Specifications for Power Chassis Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 25 amps Number and size of 5 x 2 5 mm conductor size Color code 380 415 VAC line 1 black line 2 black line 3 brown neutral blue ground green yellow Color code 200 240 VAC line 1 black line 2 black line 3 brown no connection blue must be insulated see page 99 ground green yellow AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 107 Chapter 5 MMSP Installation and Configuration Table 5 2 Connecting Power Cord of the Power Chassis to the Terminals on the Power Rail X2 Wire Description Wire Color Terminal Number Color code 39 380 415VAC line 1 black X2 AP2 T1 line 2 black X2 AP2 T2 line 3 brown X2 AP2 T3 neutral blue X2 N ground green yellow X2 PE Color code 39 200 240VAC line 1 black X2 AP2 T1 line 2 black X2 AP2 T2 line 3 brown X2 AP2 T3 no connection blue must be insulated see page 99 DH ground green yellow Contactors Power Rail X2 Terminals J N blue PE green yellow ololo Circuit Breaker O00 O00 m AP1 AP2 Ir OOO am FT gs T1 I2 18 L1 L2 L3 IN DC Power Supply Install Power Cord Install Power Cord to from Power 30
32. 5 mm 7 in 447 0 mm 17 60 in gt Figure 3 2 Mounting Hole Pattern Robot to Plate Spool AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 55 Chapter 3 Robot Installation Required Robot Arm and Signal Cable Clearance At least 254 mm 10 in of clearance is required behind the robot so the power and signal cables do not have excessively tight bends T 1 254 mm K Arm Power Cable 10 0 in EN 20 955 mm 0 825 in I NW Robot Base Arm Signal Cable 15 875 mm 0 625 in Figure 3 3 Required Clearance for Robot Cables 56 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Mounting the Robot M12 x 60mm or 1 2 13 UNC x 2 5 in Hex Head Bolt With Lock M12 M adore UNG 4 in Hex Head Bolt With and Flat Washers 3 places x 4 in Hex i Lock and Flat Washers Robot m Base 4 places 16 mm 5 8 in Plate to Floor Through Hole 4 Places Mounting Plate M12 or 1 2 13 UNC Robot To Plate 2095 9 5 di Tapped Holes s mm g Os 3 Ban Q 3 5 in Expansion Bolt Anchor p Concrete Floor Y Thread End Down x o d E 4 Places Qc ue Drawing Not to Scale S A lt _ 22 mm 7 8 in Diameter Floor Holes 4 Places Figure 3 4 Mounting Plate to Floor Installation Detail AdeptOne XL AdeptThree
33. 508 0 mm 20 00 in OO 586 mm 23 08 in gt 497 mm 19 60 in 4 1726 4 mm Es 67 97 in 144 mm s 5 7 in 4 zx 1302 mm 51 26 in 1152 9 mm TRE 45 39 in 876 3 mm eee 84 50 in 520 7 mm F fff t 20 50 in 281 mm 303 mm 11 06 in I 11 93 in Y Y Y I M y y Y See Figure 3 3 for O required clearance at rear of robot 242 mm 9 52 in Figure 11 2 AdeptThree XL Robot Top and Side Dimensions 244 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Dimension Drawings Customer External Equipment Mounting Area 104 17 mm See Figure 7 10 for cover 4 101 in dimensions Liege ated 66 04 mm 2 600 in 4X M5 10 mm Figure 11 3 AdeptOne XL External Equipment Mounting Area 237 19 mm 9 338 in 66 04 mm 2 600 in 4X M5 y 10 mm Figure 11 4 AdeptThree XL External Equipment Mounting Area AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 245 Chapter 11 Technical Specifications Dimensions of the Camera Bracket Mounting Pattern 30 48 mm 1 200 in 4X M5 y 13 mm 101 60 mm 4 000 in
34. 7 10 Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 Figure 7 18 Figure 7 19 Figure 7 20 Figure 8 1 Figure 8 2 Figure 9 1 Figure 9 2 20 Location of Power Labels Moving Blue Wire From AP1 L2 to Neutral 380 415 VAC Insulating Blue Wire in Power Cord 380 415 VAC Typical 380 415 VAC Connection for MMSP System Typical 3 Phase 200 240 VAC Connection for MMSP System Connectors on Power Rail Adept XL Robot System Grounding Diagram Main Components of the Safety System Category 3 E Stop Board and Teach Restrict Interface TRI Board on Control Rail 113 Category 3 E Stop Schematic Sheet 1 Of 2 eese Category 3 E Stop Schematic Sheet 2 of 2 Connecting the A Series Monitor and Keyboard isses AdeptWindows Installation The Controller IP Address One PC One Controller User Connector Locations on the Tower Assembly Adept XL Robot Base Showing Air Filter and Cable Connector Locations 139 Gripper Solenoids Connector Locations Solenoid Valve Assembly Tube and Cable Routing Tower Bracket Tubing Cable Tie Installation esee User Connections in the Adept XL Robot Adept XL Robot Camera Mounting Bracket J1 Access Cover Mounting Locations for Tooling 0o0oooommo m o J2 Upper Cover Mounting Locations for Tooling Micro Style Connector Pinouts JCOM Pin Locations AWC User Communication Connectors JUSER 37 Pin D sub Connector J User 37 Pi
35. AC Power Chassis Figure 5 12 Connectors on Power Rail AC Power Requirements for MMSP Option The AC power for the power chassis is routed through the security panel See Power Requirements on page 48 for power requirements The power consumed by the security panel itself is negligible and is included in the 20 amp circuit requirement 108 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option Connecting AC Power to the Security Panel The main AC power supply for the robot is connected to the circuit breaker F1 on the Power Rail X2 The 3 phase AC power cord must be supplied by the user The current rating should equal or exceed that specified in Table 5 3 The cord must meet all applicable local national and international standards and regulations for current voltage ratings wire gauge colors etc Connect each conductor of the power cord securely to your AC power source refer to the first two columns of Table 5 4 for the color code Install the other end of the power cord to the terminals shown in the terminal number column The installation must meet all applicable local national and international standards and regulations WARNING Electrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord An incorrect installation can injure or kill anybody who touches the equipment in the robot wo
36. Back Figure 4 6 Installing Mounting Brackets on an Adept MV Controller AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 73 Chapter 4 Adept MV Controller Installation M4 x 25mm pan head screws two places OS To Install Mounting Brackets on an Adept PA 4 Power Chassis e Remove and discard three existing countersunk screws from the chassis side at locations shown in drawing o o Place bracket in desired position and secure with indicated M4 screws and washers from the accessories kit co e Repeat process for the other side of the controller If the controller is joined to an Adept MV controller o o o see Figure 4 6 for the location of the screws on the MV controller o o Note See Figure 11 11 on page 252 for M4 x 10mm pan head screw dimensions of the chassis and mounting brackets Panel Mount M4 x 25mm pan head screws M4 x 25mm pan head screws two places two places o o o o pi o o SEO M4 x 10mm pan head screw V x 10mm pan head screw Rack Mount Flush Rack Mount Set Back Figure 4 7 Installing Mounting Brackets on an Adept PA 4 Power Chassis 74 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Panel Switches and Indicators 4 2 Controller Interface Panel Description The CIP is the primary hardware interface to an Adept controller The CIP can be face gasket
37. CMD1 The program file CMD1 V2 must reside on the default disk and it must contain a command program named cmd1 If the file does not exist or does not contain a correctly named program the operation will be aborted and the appropriate error message will be displayed on the LCD If CMD2 is pressed the file CMD2 V2 will be loaded and cmd2 will be COMMANDed Prog Set Function Using the Prog Set button you may select a new program to execute set the starting step number set how many cycles of the program to perform set the monitor speed and start a memory resident application program See Figure 9 10 1 1 50 NEW STEP CYCLE SPEED START OL JO OL JO JO Figure 9 10 Program Set Function Button New Press the NEW soft button and the LCD displays AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 209 Chapter 9 Using the Manual Control Pendant MCP 9 4 SELECT A NEW PROGRAM progl prog2 prog3 prog4 lt MORE gt To select a different program press the soft button under the program name To see additional programs if there are more programs press the lt MORE gt soft button Step Press STEP and the step number will blink and the typing cursor will appear next to the step number Use the data entry buttons to enter the program step to start execution Complete the entry by pressing REC DONE Cycle Press CYCLE and the cycle count will blink and the typing cursor
38. Connectors See Figure 4 10 for the location of the following connectors RS 232 JCOM There is one RS 232 connector on the back of the CIP It is a DB9 connector This RS 232 has no hardware handshake lines See RS 232 JCOM Connector on page 158 for details Manual Mode Safety Package MMSP The Manual Mode Safety Package MMSP designed to meet CE Category 3 requirements for the Adept XL robots is connected here See Installation of the MMSP Option on page 95 for details AUX JEXT This connector is reserved for Adept internal use CIB JSLV This connector is reserved for Adept internal use DeviceNet JDVC DeviceNet is a field bus for industrial devices This standard supports a variety of products including sensors digital I O analog I O RS 232 and PLCs Adept directly supports Digital I O devices and has currently qualified DeviceNet products from Wago and Beckhoff In the future Adept will offer direct support for Analog I O Other DeviceNet product types such as keypads and displays can be controlled using the V FCMD program instructions see the V Language Reference Guide for details See DeviceNet Communication Link on page 156 and the Adept MV Controller User s Guide for details on DeviceNet installations AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 77 Chapter 4 Adept MV Controller Installation Digital I O Connections There are 44 digital inputs and 40 dig
39. E Stop Board 1 8 m 6 ft SCSI Interface Cable MMSP Security Panel CIP to Cat3 ESTOP Cable Controller Interface Panel Side View User Supplied Contactor Adept MV Controller 7 L AC Supply N 100 240VAC PE Figure 7 18 System Power Switch Circuit MMSP Option Manual Mode Safety Package MMSP Connector The CIP also provides a connection for a user supplied MMSP circuit see Figure 7 14 Figure 7 15 Table 7 10 and Table 7 11 for the customer MMSP circuitry AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 171 Chapter 7 Optional Equipment Installation Remote User Panel Connections The CIP provides connections for a remote user panel circuitry that allows a second user panel at another location see Figure 7 14 Figure 7 15 Table 7 10 and Table 7 11 for the customer remote user panel circuitry Remote MCP Connections 172 For the following remote MCP connections see Figure 7 14 and Figure 7 15 and refer to Table 7 10 and Table 7 11 for the customer remote MCP circuitry NOTE If a remote MCP connection has been added through the JUSER connector the optional MCP bypass plug P N 10335 0
40. Figure 5 9 Insulating Blue Wire in Power Cord 380 415 VAC 104 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option Connecting AC Power to the Adept PA 4 Power Chassis The Adept PA 4 power chassis provides amplified power signals to drive the robot motors in an Adept robot system The amplifier modules in the Adept PA 4 power chassis receive control signals from the Adept MV controller The amplifier modules then provide the necessary current to drive the various robot joint motors The facility AC power supply must conform to the requirements detailed in Power Requirements on page 48 If you need to change the AC voltage setting from 380 415 VAC to 200 240 VAC see page 99 WARNING Electrical hazard Verify that the voltage settings are correct before turning on power Operating the Adept PA 4 power chassis with incorrect voltage settings can cause damage or injury WARNING Electrical hazard Voltage regulations in Europe have changed from 220V single phase to 230V The result is that the 3 phase voltage is now 400V SQRT 3 230V It is absolutely not possible to use 3 phase 380V power without a neutral on an Adept robot equipped with the MMSP The neutral is mandatory to run the PA 4 power chassis with 3 phase 380V In the case of 3 phase 380V we rectify only the 220V between two lines and neutral which results in 220V input voltage for the rectifier of the amplifiers If you use
41. Guide for physical installation See the Instructions for Adept Utilities Program for software setup Recommended Vendors for Mating Cables and Connectors A variety of vendors have molded cable assemblies for the Micro style connector including Brad Harrison Crouse Hinds Lumberg Turk and others In addition Hirshmann Phoenix Contact and Beckhoff have mating micro connectors which have screw terminals in the plug to allow the user to make custom cables 156 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Ethernet Connections 7 8 Viewed From Contact End Male Connector pins Micro Style 5 Connector Female Connector sockets Legend 1 Drain Bare 2 W Red 3W Black 4CAN H White 5 CAN_L Blue Figure 7 11 Micro Style Connector Pinouts Ethernet Connections The Ethernet connector is a shielded RJ45 receptacle see Figure 7 13 on page 159 for the location of the Ethernet connection See the AdeptNet User s Guide for details on TCP IP FTP and NFS capabilities Adept strongly recommends the use of shielded twisted pair cables to eliminate interferences from motor amplifier and other sources of electromagnetic radiation Ethernet packet transmissions can be greatly impaired when shielded cable is not used AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 157 Chapter 7 Optional Equipment Installation 7 9 Connecting User Supplied Serial Communication
42. If one of the LEDs is lit the MCP can be returned to background mode by pressing the REC DONE key more than one press may be necessary The predefined functions are described below in section 9 3 When the MCP is in background mode the viewing angle of the LCD can be changed There are three different angles Press the 2 5 or 8 button to select a different viewing angle MCP Predefined Functions Introduction This section describes the manual control pendant functions related to Loading and starting programs Editing global variables Displaying system status Predefined Function Buttons The MCP has five predefined function buttons They are listed and explained below AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 203 Chapter 9 Using the Manual Control Pendant MCP E 6 5 leo E Figure 9 5 MCP Predefined Function Buttons The Edit Function The Edit function button allows editing of location variables and real variables that are used by V programs SELECT DATA TO MODIFY REAL LOC Figure 9 6 EDIT Function Button Real Press the REAL soft button and the LCD displays SELECT REAL VARIABLE TO EDIT varl var2 var3 var4 lt MORE gt var1 var2 etc are global variable names Press the soft button under the variable name to edit that variable The lt MORE gt soft button is shown only when there are more than five glob
43. Lubricate joint 1 encoder gear Every 3 months or approximately 1000 hours Check all screws in robot cover plates and Monthly robot mounting base Check all cable connections Monthly Drain robot compressed air filter moisture trap Monthly Check air filters on controller and power Monthly chassis Check air filter at robot base Monthly Run Safety Utility MMSP Option only Every six months NOTE The frequency of these procedures will depend on the particular system its operating environment and amount of use Use the times in Table 10 1 as guidelines and modify the schedule as needed WARNING The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons as defined in section 1 12 on page 39 The access covers on the robot are not interlocked disconnect power if covers must be removed AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 221 Chapter 10 Maintenance 10 1 Testing the MMSP Hardware Run the safety utility program every six months to test the components of the Category 3 safety system See Using the SAFE_UTL Program MMSP Only on page 184 for details 10 2 Robot Lubrication The quill shaft and joint 1 encoder gear require periodic lubrication The frequency of lubrication will depend on the operating environment and amount of use Initially check the lubrication areas of the Adept XL robot o
44. MCP The TB5 contacts monitor the status of all emergency stop switches See Category 3 E Stop Board and Teach Restrict Interface TRI Board on Control Rail on page 113 for details on these connections The System Power OUT is connected to the CIP system power switch This output can be used to control power to the Adept MV controller and to control auxiliary equipment using a customer supplied relay or contact The terminals for the customer Manual Mode 1 and customer Manual Mode 2 voltage free contacts are two switches that are closed in Automatic mode and open in Manual mode These contacts can be used to shut off workcell peripherals conveyors feeders PLCs network interfaces when programming the robot in Manual mode When used in this fashion the MCP becomes the single point of control for the robot The customer Safety Relay IN N C normally closed feedback contacts must be closed with a jumper if they are not used These contacts must be used to check user supplied relays in the emergency stop circuit for example if there is relay contact in the emergency stop circuit instead of a E Stop switch The terminals for the passive E Stop and related signals are on terminal block TB5 The following table gives the terminal assignments and the signal names Table 5 6 Terminal Assignment on TB5 for Passive E Stop Contacts Terminal Signal Name TB5 1 Customer E Stop 1 OUT Voltage
45. N 42066 14000 Connect tube D 205 mm 8 in to the single end of the 1 4 inch Y union connector Connect tube B and tube C to the pair of fittings shown in Figure 7 3 Connect tube E to the 1 4 inch inlet elbow of the valve assembly as shown in Figure 7 3 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Robot Solenoid Kit Tube B and Tube C Connect Here Two Position 24VDC Solenoid Air Valves Tube E Connects Here i Four Station Air Valve Manifold Quick Disconnect Connectors Figure 7 3 Gripper Solenoids Connector Locations 10 Identify tubes A1 A4 228 cm 90 in by marking each end with wire markers 11 Wire tie tubes A1 A4 into pairs A1 A2 and A3 A4 12 Starting from the outer link housing access port route tubes A1 A4 through the left side cable tray in the outer link see Figure 7 5 Bring the tubing up through the tower bracket one pair on each side of the bracket Route the air lines through the quill see Figure 7 6 Leave approximately 61 cm 24 in of tubes A1 A4 extending from the edge of the outer link cable tray NOTE Left is as viewed from the rear of the robot AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 143 Chapter 7 Optional Equipment Installation Solenoid Valve Electrical Connections 4 B Port Valve Tubing ee Didi Outer Link cover Cable Removed Tube E Mounting Screws Tube C Tubes A1 A4 Tub
46. Power turned on lower the quill to its fully extended position so the bellows folds are as open as possible 2 Turn off AC power to the power chassis 234 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Special Maintenance for Adept XL IP 54 Robot NOTE Make sure the robot remains positively pressurized so the internal air flow can work to dry out any internal condensation that may develop during cleaning 3 Adept recommends that the robot be washed by hand using sponges towels or soft brushes and mild detergents or sanitation chemicals 4 Rinse the robot with a low pressure 0 06 Bar 10 liters minute water hose typical of a garden hose output 5 Inspect the bellows the outer exposed edges of all gaskets and the rotary seal areas after every cleaning to look for signs of wear chafing abrasion or other indications of problems Drying Time Before Operation Allow the Adept XL IP 54 robot to dry for 15 minutes before returning to operation Bolt Removal Resealing Procedure Adept XL IP 54 Robot The access cover bolts and screws on the inner and outer links of the Adept XL IP 54 robot are sealed at the factory to prevent moisture entering the robot as well as to avoid a crevice or depression If any bolts are loosened or removed they must be resealed according to the procedure listed below Hex Fastener ABS Ferrule Washer SS Access T SS Loctite 2442 Figure 10 7 Ade
47. Rev C Tests Performed Periodically If brake valve 2 is functioning properly the system will disable High Power and you can plug terminal lug 205 back onto brake valve 2 Move outside the workcell and press ENTER to complete the test Press the High Power push button when prompted If the tests pass you are prompted to reassemble the electrical bulkhead When the reassembly is complete press ENTER to continue If all brake valve tests pass the program returns to the main menu M6 x 30 mm Electrical l Bulkhead Brake Solenoid Screws 8 Electrical Connectors Electrical Bulkhead Cover Figure 8 2 Brake Solenoid Valve Electrical Connectors AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 195 9 1 Using the Manual Control Pendant MCP The final step in verifying that the system is installed and working correctly is to move the robot through its range of motion using the MCP The following sections tell you how to move all of the joints of the robot Robot Operating Modes To safely move the robot you must understand the robot s two different operating modes Manual and Automatic The CIP has a two position key switch that controls the robot s operating mode For safety reasons High Power is automatically disabled when the operating mode is changed Manual Operating Mode In the Manual lt 250 mm s position robot motion can be initiated only from the MCP In Manual mode the
48. Space Around the Chassis iiis 71 Rack or Panel MOUNTING ida ia 71 Panel Mounino s 23x RR ated qu etas m ep 72 Rack MOUNTO a der ota cct ce ac E eee pce eere e 72 4 2 Controller Interface Panel Description 0 0 0 0 eee eee 75 Panel Switches and Indicators iiis 75 Emergency Stop Switch iiie enn 75 Manual Automatic Mode Switch iile 75 High Power Enabling Switch Lamp eee 76 Manual Control Pendant MCP Connector 0 isses 76 System POWSRSWITCEY n d ne tek set Lote hand ao bine PP dae d 76 NET SWIIGDNA s us cti da Sar rta eb ql ts REA 76 Side COornneGlTOELS sae t a dee edet den cale ee ted de dt e e egere E 76 AWG Interface JAWO iubet tead SL et dts dios 76 User Connector JUSER v oos eb e E e dene rene 76 Back Panel Connector ves ex ar Sead EY SE Y ded e Ra 77 R9 292 G 6 OU scs ene tos sees ale ts ds 77 Manual Mode Safety Package MMSP s sse eee 77 PUG JEXT M scr tesi er hor LX uae Sook le ll LA Mi cA Ue 77 GINEBRA crc 77 DeviceNelGDVG s sco eure Rus ore toL EO e Xen e cat PNIS 77 Digital T O Gorinectllons 24 eenetax cce emer eT EA 78 4 3 Mounting the Controller Interface Panel CIP oooooo 79 Location atte CIP sna eS e E Aes ie GA A ERES 79 4 4 Connecting the CIP to the AWC 2 ccc eee 79 Extended Length CIP to AWC Cable aaua aaaea es 80 4 5 Connecting the MCP to the ClP o ocooocoocccncrn eee 80 MGCP CIOS ni O Cc
49. Use for Remote MCP 7 26 Remote ENABLE hold to run N O contacts make to enable Yes Use for Remote MCP 8 27 Muted Safety Gate CH 1 causes N C contacts Yes E Stop in AUTOMATIC mode only 9 28 Muted Safety Gate CH 2 same as N C contacts Yes pins 8 and 27 10 29 Remote MANUAL AUTOMATIC CIP s MANUAL AUTOMATIC Yes switch CH 1 MANUAL Open switch must be in AUTOMATIC AUTOMATIC Closed mode 11 30 Remote MANUAL AUTOMATIC CIP s MANUAL AUTOMATIC Yes switch CH 2 MANUAL Open switch must be in AUTOMATIC AUTOMATIC Closed mode Voltage Free Contacts Provided by Adept 12 31 System Power Switch Contacts Use Mainly used to turn on MV 5 10 with external relay circuit to turnon AC power with System Power AC Power switch on CIP 13 32 E Stop indication CH 1 Contacts are closed when CIP MCP and user E Stops are not tripped 14 33 E stop Indication CH 2 same as pins Contacts are closed when CIP 13 and 32 MCP and user E stops are not tripped AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 161 Chapter 7 Optional Equipment Installation Table 7 10 Contacts Provided by the JUSER Connector Continued Pin Description Comments Shorted if Pairs SSe a NOT Used 15 34 MANUAL AUTO indication CH 1 Contacts are closed in AUTOMATIC mode 16 35 MANUAL AUTO indication CH 1 Contacts are closed in AUTOMATIC mode Nonvoltage Free Contacts 2 21 Adept Supplied 5 VDC and GND for Use with Remote Hig
50. Using the SAFE UTL Program MMSP Only 000 eee eee 184 Category 3 Robot COMPONENIS 0 eee 184 ACCGeleroieters vue ia aere band pei Bae Aled Gd rds 184 B Amplifier Voltage Restrict eee 184 CIP Switches and BUTTONS ai e eean ctr tie tte o tere n s 184 MEP Enabling Swit inn iii ete eR cC RON ut pea 184 Dual Brake Solenoid Valves sssss ee 185 14 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Table of Contents Robot Brakes xot evo eem eri ed emet eed ba ahd 185 8 5 SAFE UTLM2 aee A A eate ntque t ode fe Ada 185 Commissioned vs Not Commissioned aaua ees 185 starting the SAFE UPL Oty eri a e nde e e ee e etes 186 8 6 Tests Performed at Time of Commissioning lesse 186 Aecelerotneters Testo s a tim a tao pe ct o i af 187 B Amp Voltage Restrict Test 189 CIPSWiteh and BUON lestis tod esent e arco Eat es risas 190 MERE STOP FUNGHON Site 1 etre eI eie cock olla heed day ede erre cete og 191 Brake Holding Force TeSt ise e 192 Additional MMSP Diagnostic Tests 0 leen 193 8 7 Tests Performed Periodically 0 0 eee 193 I ed ired Tools 4 vy de Reed HA ER OF DEG EE OR BE ee Pee 194 Testing the Dual Brake Valves With MMSP 0 000 ee eee 194 9 Using the Manual Control Pendant MCP s 197 9 1 Robot Operating MoOdes 0ooocococ eee 197 Manual OperatingiMode vita e Te ter td t lena ert 197 Automatic Operating
51. Valve The program displays the following prompt Do you want to use the default test point Y N Y Respond Y to enable High Power and move the robot to the test location all joints in their midrange position Press the High Power push button when prompted The robot moves to the test location and performs the first brake test If the test passes press ENTER to disable High Power and prepare for the next brake test To complete the test you must remove the electrical bulkhead and then test each brake solenoid with its electrical connection removed Unscrew the eight M6 screws and remove the electrical bulkhead from the robot base see Figure 8 2 on page 195 Do not disconnect any cables or air lines When the bulkhead is removed and carefully set back move out of the workcell and press ENTER to continue Unplug terminal lug 206 from brake valve 1 and move outside the robot workcell Press ENTER to enable High Power and test brake valve 1 Press the High Power push button when prompted If brake valve 1 is functioning properly the system will disable High Power and you can plug terminal lug 206 back onto brake valve 1 Move outside the workcell and press ENTER to test the next solenoid Unplug terminal lug 205 from brake valve 2 and move outside the robot workcell Press ENTER to enable High Power and test brake valve 2 Press the High Power push button when prompted AdeptOne XL AdeptThree XL Robot Instruction Handbook
52. XL AdeptThree XL Robot Instruction Handbook Rev C 101 Chapter 5 MMSP Installation and Configuration a CN Expo EoES ES E a EE ENHEEEENENENEENEE adept technology Inc adept technology Inc San Jose CA San Jose CA Model MV 10 Part No Model PA 4 Part No Serial No Serial No VOLTAGE AMPERAGE FREQUENCY VOLTAGE AMPERAGE FREQUENCY ooa ae cso ie 292020 Anar ani PTT O O PTT TT J 2 Figure 5 7 Location of Power Labels Changing the Voltage Setting for the Power Chassis From 200 240VAC to 380 415VAC To change the AC voltage setting from 3 phase 200 240 VAC to 3 phase 380 415 VAC follow the three part procedure below This procedure must be performed by a skilled person and should be completed before installing the power chassis Also see Connecting AC Power to the Adept PA 4 Power Chassis on page 105 WARNING Electrical hazard Changing the voltage setting in the power chassis must be done by a skilled person The power supply can injure or kill a person who does not perform this procedure correctly Part 1 Moving Blue Wire on Security Panel 1 Locate the blue wire labeled Neutral that is installed on the L2 position on contactor AP1 X2 AP1 L2 2 Remove that wire from the L2 position on contactor AP1 X2 AP1 L2 and install it in the neutral terminal on the Power Rail X2 N See Figure 5 8 on page 103 102 AdeptOne XL Adep
53. XL Robot Compressed Air Filter 228 Adept XL Robot Fan Filter Inspection and Cleaning 0 229 Adept PA 4 Power Chassis Fan Filter Inspection and Cleaning 229 Adept MV Controller Fan Filter Inspection and Cleaning 229 10 5 Changing the Lamp on the CIP High Power Enable Switch 230 10 6 Controller Fuse Information 0 2 00 ccc eee 233 10 7 Special Maintenance for Adept XL IP 54 Robot 234 Rotary Seal Assemblies 0 eens 234 Saelices 234 Cleaning Information a ORT 234 Removing the End Effector for Cleaning oo oooommm oo 234 Cleaning Procedure Sirise irete tts 234 Drying Time Before Operation oo ci sens 235 Bolt Removal Resealing Procedure Adept XL IP 54 Robot 235 10 8 Adept XL Clean Room Robot Bellows Replacement 236 Required Materials and Tools 0 iens 236 16 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Table of Contents Removing the Bellows 0 ete ees 236 Installing the New Bellows es m 236 F rfhierlnstEUCTIOFiss tie Dee cete A ere gore do da e cn e fa inc eue Meet 237 10 9 PA 4 Power Chassis Circuit Breaker and Fuse Information 238 Chassis Circuit Broken xx cede y tad ae E eek em qa Y haa n trs 238 Chassis and Amplifier Module FUSES 0 ce ees 238 Removing and Installing Amplifier Modules 0 0 0 000 cee 238 Removing Amplifier Modules
54. XX J6 X XX These values represent the current joint positions of the robot or motion device Values will be shown only for joints the robot or motion device actually has Rotational joint values are expressed in degrees and translational joint values are expressed in millimeters World Location When this button is pressed the display shows X xxx xxmm Y xxx xxmm Z XXX Xxmm ll ll ll XXX XX p XXX XX Y XXX XX Y The values represent the current location of the robot or motion device in world coordinates See Moving a Robot or Motion Device With the MCP on page 210 for details on world coordinates Status amp ID When this button is pressed the display shows Status SOFTWARE CNTRLR ROBOT I ID ID ID S The Status button displays program name 50 1 0 Program Speed Cycle Left 206 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C MCP Predefined Functions Program shows the name of the currently executing or most recently executed program Speed shows the current monitor speed Cycle shows the total number of cycles specified when the program was executed Left shows the number of cycles of the program remaining to execute The Software Controller and Robot ID buttons display the ID information for those items Digital I O When this button is pressed the display shows 0000 0011 0032 0001 OUT IN SOFT The top line shows the status of the range of digital
55. a line instead of the neutral in the 3 phase 380V configuration that will immediately destroy the PA 4 power chassis The only way to use 3 phase 380V without a neutral is to add a step down transformer to bring the voltages down to 3 phase 220V In that case it is also necessary to switch the configuration of the PA 4 power chassis to 3 phase 220V IMPORTANT You must also change the wiring of the 24V power supply on the mounting panel of the MMSP when changing the voltage configuration of the PA 4 power chassis The voltages in Europe have changed and there is no longer single phase 220V power it is now 3 phase 230V The result is that the 3 phase voltage is now 400V SORT 3 230V AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 105 Chapter 5 MMSP Installation and Configuration Typical AC Power Installation Diagrams L1 30 380 415V 200 240V L3 200 240V 20A N A PE e MMSP OPTION Fa 108 200 240 VAC 24 VDC PE N L1 Note F4 is user supplied noue de PANE Figure 5 10 Typical 380 415 VAC Connection for MMSP System L1 30 L2 a T 1 200 240V 200 240V 3 20A PE e e SN NC MEC i3 2 bu MMSPOPTION le a Fs 108 ae mM 20A 200 240 M VAC i e a XeseXess APIO 24 VDC Note F4 and F5 are PE L2 L1 user supplied Adep
56. be mounted 15850mm y 6 24 in 79 25 mm 3 12 in 4X Y 3 18 mm 0 125 in X 20 Dimple NOTE M4 x 0 7 Recommended maximum hole size 45 72 mm 1 80 in 96 77 mm DS 3 81 in Material Aluminum O 74 17 mm 2 92 in 148 34 mm lt 5 84 in Boss 64 mm i 8 9 65 mm View AA 0 34 in 2I 0 38 in Figure 7 9 JI Access Cover Mounting Locations for Tooling AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 151 Chapter 7 Optional Equipment Installation 63 50 mm 127 00 mm 2 50 in 5 00 in 4X 3 18 mm 0 125 in X 20 Dimple NOTE M4 x 0 7 Recommended maximum hole size 44 45 mm 1 75 in fJ_ T 127 00 mm 5 00 in 8 13 mm 0 32 in Material Aluminum Y Boss 9 65 mm 0 38 in View A A Figure 7 10 J2 Upper Cover Mounting Locations for Tooling 152 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installing End Effectors on an Adept XL Robot 7 6 Installing End Effectors on an Adept XL Robot The user is responsible for providing and installing any end effector or other end of arm tooling End effectors can be attached to the user flange using either four M6 screws or a ring clamp which are supplied in the accessories kit An M6 x 12 mm dowel pin is also supplied in the accessories
57. cable tie wraps e Pair of diagonal wire cutters e Solenoid valve upgrade kit Adept P N 90862 00100 e Open end wrenches 7 8 in Installation Procedure Install the 24 Volt Valve Assembly 1 Turn off power to the PA 4 power chassis AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 141 Chapter 7 Optional Equipment Installation Remove air pressure from the robot Plug the four individual two wire connectors on the valve harness into the solenoid valves Match each connector to the appropriate valve as follows see Figure 7 4 on page 144 SOL 1 to valve 1 SOL 2 to valve 2 e SOL 3 to valve 3 e SOL 4 to valve 4 Mount the Adept XL 24V solenoid valve assembly P N 30862 00100 to the joint 2 upper cover using see Figure 7 4 on page 144 Two M3 X25 mm socket head cap screws P N 51001 65025 Two M3 stainless steel flat washers P N 54000 96500 e Loctite 222 thread locking adhesive P N 87002 00222 Cutseveral lengths of tubing provided in the kit according to the measurements given in Table 7 2 Table 7 2 Nylon Tubing Lengths Tubing Quantity Length puc ae natural 4 228 cm 90 in Al A4 1 4 inch natural nylon 1 83 mm 3 1 4 in B 1 96 mm 3 3 4 in C 1 205 mm 8 in D 1 4 inch yellow nylon 1 423 mm 16 5 in E Connect tube B 83 mm 3 1 4 in and tube C 96 mm 3 3 4 in to the dual end of the 1 4 inch Y union connector P
58. can be swapped and the two output cables can be swapped This could result in a dangerous situation when you restart the controller 3 Remove the CIP from its mounting location 4 Remove the seven screws from the front of the CIP including the MCP bypass plug retaining screw see Figure 10 4 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Changing the Lamp on the CIP High Power Enable Switch Remove these seven screws caer Figure 10 4 CIP Front Panel Screws 5 Carefully pull the front panel away from the body of the CIP You will encounter considerable resistance as there are several plug type connectors that you need to disconnect as you pull the front panel away from the body of the CIP Pull the front panel as straight away as possible 6 Locate the lamp body on the back side of the front panel Turn the lamp body approximately 20 degrees in either direction and then pull the lamp body straight back 7 Ensure that the lamp body is now free Remove the old lamp and insert a new lamp 8 Replace the lamp body by pushing it straight into the lamp housing recepta cle Make sure the contacts on the lamp body are properly oriented see Figure 10 5 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 231 Chapter 10 Maintenance 232 The prongs on the lamp body must be aligned as shown E e EIE Figure 10 5 Lamp Body Contact Alignme
59. disappear and be replaced with the typing cursor Use the data entry buttons to enter a new value and complete the entry by pressing REC DONE Press the NEXT soft button to show the next component of the location variable The location s X Y Z y p and r values will be shown in succession X Y and Z values are given in millimeters y p and r values are given in degrees If a precision point is being edited the joint values for all the joints in the robot will be shown in succession Press the HERE soft button to record the current robot location in the variable being edited WARNING Be extremely careful when changing location values When the robot moves to a modified location it could damage equipment in the workcell 1 If the variable being edited is from an array an additional soft button is displayed that allows you to specify the index of the variable to edit AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 205 Chapter 9 Using the Manual Control Pendant MCP The Display Function The Display function button allows either the current joint values the current world location the system status the digital I O status or the last error message to be displayed on the MCP JOINT WORLD STATUS DIGITAL LAST VALUES LOCATION 8 ID 1 0 ERROR Figure 9 7 DISPLAY Function Button Joint Values When this button is pressed the display shows Jl x xx J2 X XX J3 X XX J4 X XX J5 X
60. enter the workcell when the robot is in AUTO mode AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Intended Use of the Robots 2 Ifno one will enter the workcell with High Power ON not even to teach robot locations then the user must provide a Category 3 dual channel and cross checked interlocked barrier system The system must disconnect the AC power supply to the robot if any person enters the workcell Installations Requiring Programmer to Enter Workcell 1 5 The Manual Mode Safety Package MMSP is available for the Adept XL family of robots The MMSP protects a person teaching robot locations while inside the user provided safety barrier with High Power ON As a consequence of 1 The potential for fatal injury 2 The high probability that an operator could not avoid being hit by the robot in a high acceleration runaway failure condition EN 1050 specifies use of a Category 3 Control System per EN 954 EN 954 defines a Category 3 Control System as one in which 1 No single failure can cause a loss of the safety function 2 Any failure that does occur can be checked prior to enabling power The optional Manual Mode Safety Package MMSP described in this handbook employs a fully redundant Emergency Stop that incorporates Teach Restrict sensors and self checking hardware Through use of a thorough Failure Mode and Effect Analysis it has been determined that the MMSP when installed and op
61. g CR10 p 2 CR9 P CR7 p a a i SR6 A S A SR4 g Y Y LN R7 RL1 SR5 N A A ESTOP E o gt PIS gx M M 6 M M COM e e d e e bd e e e Note The description of the numbers are in Table 5 7 on page 120 Figure 5 16 Category 3 E Stop Schematic Sheet 1 of 2 118 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Category 3 Emergency Stop Circuitry E x ESTOP24V Leza USER 24V x E L2 EE i E N ME bosses VFP3 TB1 5 B a Se IE RED Dir ort fH SE NETWORK exbb xo tha Bg ce ee ce p PI KEYSW2 i i Li VFP3 RLA vt ME A pups Feedback _ 4 VFP3 ALS Mesedoss2a API hc est e Input 5 p J SIOCOM EU NON NAP PRA PE N 3 L2 HE O ROBOT 12VDC BRKREL poe D BFS 3 3 12 VUA SRI RL3 RL2 SR2 43 1 1 11 l 44 34 24 24 34 24 po SR1 us 43 SR3 SR1 SR3 SR2 SR1 1 33 BRKREL 23 23 33 23 11 20 84 ere ee pte 2 1 4 spe SOL1 SOL2 22 ohm 1 2 W 33 R11 220 1W oe 1W r3 1W neo T ROBOTCOM SR3 1 2 1 2 E e i 11 ca P cR4 P CR6 p CR5 7 9 7 Ito D SR1 sR2 Z s3 A Z z A M M i M lt x CR1 Aegis 00 ecd i i Z CAPE AP2 470mF 25V UD ESTOPCOM e e e e e e e e e e Note The description of the numbers are in Table 5 7 on page 120 Figure 5 17 Category 3 E Stop Sch
62. hold the MCP enable switch press the High Power button within the allowed time MAN HALT Button When there is no program executing or a program has paused for a pendant teach routine pressing the MAN HALT button selects manual mode In manual mode the MCP has control of the robot Ifa program is executing the MAN HALT button will stop program execution without shutting off High Power Manual mode cannot be entered if High Power is off the E Stop button LED is not illuminated To enable High Power press the COMP PWR button The MCP is in manual mode when 1 The LED on the MAN HALT button is illuminated and 1 Tf the robot has not been calibrated and High Power is turned on the MCP E Stop switch LED will be lit and both the COMP PWR and MAN HALT LEDs will be off AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 211 Chapter 9 Using the Manual Control Pendant MCP 212 2 One of the manual state LEDs is also illuminated the manual state LEDs indicate the type of manual motion that has been selected either World Tool Joint or Free The system will remain in Manual mode until High Power is turned off or the COMP PWR button is pressed When you have finished moving the robot manually press the COMP PWR button to return control to the controller If a program attempts to execute with the MCP in manual mode the error Comp mode disabled will be displayed When the MAN HALT button is pressed
63. includes the MMSP option skip the remainder of this chapter and go to Chapter 5 to continue with the system installation The remaining sections in this chapter are for systems that do not include the MMSP option AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Changing From 380 415 VAC to 200 240 VAC 4 9 Changing the Power Chassis Voltage Setting This section covers changing the voltage selection for systems that do not have the MMSP option If you are installing a system with the MMSP option see Chapter 5 Changing From 380 415 VAC to 200 240 VAC Complete the following procedure to change the AC voltage setting from 3 phase 380 415VAC to 3 phase 200 240VAC Also see Connecting AC Power to the Adept PA 4 Power Chassis on page 92 WARNING Electrical hazard Changing the voltage setting in the power chassis must be done by a skilled person The power supply can injure or kill a person who does not perform this procedure correctly Part 1 Insulating Power Chassis Power Cord All Systems e gt a yg 7 WARNING High AC voltage is coupled through capacitors to the blue wire of the PA 4 power chassis power cord If you change the voltage setting from 380 415 VAC to 200 240 VAC you must add additional insulation to the blue wire according to the directions provided below Failure to do this could result in injury or death Make sure the power chassis and controller are turned off Disconnect t
64. is connected to the robot The brake release function does not need electrical power and will work even if the controller is turned off or is not connected to the robot Limiting Joint Travel The joint motion or travel is limited by both software and hardware limits The program mable software limits are known as softstops the fixed hardware limits are referred to as hardstops See Table 11 2 on page 261 for the AdeptOne XL and Table 11 4 on page 263 for the AdeptThree XL Softstops Softstops are used when the normal motion range of the robot must be limited if other equipment is installed inside the envelope for example The softstops for each joint are set to their maximum value at the factory To limit any joint s motion range change the joint s softstop value using the SPEC utility program on the Adept Utility Disk supplied with the system Refer to the Instructions for Adept Utility Programs for information regarding this utility program When you are using the MCP to move the robot the robot will stop abruptly when it encounters a softstop This abruptness does not mean a hardstop has been contacted Hardstops 62 In most cases the softstop will prevent joint travel from contacting a hardstop however contact is possible during high speed operation The hardstops are designed to withstand large forces without damaging the robot The hardstops for each joint are fixed mechanical stops The hardstops for joints 1 and 3
65. kit This dowel pin fits in the through hole in the user flange and can be used as a keying or antirotation device in a user designed end effector If hazardous voltages are present at the end effector you should install a ground connection from the base of the robot to the end effector See Figure 4 20 on page 94 Also see Figure 11 6 on page 247 for dimensions of the user flange Calculating Payload Inertia The V program instruction GAIN SET allows you to optimize the servo gain settings for various payloads If you intend to use GAIN SET see V Language Reference Guide for the purpose of gain scheduling you will need to calculate the inertias for each payload configuration In order to select an appropriate value for the servo gain set number you must know the approximate inertia of your payload This is the inertia of the load about an axis that passes through the centerline of the robot quill The inertia should be calculated in kg cm The inertia of any payload can be modeled as the sum of the inertias contributed by individual elements of the gripper and part That is by the formula Total Inertia Inertia of Gripper Inertia of Parts In most cases approximations can be made For example if the mass of the parts carried by the gripper far exceeds the mass of the gripper then you may choose to ignore the inertia contributed by the gripper itself Note that the inertia of a given mass increases significantly as its distance
66. maintenance for Adept XL IP54 robot 234 Specifications Adept shipment 49 mounting surface 45 Speed setting on MCP 210 Speed bars 213 and Slow button 202 onMCP 212 Spool 45 Spool to floor installation detail 58 Standards related organizations 32 Start button on MCP 210 Starting program execution onMCP 210 Starting the SAFE_UTL Utility 186 Status displaying system on MCP 206 Status amp ID 206 Step 209 selecting starting on MCP 209 STEP button 212 Stops Cartesian limit 63 Storage information 50 Store All function on MCP 208 Storing programs with the MCP 208 Support phone numbers 41 Surface specifications mounting 45 System cable connections without MMSP option 82 cable lengths 83 grounding information 88 operating environment requirements robot 47 power switch 76 System power switch AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 287 Index circuit 170 circuit MMSP option 171 Systems with MMSP option 44 without MMSP option 44 7 TB1 TB2 terminal assignments 122 TB3 terminal assignments 123 TB4 terminal assignments 114 TB5 terminal assignments 116 TCP IP interface Ethernet connection setting up the 130 Teach Restrict board location of connectors 113 Technical specifications 243 Terminal assignments for Customer E Stops 114 on TB4 for Customer Supplied E Stop switches 114 on TB5 for Passive E Stop Contacts 116 Terminal block connectors for TB1 to TB5 114 Terminal text ba
67. move with the brakes engaged which should cause a failure The following messages are displayed during the test esting with brakes engaged esting Joint 1 Press the HIGH POWER button when it blinks Motor stalled Mt 5 1 192 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Tests Performed Periodically After the system faults joint 2 is tested The High Power button must be pressed to switch on High Power After testing of joint 2 is complete joints 3 and 4 are also tested The system then tests Joints 1 to 4 with the brakes released If the Brake Holding Force test passes the main menu is displayed Exit SAFE_UTL by selecting option 0 from the main menu The following message is displayed The current robot has passed all MMSP tests The robot will be marked as commissioned in controller NVRAM Press ENTER to continue High Power can now be enabled with the MANUAL AUTO key switch in the Manual position Additional MMSP Diagnostic Tests 8 7 The MMSP menu includes three diagnostic tests choices 7 8 and 9 which allow you to perform tests independent of the MMSP Commissioning function You can test the accelerometer the B amp voltage restrict and the CIP Follow the instructions on the screen as you step through the tests Tests Performed Periodically The Category 3 robot components must be tested every six months These tests are performed using the SAFE
68. of the emergency stop circuitry Verify that these connections are secure and reliable and that a redundant pair of contacts is installed one for each E Stop channel Double check that the state of the contacts on each pair matches and the contacts are closed Each contact is separately connected to its respective E Stop channel Inadvertent connection between the E Stop channels will short the E Stop power supply making it impossible to apply High Power 2 There are two pairs of contacts in the JSIO connector that must be connected to ensure proper continuity of the emergency stop circuitry Verify that these connections are secure reliable and closed prior to enabling power 3 Make sure that guarding around the workcell is properly connected to either the Muted Safety gate inputs on the JUSER connector or if appropriate to the User E Stop connections on the JUSER connector Make sure that all gate E Stop push button switches and other interlocks have two independent electrical poles Make sure that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Make sure that all interlock or emergency stop devices are wired in series not in parallel before connecting to the User E Stop connections Identify all wiring with Channel 1 or Channel 2 Inadvertent connection between the channels will short the E Stop power supply making it impossible to apply High Power 4 Ma
69. operator cannot initiate a motion with the system keyboard and executing programs that require robot motion will halt when a motion instruction is processed This protects the operator in the workcell from unexpected motions of the robot In Manual mode the maximum speed of the tool center point and the joints of the robot is reduced to less than 250 mm per second 10 inches per second Also the motors run at reduced torque This speed and torque reduction is implemented in the software However in Category 3 robots this software limitation of speed and torque must be supported by redundant self checking hardware The optional MMSP provides this additional hardware If the robot tries to move with a higher speed sensors in the robot and the power amplifiers will detect this fault and turn off High Power to the power chassis The MMSP option uses a redundant two channel design with automatic self test WARNING If an Adept XL series robot is not equipped with the optional MMS the robot safety barriers must prevent any personnel from entering the workcell while amplifier power is turned on even when the robot is in Manual mode See Category 3 E Stop on page 166 for requirements for robots not equipped with the MMSP option See section 1 13 on page 40 for a description of safety equipment for an operator who is working in the robot workcell AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 197 Chapter 9 Using the Manual
70. or panel mount 71 joining power chassis to controller 69 keyboard 126 MCP cradle 81 monitor 126 mounting surface 45 of the Controller Interface Panel CIP 79 of the MMSP option 95 overview 43 power chassis in rack or panel 71 power cord to controller 87 power cord to security panel 109 required tools 53 robot on base 60 text based system 128 time for Adept XL camera mounting bracket 149 Installation detail mounting plate to floor 57 mounting spool to floor 58 Installations not requiring programmer to enter workcell 34 requiring programmer to enter workcell 35 Installing AdeptWindows PC 129 amplifier modules 239 base for the robot 54 end effectors on an Adept XL robot 153 mounting brackets on an Adept MV controller 73 on an Adept PA 4 power chassis 74 robot mounting plate 58 robot mounting spool 59 terminal based system 128 the AdeptWindows software 129 the A Series monitor and keyboard 126 the new bellows 236 Insulating blue wire in power cord 200 240 VAC 90 100 380 415 VAC 92 104 Intended use of the robots 35 IP 54 Adept XL robot 273 IP 54 and Adept XL Clean Room robot spare parts list 241 IP 54 hardware upgrade kit 274 IP address controller 133 J J1 access cover mounting locations for tooling 151 J2 upper cover mounting locations for tooling 152 JCOM connector pin assignments 158 pin locations 158 282 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Index JDIO 1 4 78 Joining an
71. power supply lines as a result of power interruptions to high energy equipment such as a blown fuse on one branch in a 3 phase system This will cause high current pulses at relatively low voltage levels The user shall take the necessary steps to prevent damage to the controller system such as by interposing a transformer See IEC 1131 4 for additional information AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Before Unpacking the Adept Equipment PA 4 Power Chassis Power Requirements Table 2 4 Adept PA 4 Power Chassis Power Requirements Nominal Minimum Maximum Recommended Voltage Frequency Operatin Operatin Externa Ranse Phasing Voltage 8 vel ee 5 Circuit Breaker 8 8 8 user supplied 380 to 415 50 60Hz 342 VAC 424 VAC 20 amps VAC 3 phase with neutral 200 to 240 50 60Hz 180 VAC 245 VAC 20 amps VAC 3 phase Power to the Adept MV controller and PA 4 power chassis must come from a single source Specifications for the Adept power chassis are based on two A and one B amplifier modules and an Adept XL robot 2 5 Before Unpacking the Adept Equipment Carefully inspect all shipping crates for evidence of damage during transit If any damage is indicated request that the carrier s agent be present at the time the container is unpacked 2 6 Adept Shipment Specifications Adept ships the equipment in a number of boxes and shipping crates dependin
72. provides two methods for user supplied emergency stop circuits This gives the AWC system the ability to duplicate E Stop functionality from a remote location using voltage free contacts Both the JUSER connector and the JSIO connector provide external E Stop connections into the CIP The JUSER connector has a two channel E Stop input on pins 4 to 23 and 5 to 24 The JSIO connector provides a single channel E Stop that controls two relays in the CIP This E Stop is for compatibility with legacy applications using the 50 pin connector on the SIO board These JSIO pins are 41 to 43 and 42 to 44 see Figure 7 14 Figure 7 15 Figure 7 16 and Table 7 10 for the customer E Stop circuitry The two required connections will be arranged in series NOTE These pins must be shorted if not used Both channels must open independently if used Although an E Stop will occur the CIP will malfunction if one channel is jumpered closed and the other channel is opened It also will malfunction if the channels are shorted together Remote Sensing of CIP MCP and User E Stop Push Button Switches A method has been provided to indicate the status of the E Stop chain inclusive of the CIP E Stop push button the MCP E Stop push button and the user emergency stop contacts NOTE These contacts do not indicate the status of any contacts below the User E Stop contacts Thus they will not indicate the MCP ENABLE contacts or the Manual mode teach restrict sensor conta
73. required and are removed when the IP54 option is installed Adept PA 4 Power Chassis Fan Filter Inspection and Cleaning The air filter located on the front of the chassis should be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must be inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or unusable for any reason order a new air filter The PA 4 fan filter part number is 40330 11200 WARNING Dangerous voltages are present inside the power chassis Turn off the power to the power chassis and protect it against an unauthorized return to service before opening the front grill to inspect the air filter Failure to observe this warning could cause injury or damage to your equipment 1 Turn off the power to the power chassis and protect it against an unauthorized return to service 2 Open the front grill by loosening two screws and swinging the grill out 3 Pull the air filter out and inspect for dust or dirt particles If cleaning is required use compressed air to clean the filter Follow all appropriate safety procedures regarding the use of compressed air 4 Replace the cleaned air filter and secure the grill Adept MV Controller Fan Filter Inspection and Cleaning The air filter located on the front of the chassis should be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must b
74. requirements Table 2 2 Robot System Operating Environment Requirements Ambient temperature Adept XL robot 5 C to 50 C 41 F to 122 F controller while accessing floppy or hard drive 5 C to 40 C 41 F to 104 F controller while not accessing floppy or hard drive 5 C to 50 C 41 F to 122 F power chassis 5 C to 40 C 41 F to 104 F Humidity 5 to 90 non condensing Altitude up to 2000 m 6500 ft Pollution degree 2 IEC 1131 2 EN 61131 2 Free space around Adept MV controller and power chassis for proper cooling 25 mm 1 inch in front 15 mm 1 2 inch at top Robot protection class IP20 NEMA Type 1 A robot that meets IP54 standards is available See IP 54 Adept XL Robot on page 273 Controller and power chassis subassembly protection class unmounted IP20 NEMA Type 1 Recommendations for customer supplied enclosure for Adept controller and power chassis Mandatory for installations in EU or EEA countries Enclosure should meet EN 60204 IEC 204 requirements and be rated at IP54 Also enclosure must provide a method of locking the enclosure power disconnect in the OFF position chassis dimensions NOTE See Chapter 11 for robot Adept MV controller and PA 4 power AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 47 Chapter 2 Installation Overview 2 4 Power Requirement
75. screws on each front panel This ensures proper grounding of the controller from an EMC standpoint and ensures good connection to the controller backplane 2 Secure all amplifier modules and blanking plates on the Adept PA 4 power chassis Tighten both the top and bottom mounting screws on each front panel This ensures proper grounding of the amplifier controller subsystems from an EMC standpoint and ensures good connection to the drawer connectors at the rear of the chassis The drawer connectors carry power and interlock signals from into the power chassis from the amplifiers NOTE There is a safety interlock built into the Adept PA 4 power chassis that prevents power from being applied if the amplifier modules are not correctly screwed into place 3 Secure the cable connections from the EJI board to the amplifiers in the Adept PA 4 power chassis Tighten the screws on the D sub connectors on the EJI to Amp cable assembly 4 Tighten the screws on the cable connections from the EJI board and other motion boards to the mechanisms to ensure integrity of signal connections especially encoder feedback and to ensure integrity of shields and other EMC measures 5 Tighten the screws on the cable connections from the amplifiers to the mechanisms to ensure integrity of power connections and to ensure integrity of safety grounds and shields 6 Secure the cable connection between the AWC and CIP Verify that the plug is latched on both ends o
76. securely 3 Connect the 50 pin male end of the JSIO to Cat3 E Stop cable to the JSIO connector on the CIP Connect the other end to J2 on the Category 3 E Stop board AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 97 Chapter 5 MMSP Installation and Configuration 98 Category 3 Teach Restrict E Stop Board Interface Board TRI TB1 TB2 TB3 UND es 12 1 3 rags Anse E oO O O E L ee J3 J2 lke m oo 1 12 1 TB4 TB5 TB6 J5 Figure 5 3 Connectors on the Control Rail Connecting the Security Panel to the Adept Robot For speed limiting of joints 1 and 2 in Manual mode the User to E Stop Teach Restrict cable must be installed between the Security Panel User 2 connector on the Arm Signal cable the E Stop board and the Teach Restrict Interface board The robot cannot be operated in Manual mode until this connection is made Installation procedure for the User to E Stop Teach Restrict cable see Figure 5 1 and Figure 5 3 1 Tum off the PA 4 power chassis and Adept MV controller 2 Remove the brake release jumper if installed from the Security Panel User 2 connector on the robot Arm Signal cable 3 Plug the 15 pin female connector marked Security Panel User 2 of the User to E Stop T
77. securely Changing the Voltage Setting for the Power Chassis From 380 415 VAC to 200 240 VAC To change the AC voltage setting from 3 phase 380 415VAC to 3 phase 200 240VAC follow the thre e part procedure below This procedure must be completed before installing the power chassis Also see Connecting AC Power to the Adept PA 4 Power Chassis on page 105 Part 1 WARNING Electrical hazard Changing the voltage setting in the power chassis must be done by a skilled person The power supply can injure or kill a person who does not perform this procedure correctly Insulating Power Chassis Power Cord WARNING High AC voltage is coupled through capacitors to the blue wire of the PA 4 power chassis power cord If you change the voltage setting from 380 415VAC to 200 240VAC you must add additional insulation to the blue wire according to the directions provided below Failure to do this could result in injury or death Turn off the power chassis and controller Disconnect the controller and the Security Panel from the AC power source Verify that power remains off during all parts of this procedure Disconnect the 5 wire power chassis power cord at the power source from the AP2 T1 T2 T3 neutral and protective earth terminals on the Security Panel Locate the two pieces of shrink tubing in the accessory kit one is 7 mm 1 4 inch diameter the other is 19 mm 3 4 inch Place the 7 mm 1 4 inch shrink tubing over the
78. semen Auto closed N Network closed 164 J User 37 pin D sub Controller Interface Panel Remote Connections CIP Internal connectors 5V H 1A PTC Fuse User Supplied Connections F Remote High Power on off Momentary P B switch lamp 5 6V 0 3A max If JP2 installed then min current To Las 100mA request lt Central Control High Power on off Momentary signal 100msec 1 sec Manual Auto in Auto Local Network in Network Local Network User 24V System Power Line User AC Power On Controller Remote MCP connector use USER ESTOP and USER ENABLE for MCP E Stop and hold to run connections RS232 ax 12 V TX o MCP Figure 7 1 5 J User 37 Pin D sub Connector AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP JSIO 50 pin D sub CIP connectors User Supplied Connections 2AN L Auxiliary ESTOPs L User ESTOP Legacy SYSIO inputs jumper closed when not used V High Power on V IN1 PE1 l V Passive ESTOP out Figure 7 16 JSIO Emergency Stop Circuit Emergency Stop Circuit The CIP
79. setting is shown and replace it see Figure 5 6 on page 101 Close the grill and secure the two screws Clearly mark or alter the ID label on the side of the PA 4 power chassis to show the new voltage configuration see Figure 4 18 on page 90 Part 2 Insulating Power Chassis Power Cord WARNING High AC voltage is coupled through capacitors to the blue wire of the PA 4 power chassis power cord If you change the voltage setting from 200 240 VAC to 380 415VAC you must add additional insulation to the blue wire according to the directions provided below Failure to do this could result in injury or death Make sure the power chassis and controller are turned off Disconnect the controller and the PA 4 power chassis from the AC power source Verify that power remains off during all parts of this procedure If installed remove the 4 wire plug Remove and discard the 19 mm 3 4 inch shrink tubing from the end of the power cord Remove and discard the 7 mm 1 4 inch shrink tubing from the end of the blue wire in the power cord see Figure 4 19 on page 92 Place the 19 mm 3 4 inch piece of shrink tubing from the accessory kit over the end of the power cord Use a heat gun to apply the shrink tubing see Figure 4 19 Install a 5 wire plug or wire directly to an appropriate service disconnect according to the 200 240VAC section in Table 4 3 on page 93 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 91 Chapter
80. the brake and allow manual quill movement See section 3 2 on page 62 for instructions on using the Brake Release button 1 Za Support the joint 3 quill Remove the eight M6 x 30 mm screws that attach the electrical bulkhead to the base cover and robot base Remove and support the electrical bulkhead six inches away from the robot base see Figure 10 1 on page 224 Ensure that no stress is being applied to the internal robot harness Apply grease to the entire circumference of the joint 1 encoder gear Use the brake release button located on the underside of the inner link to free up joint 1 and expose the portion of the gear covered by the joint 1 lower damper WARNING Impact Hazard The robot quill shaft will drop when the brakes are released if not properly supported Install the electrical bulkhead to the base cover and robot base with eight M6 x 30 mm screws Tighten all screws on the base cover and electrical bulkhead Remove the joint 3 quill support AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 223 Chapter 10 Maintenance k n Joint 1 Encoder Gear M6 x 30 mm Electrical Bulkhead Screws 8 A i he Ji a Robot Base Joint 1 and Joint 2 Brake Cylinder Electrical Bulkhead Cover Figure 10 1 Adept XL Robot Base Assembly 224 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C
81. the F2 J7 J12 key can be used to access the 7th to 12th joints Only the robot currently selected by the MCP is affected The currently selected joint is shown by the state of the LED on the joint axis key as described below If you press the key for joint 1 and the LED is steady you are controlling joint 1 If you press F2 J7 J12 then press the key for joint 1 the LED will flash indicating that you are controlling joint 7 Table 9 1 Robots With More Than 6 Axes Joint Axis LED state Joint range OFF None STEADY 1 to 6 FLASHING 7 to 12 The MCP cycles from one range to the other each time the F2 J7 J12 key is pressed AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Maintenance The Adept XL robot requires very little maintenance due to its direct drive design Joint 1 and 2 bearings need no maintenance at all This chapter describes the preventive maintenance procedures that are required to keep the robot system operating properly NOTE The Adept XL IP54 robot requires additional maintenance relating to rotary seal assemblies Please refer to section 10 7 on page 234 for this maintenance information See Table 10 1 for a summary of the preventive maintenance procedures and guidelines on frequency Table 10 1 Recommended Preventive Maintenance Schedule Recommended Schedule Item hours Lubricate the upper and lower quill shaft Every 3 months or approximately 1000 hours
82. the first time the MCP will be in world state Pressing the MAN HALT button again selects the next state to the right tool joint free eventually wrapping back to the leftmost state world If manual mode is terminated and reentered without turning off system power the last active state is selected As an additional safeguard when High Power is enabled and the CIP switch is turned to Manual High Power is disabled and any Manual mode selection is canceled DIS PWR Button The Disable Power button will shut down High Power to the robot or motion device when pressed Unlike the E Stop Button the Disable Power Button initiates a controlled stop where the robot is decelerated under software control After the robot has stopped power is turned off RUN HOLD When the RUN HOLD button is initially pressed it will stop the robot and pause the executing program task 0 If you then press and hold down the button the program proceeds until the button is released When the button is released the robot stops and the executing program pauses until the button is pressed again Joint Axis Control Buttons The buttons on the far right side are the joint axis control buttons When the MCP is in manual mode these buttons select which robot joint will move or the coordinate axis along which the robot will move The X 1 Y 2 Z 3 RX 4 RY 5 and RZ 6 buttons are covered starting on page 213 The MCP must be in manual mode before a joint axis
83. to 3 VDC On state voltage range 10 to 24 VDC Typical threshold voltage Vin 8 VDC Operational current range 0 to 20 mA Off state current range 0 to 1 2 mA On state current range 7 to 20 mA Typical threshold current per channel 10 mA Impedance Vin Iin 1 3 kQ minimum Current at Vi 24 VDC In lt 20mA in Turn on response time hardware Software scan rate response time 5 psec maximum 16 ms scan cycle 32 ms max response time Turn off response time hardware Software scan rate response time 5 psec maximum 16 ms scan cycle 32 ms max response time The input current specifications are provided for reference voltage sources are typically used to drive the inputs 2 ms response time maximum latency for fast inputs 1001 to 1004 depending on program task configuration when used with V INT EVENT instruction AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 121 Chapter 5 MMSP Installation and Configuration 122 Table 5 9 Digital Input Signal Assignments on Terminal Blocks TB1 and TB2 b Pa Terminal Signal Terminal Signal TB1 1 24V 1Amp 2 24 V return TB1 3 Input 1001 4 1001 return TB1 5 Input 1002 6 1002 return TB1 7 Input 1003 8 1003 return TB1 9 Input 1004 10 1004 return TB1 11 Input 1005 12 1005 return TB2 1 Input 1006 2 1006 return TB2 3 Input 1007 4 1007 return TB2 5 Input 1008 6
84. will appear next to the cycle count Use the data entry keys to enter the number of program cycles to execute Complete the entry by pressing REC DONE Speed Press SPEED and the current monitor speed will blink and the typing cursor will appear next to the monitor speed Use the data entry keys to enter a new monitor speed Complete the entry by pressing REC DONE Start The Start button works only when High Power is enabled this option cannot be used with DRY RUN enabled Press START and the program displayed above the NEW soft button will begin execution Moving a Robot or Motion Device With the MCP Introduction 210 The MCP is used with a robot or motion device primarily to teach robot locations for use in application programs The MCP is also used with custom applications that employ teach routines that pause execution at specified points and allow an operator to teach or reteach the robot locations used by the program The Adept AIM software system makes extensive use of the pendant for teaching robot locations When you move the robot using the MCP motion will be in world state tool state joint state or in free state When moving in world state directions are sent from the MCP to move the robot in a Cartesian coordinate system centered at the base of the robot When moving in tool state directions are sent from the MCP to move the robot in a Cartesian coordinate system centered at the robot s end of arm tooling location
85. x 30 mm Joint 3 Upper Quill Shaft Outer Link A Cutaway Quill Bellows Joint 4 hi Figure 10 2 Adept XL Robot Upper and Lower Quill Shafts Joint 3 Lower Quill Shaft CAUTION When reinstalling the quill cover of an Adept XL IP54 Robot you must reseal the bolts that secure the cover Refer to the procedure in section 10 7 on page 234 for complete details 226 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Lubrication A A LEN Joint 3 Upper Quill Shaft e Outer Link Quill Bellows Cutaway With Top Clamp Removed and ek Bellows Lowered A k K Joint 3 Lower E Quill Shaft Joint 4 ALONE Quill Shaft Lube Point A Lube Point B Top View Looking Down Note Lubrication Must To Be Applied To the Quill Shaft In a Vertical Y Pattern Lube Point C Section A A Figure 10 3 Joint 3 Upper Quill Shaft Lubrication AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 227 Chapter 10 Maintenance Lubricating Joint 3 Lower Quill Shaft Adept XL Robot 1 Turn off power to the PA 4 power chassis 2 Move joint 3 to the fully extended bottom travel position 3 Loosen and remove the top clamp on the bellows using a flat bladed common screw driver Then slowly and gently pul
86. 0 3 mm 0 41 in 4x Figure 11 11 Controller and PA 4 Dimensions With Mounting Brackets Installed 252 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Dimension Drawings Dimensions of the Manual Control Pendant MCP 221 74mm 8 74 in 184 15 mm 7 26 in 1 I 114 30 mm O O 4 50 in p pS 250 70 mm Teas e e 9 88 in Y e 279 40 mm E 11 01 in 103 12 mm 4 06 in OOO goo Y TTAN n id OOM Y Y 2 05 in 114 30 mm PUITS eee lay Tod gt 11 66 mm ESTOP Button Oe 0 46 in 5 84 mm i 0 23 in J A A Switch Depressed Y 48 26 mm 1 90 in Figure 11 12 Manual Control Pendant MCP Dimensions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 253 Chapter 11 Technical Specifications Dimensions of the MCP Cradle 10 2 mm 0 40 in 28 7 mm 4X 1 13 in 2 X Dd pa E Y 1 A 271 5 mm 10 69 in 203 2 mm 8 0 in 2 X 4 8 mm 0 19 in 4 X Y T m 9 7 mm i 0 38 in HA 4X 6 9 7 mm Y a 0 38 i
87. 1008 return TB2 7 Input 1009 8 1009 return TB2 9 Input 1010 10 1010 return TB2 11 Input 1011 12 1011 return NOTE Digital input signal 1012 is not available because it is used by the MMSP option Output Signals See Figure 7 20 on page 176 for a typical output signal circuit The terminal block TB3 handles the digital output signals 0001 to 0005 refer to Table 5 10 for output specifications The locations of the signals on the terminal block are given in Table 5 11 The terminal blocks provide separate and connections for each channel no internal common connections This allows you to wire for current sourcing or current sinking mode Each output circuit is short circuit protected AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Digital Signals on the Category 3 E Stop Board Table 5 10 DIO Output Specifications for TB3 Operating voltage range 0 to 24 VDC Operational current range per channel Tout lt 100 mA V drop across output in on condition V drop S 0 85 V at 100 mA Varop lt 0 80 V at 10 mA Output off leakage current Tout lt 600 pA out Turn on response time hardware Software scan rate response time 3 psec maximum 16 ms scan cycle 32 ms max response time Turn off response time hardware Software scan rate response time 200 usec maximum 16 ms scan cycle 32 ms max response time CAUTION The above specificatio
88. 1060 must be installed in the MCP connector on the CIP Remote E Stop Circuit When using a remote connector for the MCP the MCP E Stop push button contacts red mushroom switch must be wired in series with any other E Stop contacts on the USERESTOP CH1 pins 4 and 23 and USERESTOP CH pins 5 and 24 Remote Enable Switch Connections Two pairs of pins on the JUSER connector pins 6 25 and 7 26 provide connection for an MCP enable switch momentary push button This input duplicates the functionality of the MCP Enable switch on MCP Electrically the enable switch is wired in series with the MCP enable switch connections on the CIP If the MCP is connected remotely using the remote MCP connection on the JUSER connector wire the MCP enable switch of the MCP to these pins NOTE These pins must be shorted if not used NOTE The MCP III uses only one switch channel for the Enable function The MCP E Stop button uses two channels The MCP Enable switches E Stop channel 1 directly while channel 2 is switched by a sense relay DM1 in Figure 7 14 This means that only channel 1 of the remote Enable switch is active Please contact Adept for custom modifications of the MCP III or MCP bypass plug if you need a two channel MCP enable function AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting User Supplied Digital O Equipment 7 11 Connecting User Supplied Digital I O Equipment There are tw
89. 13 WORLD State Four Axis SCARA 000occoooco eens 214 TOOL State Four Axis SCARA 00oocoooc eens 215 TOOL State Six AxiS Robot uedes at EE Er eee eee 216 JOINT State Four Axis SCARA oo ccc eee eens 217 JOINT State Sb Axis Robot 0oooococoo enn 218 FREE State FourzAxis SCARA ru street dtd a 219 Adept XL Robot Base Assembly oooocoooooccoc essen 224 Adept XL Robot Upper and Lower Quill Shafts 0 00 cee ee 226 Joint 3 Upper Quill Shaft Lubrication sssaaa e 227 CIP FromtParelSGrews 5 ee roe eg Pika ah na a oio Tct 231 Lamp Body Contact Alignment seen 232 Adept MV Controller Fuse Holder necs eret 233 Adept XL IP 54 Robot Bolt Resealing Detail a aaaea 239 Adept XEQUIEBSIOWS is aaa GR Pee in I mU ER 237 AdeptOne XL Robot Top and Side Dimensions sisse 243 AdeptThree XL Robot Top and Side Dimensions sss 244 AdeptOne XL External Equipment Mounting Area sss 245 AdeptThree XL External Equipment Mounting Area sssss 245 Adept XL Camera Bracket Mounting Pattern isses 246 Adept XL Robot Tool Flange Dimensions i i esee 247 Adept MV 10 and Adept MV 5 Controller Dimensions 248 Adept PA 4 Power Chassis Dimensions ees 249 Adept Controller Interface Panel CIP Dimensions 0 0 0 0 cee eee 250 MMSP Security Panel Dimensions 0000 es 251 Controller and PA 4 Dimensions With Mounting Brackets Installed
90. 137 Chapter 7 Optional Equipment Installation User 2 J221 DeviceNet 9 pin D sub 5 pin B Shown with the Accelerometer Harness Used by the MMSP Option Installed User 1 J225 po 15 pin D sub Y TT j Tower Bracket Accelerometer MMSP Option E o o o SS SS o Figure 7 1 User Connector Locations on the Tower Assembly 138 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C User Signal and Solenoid Driver Lines Nes Arm Power Cable Connector Fan Filter Housing Compressed Air Inlet with Filter Arm Power Cable Connectors Robot Spare Air Line Base DeviceNet Connector Signal User Cable Connector Figure 7 2 Adept XL Robot Base Showing Air Filter and Cable Connector Locations AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 139 Chapter 7 Optional Equipment Installation Table 7 1 Pinouts for User Connectors Connectors on Robot Tower Connectors on Arm Signal Cable USER1 J221 15 Pin 25 Pin at robot base USER1 15 Pin Pin No Signal Pin No Signal Pin No Signal 1 USER1 1 1 USER1 1 1 USER1 1 2 USER1 1 2 USER1 1 2 USER1 1 3 USER1 2 3 USER1 2 3 USER1 2 4 USER1 2 4 USE
91. 2 EWG Anhang I und den unten aufgefuehrten Standarts entspricht Dies gilt nur wenn das Geraet unter den unten genannten Bedingungen verwendet wird Wir weisen daraufhin daf die Inbetriebnahme der Maschine solange untersagt ist bis festgestellt ist dafs die Maschine in die diese Maschine eingebaut werden soll den Bestimmungen der Richtlinie in der jeweils gueltigen Fassung entspricht Dies schlie t die anwenderseitig in die Maschine zu installierenden Erg nzungen und Schutzeinrichtungen ein FRANCAIS Par la pr sente nous d clarons que la machine d crite ci dessous livr e en l tat est conforme la directive communautaire 89 392 CEE Annexe I sur les imp ratifs fondamentaux en mati re de sant et de s curit La machine ne pourra tre mise en service avant que la machine dans laquelle elle sera incorpor e ne soit d clar e compl tement conforme aux dispositions des directives en cours de validit Ceci comprend tout quipement compl mentaire et dispositif de protection ITALIANO Si dichiara che la macchina come da noi fornita soddisfa i requisiti fondamentali definiti nella direttiva CE 89 392 EEC Appendice I in fatto di sicurezza e sanit La messa in funzione della macchina resta vietata fintanto che l intero sistema nel quale questa incorporata sia stato dichiarato conforme alla versione vigente della suddetta normativa Il sistemasi intende comprensivo di tutte le parti accessorie e dispositivi di sicurezza
92. 21 and 3 and 22 of the JUSER connector provide this remote capability The first two circuits allow the duplication of the CIP High Power push button lamp with no difference in operation Pins 2 and 21 provide power for the lamp 5 VDC and ground respectively Pins 1 and 20 are inputs for voltage free N O contacts from a user supplied momentary push button switch The user supplied remote High Power switch drives a relay in the CIP The contact of the relay generates a vt High Power request signal which is used internally The electrical characteristics are as follow Coil 24 VDC at 1440 Q including a parallel flyback diode Timing the High Power signal transition will be seen only if the signal is off at least 32 milliseconds followed by on for at least 32 milliseconds After a positive transition there must be no positive transitions for at least 2 seconds before another positive transition will be recognized Remote High Power On Off Lamp The CIP High Power On Off Lamp will cause a V error if the lamp burns out This error prevents High Power from being turned on This safety feature prevents a user from not realizing that High Power is enabled because the High Power indicator is burned out This feature can be added to the remote High Power lamp as well A jumper must be installed on JP2 inside the CIP See Changing the Lamp on the CIP High Power Enable Switch on page 230 for details on accessing the JP2 jumper The rem
93. 232 Term RS 232 EtherNet RAR Figure 7 13 AWC User Communication Connectors Serial Port 2 RS 232 This connector is identical to the RS 232 Term connector This connector can be used for general serial communication but not for connecting any user supplied terminals This port is designated LOCAL SERIAL 3 To configure the port speed and other communications parameters use the CONFIG_C utility program the V FSET program instruction or the FSET monitor command Table 7 8 RS 232 Term Connector Pin Assignments Pin Signal Type 1 DTR Output 2 CTS Input 3 TXD Output 4 GND Ground 5 RXD Input 6 RTS Output 7 DCD Input 8 GND Ground AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 159 Chapter 7 Optional Equipment Installation 160 RS 422 485 Connector The RS 422 485 connector is a 6 pin circular mini DIN female connector see Figure 7 13 on page 159 The pin assignment are shown in Table 7 9 RS 422 485 is a point to point protocol for connecting to a single destination This port can also be configured as a multi drop port RS 485 To change the configuration of the RS 422 485 port use the CONFIG_C utility program or the V FSET program instruction This port is designated LOCAL SERIAL 1 Table 7 9 RS 422 485 Connector Pin Assignments Pin Signal Type 1 GND Ground 2 GND Ground 3 TXD Output 4 RXD Input 5 TXD Output 6 RX
94. 4 The time out value can be changed using the CONFIG_C utility AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C SAFE_UTL V2 8 5 To enable High Power release and then press the Enable switch The High Power push button lamp will begin flashing Press and hold the High Power push button for 1 2 seconds and High Power will be enabled You will perform the above procedure several times while running SAFE_UTL Dual Brake Solenoid Valves Two brake solenoids are used to release the robot brakes If one solenoid fails by sticking open the brakes will still engage If one solenoid fails by sticking closed the brakes cannot be released These components were tested at the factory and do not need to be tested at the time of commissioning Both solenoid valves however must be tested periodically thereafter See Tests Performed Periodically on page 193 Robot Brakes Brakes are in place to prevent robot motion when High Power is off and to stop the robot during an Emergency Stop The Adept XL brakes can be manually released by pressing the brake release button located on the joint 1 inner link Brakes are used on joints 1 2 3 and 4 SAFE_UTL V2 Adept provides the SAFE_UTL V2 file in the UTIL subdirectory on the controller hard disk drive C or D This utility must be used to test the Category 3 robot components during the commissioning procedure It is also used to test the components periodically If
95. 49 PIOGGGUle e dep a Ra deeds fas o a Sie 149 7 5 Mounting User Equipment on the Robot Arm 00 eee eee ees 151 7 6 Installing End Effectors on an Adept XL Robot Luuss 153 Calculating Payload Inertia llle 153 Adept XL Initial Payload and GAIN SET Tuning Values for Joint 4 154 7 7 DeviceNet Communication Link lllselee eere 156 Recommended Vendors for Mating Cables and Connectors 156 7 8 Ethernet Connections 000 cee ee eee 157 7 9 Connecting User Supplied Serial Communications Equipment 158 RS 232 ICOM CONNMSCTO ca vu cee a OA ee EQ OR PE Tecra 158 AdeptWindows Controller AWC Board Serial I O Ports 159 Serial Port 2 8S9 232 5 xi cartes ca bea Pewee eee wk wk 159 RS 422 485 Connector te 160 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 13 Table of Contents The SIO Board Serial Ports eo bre ee rece A Re er es 160 7 10 Connecting Customer Supplied Safety and Power Control Equipment to the CIP 22 aal RR ak a ee ee aes 161 Emergency stop Creu 3 dra ri r e sa da X RO SE YI EG Leeks 165 Remote Sensing of CIP MCP and User E Stop Push Button SWITCHES cs epe dul t as beret hae eger e rcd ca esc wh AA 165 Muted Safety Gate E Stop Circuitry o oooo oommmmmm mm 166 JSIO ESTOPEMCUITY ss a m ttt ete D e li CR s Deer E 166 Cego o ESTO vet Aste t por tp ex cA els 166 Remote Manual Mode Control
96. 5 8 DIO Input Specifications for TB1 and TB2 on the Security Panel on page 121 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 173 Chapter 7 Optional Equipment Installation Table 7 12 DIO Input Circuit Specifications JSIO Connector Continued On state current range 2to6mA Typical threshold current 25 mA Impedance Vin lin 3 9K Q minimum Current at Vi 24 VDC In lt 6mA Turn on response time hardware 5 psec maximum Software scan rate response time 16 ms scan cycle 32 ms max latency Turn off response time hardware 5 psec maximum Software scan rate response time 16 ms scan cycle 32 ms max latency a See Fast Input Signals 1001 to 1004 below for exceptions NOTE The input current specifications are provided for reference voltage sources are typically used to drive the inputs In Figure 7 19 on page 175 example 1 shows inputs 1001 to 1004 with a negative common example 2 shows inputs 1005 to 1008 with a positive common and example 3 shows inputs 1009 to 1012 with an independent power supply no common NOTE These are examples Any of the three methods can be used on any channel REACT Input Signals 1001 to 1012 Inputs 1001 to 1012 only may be used by the V REACT and REACTI instructions See the V Language Reference Guide for information on these instructions If you are going to use these instructions you should plan your digi
97. 5 for monitoring the emergency stop circuitry The Passive E Stop output uses positive drive electromechanical relays that the customer can use to monitor the emergency stop circuit Many safety standards do not permit electronic control of E Stop signals therefore the passive E Stop output is often required to ensure that the user s equipment is shut down if an E Stop is activated The Passive E Stop output should also be used to control any other user devices in the workcell that need to be stopped in an emergency Such devices might include other moving equipment such as conveyor belts indexing or transfer devices pneumatic systems etc The specifications for the relays in the passive E Stop circuit are e Maximum switching power 250VA volt amps 5W Maximum switching voltage 230 Volts AC 300 Volts DC e Maximum switching current 2A CAUTION The power through the relay must not exceed 250VA 5 W AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 115 Chapter 5 MMSP Installation and Configuration The user can monitor the condition of the emergency stop circuitry with separate pairs of voltage free contacts The names of these two pairs of contacts are customer Estop 1 OUT and customer E Stop 2 OUT These contacts are closed if the E Stop loop is closed and open if the E Stop loop is open In addition some users may wish to monitor only the status of the red mushroom push button switches on the CIP or the
98. 68 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C A 1 Adept XL Robot Factory Installed Options Adept XL Cleanroom Option The Cleanroom Option can be ordered for all Adept XL robots This factory installed option allows the Adept XL robot to meet Class 10 Cleanroom specifications This package includes the following 1 Integral seals on the covers NOTE Seals are present under the access covers see Figure A 1 on page 270 If removal of an access cover is necessary the seal must be put back in place The robot will not meet Class 10 Cleanroom specifications unless all seals are in place and proper vacuum is maintained 2 A sealing plate under the base of the robot 3 A vacuum fitting 1 1 4 inch male thread 4 Custom exterior paint finish Installation The Cleanroom Option requires a customer supplied vacuum system This section details the vacuum requirements of the systems installation procedures and tests to assure that the system is maintaining adequate vacuum levels Vacuum Requirements Negative air pressure applied to the inside of the robot creates flow from the outside to inside through the gap between the inner and outer links This type of system gives excellent cleanliness but does not require high levels of vacuum The quill of the robot is covered by a Nitrile rubber bellows The bottom of the bellows is clamped to a bearing so that the bellows flexes only in the Z up and down direct
99. 84 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting the Robot to the MV Controller Connecting the Robot to the MV Controller The cable between the robot and the EJI board in the Adept MV controller is called the Arm Signal cable The robot end has a large rectangular Harting style connector The controller end has a 50 pin D sub connector and two smaller 15 pin D sub connectors See Figure 4 13 on page 82 and Figure 4 14 on page 84 1 Connect the Harting style connector of the Arm Signal cable to the Arm Signal User interface on the back plate of the robot Verify that an O ring gasket is in place to seal the Harting connector to the electrical bulkhead Tighten the four captive screw securely 2 Connect the 50 pin D sub connector to the Arm Signal connector lower on the EJI board Tighten the two captive screws securely See Figure 4 15 3 The 15 pin D sub connectors are labeled User 1 and Security Panel User 2 These connectors are for user supplied equipment mounted on the robot arm or tool flange see Chapter 7 The MMSP option requires the Security Panel User 2 connector and these lines are not available when the MMSP is installed WARNING Verify that all connectors are fully inserted and screwed down Failure to do this could cause unexpected robot motion Also a connector could be pulled out or dislodged unexpectedly EJI Module in an Adept MV Controller e SE
100. Adept PA 4 power chassis to an Adept MV controller 69 atthe bottom 71 atthetop 70 Joint 1 encoder gear lubrication specs 222 Joint 3 upper and lower quill shaft lubrica tion specs 222 Joint 3 upper quill shaft lubrication points 227 Joint motion 255 Joint1 256 Joint2 258 Joint3 258 Joint 4 259 Joint state four axis SCARA 217 six axis robot 218 with SCARA robot 216 joint travel limiting 62 Joint values 206 displaying 206 Joint axis control buttons 212 JSIO 78 connector 173 connector checks 181 digital I O connector pin assignments 177 emergency stop circuit 165 E Stop circuitry 166 J User 37 pin D sub connector 164 K Keyboard installation 127 L Lamp body contact alignment 232 Last error MCP function 207 LED status indicators onthe AWC 183 Lifting and handling 50 Lifting robot with eyebolts 61 Limit stops Cartesian 63 Limiting joint travel 62 hardstops 62 softstops 62 Loc MCP function 205 Location displaying current roboton MCP 206 of power labels 102 of the CIP 79 Location variables editing with MCP 205 Lubricating Joint 1 encoder gear Adept XL robot 223 Joint 3 lower quill shaft Adept XL robot 228 Joint 3 upper quill shaft Adept XL robot 225 Lubrication type of grease for Adept XL robot 222 M Main components of the safety system 112 Maintenance Adept XL IP 54 Robot cleaning information 234 and inspection of air filters 228 cleaning controller fan filter 229 cleaning pow
101. C AdeptThree XL Robot Specifications Table 11 3 AdeptThree XL Robot Performance Specifications Continued Joint Speed maximum Joint 1 540 sec Joint 2 820 sec Joint 3 1000 mm sec 39 4 in sec Joint 4 1955 sec Weight Robot without options 266 kg 585 lb Power chassis with 3 amplifier modules approximately 16 4 kg 36 lb Adept MV controller with AWC and VGB approximately 14 5 kg 32 Ib Design Life 120 million production cycles a Maximum possible running at reduced speed b The robot tool performs a continuous path motion consisting of all straight line segments 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and returning along the same path The endpoints of the cycle are approached in COARSE mode with a brake at end point Table 11 4 AdepiThree XL Robot Softstop and Hardstop Specs Joint Default Softstop Hardstop approximate Joint 1 150 152 Braketrack 300 Hardstop Joint 2 150 152 Joint 3 0 to 356 mm 6 6mm to 371 mm 0 to 14 in 26 to 14 6 inch Joint 4 270 None In between the softstop and hardstop joint 1 has a braketrack An internal proximity sensor will cause a V error condition and shut down High Power to the robot if the braketrack area is entered AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 263 Chapter 11 Technical Specifications 11 5 Adept PA 4 Powe
102. Control Pendant MCP In Manual mode the contacts of the Customer Safety Barrier Mute are muted and the safety function of these contacts is disabled This permits a skilled operator to enter the workcell while High Power is enabled This capability can be used only with the MMSP option Automatic Operating Mode The Automatic mode 100 position permits computer control of the robot A program that is currently running the robot or motion device may cause it to move at times or along paths you may not anticipate When the white High Power light on the CIP is illuminated do not enter the workcell because the robot or motion device might move unexpectedly WARNING Impact Hazard In Automatic mode no personnel are allowed in the workcell The robot can move at high speeds and exert considerable force NOTE The MCP can be used while the CIP is in either Automatic AUTO or Manual Mode For example it is possible to initiate calibration of the robot or to enable High Power from the MCP when the CIP is in Automatic AUTO mode 198 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Manual Control Pendant Basics 9 2 E Manual Control Pendant Basics Adept motion systems are designed to allow control of the robot or motion device from the Manual Control Pendant MCP Figure 9 1 shows how to hold the MCP The pendant has a palm activated enabling switch that is connected to the remote emergency stop circuitry o
103. D Input The SIO Board Serial Ports If your system includes an SIO board there are three additional serial ports that can be accessed by any AWC board configured to run V See the Adept MV Controller User s Guide for details AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP 7 10 Connecting Customer Supplied Safety and Power Control Equipment to the CIP The connection of the customer supplied safety and power control equipment to the CIP is through the JUSER connector This connector is a 37 pin female D sub connector located on the side panel of the CIP Refer to Table 7 10 and Table 7 11 for the JUSER pin out explanations See Figure 7 14 and Figure 7 15 for the wiring diagram NOTE If you have the MMSP option you can make most of the safety and power connections to the Security Panel See Chapter 5 for details Table 7 10 Contacts Provided by the JUSER Connector Pin Description Comments Shorted if Pairs oP AMAT NOT Used Voltage Free Contacts Provided by User 1 20 Remote High Power on off used to enable High Power No momentary PB 4 23 User E Stop CH 1 mushroom PB N C contacts Yes safety gates remote MCP E stop etc 5 24 User E Stop CH 2 same as pins 4and N C contacts Yes 23 6 25 Remote ENABLE hold to run N O contacts make to enable Yes
104. Do not attempt to transport the robot boxes by hand Always use a pallet jack forklift etc The robots must always be stored and shipped in an upright position in a clean dry area that is free from condensation Do not lay the crate on its side or any other position this could damage the robot 2 8 Lifting and Handling Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit Pay special attention to tilt and shock indication labels on the exteriors of the containers If any damage is indicated request that the carrier s agent be present at the time the container is unpacked 50 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Unpacking and Inspecting the Adept Equipment Brake Release I Button on pe Underside of Inner Link Air Line Place forklift or pallet jack here Figure 2 2 Adept XL Robot on a Transportation Pallet 2 9 Unpacking and Inspecting the Adept Equipment Upon Unpacking Before signing the carrier s delivery sheet please compare the actual items received not just the packing slip with your equipment purchase order and verify that all items are present and that the shipment is correct and free of visible damage If the items received do not match th
105. E CET 81 MOP Bypass PIUG s Lk ata eet A eke p POE E 81 4 6 Robot and Control System Cable Installation 82 System Cable LengthS o oococcocccc enn 83 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 11 Table of Contents Connecting the Robot to the Power Chassis 0 0 000 cece eee 83 Connecting the Robot to the MV Controller aaa aa 85 Connecting the Adept MV Controller to the Power ChassiS 86 4 7 Connecting AC Power to the Adept MV Controllers 87 POwerEnthy BOALO xr A a 87 Connecting AC Power Cord isses nns 87 System Grounding Information i e een 88 4 8 Manual Mode Safety Package Installation o 88 4 9 Changing the Power Chassis Voltage Setting 89 Changing From 380 415 VAC to 200 240 VAC ees 89 Changing From 200 240 VAC to 380 415 VAC ccc ees 90 4 10 Connecting AC Power to the Adept PA 4 Power Chassis 92 Connecting the Power Chassis AC Power Cord to AC Supply NonsMMSPB SVSTOETI ri e dr eter ete ente etn e te OCDE Yee d as 92 4 11 Grounding the Adept Robot System 000 ee eee 93 Adept Robot Grounding rera res ionit ETE tte 93 Robot Mounted Equipment Grounding 0 eee 94 5 MMSP Installation and Configuration o oooooo o 95 5 1 Installation of the MMSP Option occococcocc 95 Connecting the Security Panel
106. E Stop error is expected If High Power can be switched on the test fails and an error message is displayed If High Power cannot be switched on the test passes MCP E STOP Button Test 2 Release the MCP E STOP button Is the red ES L I iD on the AWC module off Y N After releasing the E Stop the system will attempt to enable High Power If successful the following messages are displayed Press ENTER then press and release the HIGH POWER button on the CIP Press the MCP E STOP button and press ENTER to continue When the E STOP button is released the test is complete Release the MCP E STOP button MCP E STOP test passes Press ENTER to continue If all MCP tests pass the next test is performed or the main menu is displayed Brake Holding Force Test The holding force of the brakes is tested to ensure that the robot cannot move when the brakes are engaged The following message is displayed Brake Holding Force Test The default test point is with all joints at midrange Do you want to use the default test point Y N If you respond Y the system prompts the user to move the robot to the desired location If you respond N the system uses the default location The following message is displayed Press ENTER to enable power and move the robot to the test location High Power is switched on and joint 1 attempts to
107. Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 List of Figures AdeptzXL RODOS ie tnb o C Ie e ODE e o eon 25 Adept XL Robot Joint MOTIONS isses 26 Adept MV 10 Controller and PA 4 Power Chassis esses 26 Adept XL Robot Impact and Trapping Point Hazards o 30 Mounting SpoolSpecifications ees operiert r EEEE EKI EREET EREE d 46 Adept XL Robot on a Transportation Pallet naaa aaa 51 Mounting Hole Pattern Plate Spool to Fl00N ooa aaa 54 Mounting Hole Pattern Robot to Plate Spool saaa aaa 55 Required Clearance for Robot Cables 6 ce een 56 Mounting Plate to Floor Installation Detail isses 57 Mounting Spool to Floor Installation Detail ees 58 Lifting Robot With Eyebolts eem 61 AWC System Processor Board nau eee teens 66 AVATAR EAT Sh tind Aye aN ange eni iow are Reo 67 Dual BE Amplifier 25 i t A af Suns Alain o aec ate Auta di 68 Joining the Power Chassis and Controller at the TOP ww eee 70 Joining the Power Chassis and Controller Bottom View 71 Installing Mounting Brackets on an Adept MV Controller 73 Installing Mounting Brackets on an Adept PA 4 Power Chassis 74 C
108. Free Contacts TB5 2 Customer E Stop 1 OUT Voltage Free Contacts TB5 3 Customer E Stop 2 OUT Voltage Free Contacts TB5 4 Customer E Stop 2 OUT Voltage Free Contacts TB5 5 System Power On OUT Voltage Free Contacts TB5 6 System Power On OUT Voltage Free Contacts TB5 7 Customer Manual Mode 1 OUT Voltage Free Contacts TB5 8 Customer Manual Mode 1 OUT Voltage Free Contacts TB5 9 Customer Manual Mode 2 OUT Voltage Free Contacts TB5 10 Customer Manual Mode 2 OUT Voltage Free Contacts TB5 11 Customer Safety Relay IN Feedback Contacts N C TB5 12 Customer Safety Relay IN Feedback Contacts N C Pin 11 and 12 Jumper closed if not used The Customer System Power On OUT contacts are connected to the system power switch on the CIP When this switch is on the contacts are closed The System Power On signal can also be used to control auxiliary equipment 116 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Category 3 Emergency Stop Circuitry 5 4 Category 3 Emergency Stop Circuitry The Category 3 Emergency Stop circuitry is mounted on the Security Panel The components are on two DIN rails the Control Rail and the Power Rail The safety relay and power contactor diagram on the following two pages should help you to understand the circuitry and to install the user supplied parts of the Category 3 Emergency circuit NOTE For clarity some components are omitted such as current limiting
109. I O signals indicated on the second line 1 32 in the above example A indicates the channel is not installed a 1 indicates the signal is on and a 0 indicates the signal is off The type of signal that is being displayed is indicated by the LED on the soft buttons labeled OUT IN and SOFT The above example shows digital output signals in the range 1 to 32 Signals 1 2 are on signals 3 8 are off and no other signals in this range are installed To display a different range of signals press the soft buttons under the or labels The next or previous range of signals will be displayed Press the OUT IN and SOFT soft buttons to display input output or soft signal ranges See Connecting User Supplied Digital I O Equipment on page 173 for details on digital I O signal ranges for the CIP Also see Extended Digital I O Signals on page 177 for details on digital I O signal ranges for the optional DIO board Last Error Press LAST ERROR to display the error messages generated by V during the current session The most recent error will be displayed The rightmost soft button will be labeled lt MORE gt Pressing this button will cycle back through the error messages generated during the current session The Clear Error Function If the MCP is in the Manual position or the system switch MCP MESSAGES is enabled error messages are sent to the MCP When an error is sent to the MCP the MCP will beep displ
110. IP AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 75 Chapter 4 Adept MV Controller Installation 76 High Power Enabling Switch Lamp This switch marked with a robot figure and the international ON symbol controls High Power which is the flow of current from the amplifiers to the robot motors Enabling high power is a two step process An Enable Power request must be sent from the system terminal an executing program or the manual control pendant Once this request has been made the operator must press this button and High Power will be applied NOTE High Power cannot be enabled if this lamp is burned out See Changing the Lamp on the CIP High Power Enable Switch on page 230 for details Manual Control Pendant MCP Connector The MCP plugs into this connector The CIP works only with the MCP III P N 10332 11000 Assembly Number 90332 48050 Other Adept pendants will not work because they do not incorporate the dual E Stop channels See Connecting the MCP to the CIP on page 80 for details CAUTION Damage may result if an MCP III is plugged into older Adept controller systems that contain a VME Front Panel VFP Damage may also result if older MCPs part numbers other than 10332 11000 are plugged into a CIP System Power Switch This switch marked with a lightning bolt allows you to switch a relay or other power switching equipment to control power to the Adept controller and ot
111. IP if used to the ON I position The AWC will execute its boot sequence When the boot sequence has completed the SF OK LED should be green If this LED is red the AWC has not booted properly Turn off power to the controller and reboot If the problem persists call Adept Customer Service Note the state of the LEDs marked 1 to 3 which indicate the problems shown in Table 8 1 The other LEDs should be off If the ES E Stop LED on the AWC board is flickering red this could result from a AWC systems may occasionally oscillate after the software has tested the E Stop channels If this occurs toggle press and release the E Stop push button on the CIP The E Stop LED should now be off unless there are other problems in the E Stop circuitry b The oscillation may also be the result of a mismatch between the contacts forming a pair of contacts in the two E Stop channels Perhaps on one channel the user E Stop contacts are closed and on the other they are open Check each pair of contacts to make sure that they match and that they are all closed per Table 7 10 Contacts Provided by the JUSER Connector on page 161 c Also a short between the two E Stop channels may sometimes result in this oscillating red ES LED If the problem persists call Adept Customer Service If the E Stop LED is continuously red then at least one pair of E Stop contacts is open or the E Stop contacts on the JSIO connector are ope
112. Installation Time Approximately 10 minutes Procedure Install the two camera plates to the outer link with two M5 X 12 mm screws see Figure 7 8 on page 150 as you perform this procedure Install the two camera brackets to the two camera plates with two stainless steel washers and two M4 X 12 mm screws Mount the camera channel to the camera brackets with M4 x 12 mm screws Mount the camera to the camera mount Mount the camera and camera mount to the camera channel using M5 x 12 mm screws AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 149 Chapter 7 Optional Equipment Installation Camera Channel Outer Link Camera o Front View Plate dh us i M4 x 12 mm crews 2x P a Screws 4x M4 Stainless Steel Washer 2x Camera Aet e Bracket E Li J NE v DI SED mati PN LBS M5 x 12 mm M5 x 12 mm S EUM A PS UN Screws py Po AOS ES NIN m Screws 8x Sen Ww M4 x 12 mm ks M4 Stainless HOUSE we Steel Washer RS 2x E Camera Bracket PE M5 x 12 mm Screws 2x Camera Mount Side Bracket Figure 7 8 Adept XL Robot Camera Mounting Bracket 150 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Mounting User Equipment on the Robot Arm 7 5 Mounting User Equipment on the Robot Arm Figure 7 9 and Figure 7 10 show the locations on the inner and outer link covers where user equipment may
113. Instruction Handbook AdeptOne XL AdeptThree XL Robot Instruction Handbook AdeptOne XL AdeptThree XL Robot Trl TE TRITT 00862 00100 Rev C January 1999 J aD 150 Rose Orchard Way San Jose CA 95134 USA Phone 408 432 0888 Fax 408 432 8707 yn CC p Otto Hahn Strasse 23 44227 Dortmund Germany Phone 49 231 75 89 40 Fax 49 231 75 89 450 adept 41 rue du Saule Trapu 91300 Massy France Phone 33 1 69 19 16 16 Fax 33 1 69 32 04 62 technology inc 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 con strued 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 doc ument 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 1999 by Adept Technology Inc All rights reserved The Adept logo is a registered trademark of Adept Technology Inc AdeptOne XL AdeptThree XL HyperDrive Adept 550 Adept 550 CleanRoom Adept 1850 Adept 1850XP Adept Cobra 600 Adept Cobra 800 Adept Flexfeeder 250 Adep
114. L Robot Specifications 0ooooooooooomoo 262 11 5 Adept PA 4 Power Chassis Specifications 0oooooooo 264 EMC Test IMfonmenonss gc eret te pPRRELEA E RET pea 264 11 6 Harting Connectors 1 0 2 eee 265 Arm Power Connector Pin Identification ee 266 11 7 Robot ID Edbels 22 4 heer vera nm mx a 267 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 17 Table of Contents A Adept XL Robot Factory Installed Options 269 A 1 Adept XL Cleanroom Option 0 00 ccs 269 acie IIIS si D o en t Aeon Sa vont OD e Kae bk ON 269 Vacuum Requirements ri ren TEE E EAEE EE ns 269 Vacuum BIOO er enpe e da ed Soret 271 Vacuum Supply PUN Persas a 271 PIpe SIZe qnis cs Bd Ai Be o a See oe 271 Vacuum OWC IRA a oy A E AEEA 272 TESTING ANS VACUUM cess A toe cee ate e a aia ade be lad ae esd 272 A 2 Adept XL Robot IP 54 Option 0 0 0 eee 273 IP DA AGS PIEX RO DOT ie tot uter NC rU ER EE dang cia 273 Customer REqQuireMentss f06 cece eve pee a be OR Ea 274 Sealing the Tool Hanga ies a ee eens 274 Pressurizing of the Robot iiie 274 Index o o qvx SANSA Gort bac ae x Rd uaa SE RARE SER SER SE CS 277 18 AdeptOne XL AdeptThree XL Robot Instruction Handbook Hev C Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 2 1 Figure 2 2 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 4 1 Figure 4 2
115. Mode sss een 198 9 2 Manual Control Pendant BaSICS 0 0 00 ce eee 199 CornrniectingheMGP s vere bee alae naan 200 MGP LAYOUT ecce ete p tte pete ae Ral ee ROO wk MONS Rp rte 201 SO Ml BUT OMS 2st e ILC 201 FUNCTION BUTTONS ice ud ec tur A acer AA AAA 202 Data Enthy BUMONS 2 cara AS as 202 Mode Control and Joint Axis Control BUTONS 0 202 Speed Bars and Slow Button coco 202 Emergency Stop From the MOP arraren iei eae nn 203 Backgreund MOCG s scm panini ae iced di A I NET E e re an Tes 203 9 3 MCP Predefined Functions 0 00 eee 203 ITO GUSTO A TN SG A Be E EET 203 Predefined Function Buttons niieu mes iioa ees 203 TREE GIT FUR COM iria amp Seek tae ease ace ad ae bo da d a 204 The Display E rction uscire ope a eee TR Ed 206 The Clear Error Function 207 The CMD FUNGON sx rus nay od O EGG Der Yw Pe qned 208 Prog SetiFuncellobr 3s ce sued eR eL ER NEED 209 9 4 Moving a Robot or Motion Device With the MCP 210 Introduction s Ves oes Carte y E ee e OE RE E E PUE 210 Mode Control BUttTOLS 3 ads DRA tas mei ota ef tates 210 Emergency Stop BUMN e seanssi rs a ESEESE en 211 COMP PWR BUTTON 4 2 cs Lace s AE UR ao NAM 211 MAN HBHACLT BUTtOfy i42 teo eee dte ehe BR ERE eet e d 211 DIS PWRBUTIOMN i ior a acht Ext St ca Rd t gc Nes 212 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 15 Table of Contents RUIN JH OLD tata
116. O START is pressed the pendant display shows Enter last two digits of file name auto AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C MCP Predefined Functions Enter one or two digits and press REC DONE The system attempts to load the file AUTOxx V2 from the default disk and COMMAND the program autoxx xx refers to the digits you entered The program file AUTOxx V2 must reside on the default disk and it must contain a monitor command program named autoxx If the file does not exist or does not contain a correctly named program the operation will be aborted and the appropriate error message will be displayed on the LCD For example if you had entered 9 the system would attempt to load the file AUTO9 V2 and COMMAND the program auto9 Calib When CALIB is pressed the robot calibration procedure begins High Power must be enabled Store All When STORE ALL is pressed the pendant displays Enter last two digits of file name STORE auto_ Enter one or two digits press REC DONE and all programs and variables in system memory will be stored to a file on the default disk with the name autoxx v2 For example if you had entered 11 the file AUTO11 V2 would be created and all programs and global variables in system memory would be stored to that file CMD1 and CMD2 When CMD1 is pressed the system attempts to load the file CMD1 V2 from the default disk and COMMAND the program
117. P IP Interface Ethernet Connection on page 130 and the documentation for your PC for details If you are making a serial connection a Connect the Adept controller to your PC using a serial cable Plug one end of the cable into the RS232 TERM connector on the AWC board and the other end into an available serial port on the PC 3 Start the Adept controller 4 Start the PC WARNING Since the entire robot installation has not yet been verified do not turn on the PA 4 power chassis 5 Start AdeptWindows on the PC and make a logical connection to the controller If you are using an Ethernet connection 134 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Graphical Interface Using AdeptWindows PC a Select the File Scan Ethernet option If the configuration of your PC is correct you will see the IP address of the Adept controller b Select File Connect Via Ethernet Enter the controller IP address and click on OK The AdeptWindows PC software will present the last used IP address as the default If you are making a serial connection a Select File Connect Via COM port b Select the COM port being used on your PC and press OK 6 The V monitor window will be displayed AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 135 7 1 Optional Equipment Installation User Signal and Solenoid Driver Lines There are several pairs of wires routed from the rear of the robot to
118. Pendant MCP 253 MCP cradle 254 MMSP security panel 251 MV 10 and PA 4 mounting brackets 252 power chassis 249 security panel 251 vendor tooling mounting pattern 245 DIO Input circuit specifications JSIO connector 173 specifications for TB1 and TB2 on the security panel 121 DIO Output specifications JSIO connector 175 specifications for TB3 123 DIS PWR button 212 DISPLAY Function button 206 Dowel pin for keying on end effectors 153 Draining moisture from Adept XL robot compressed air filter 228 Drying time before operation end effector 235 Dual B Amplifier 68 overview 68 Dual brake solenoid valves 185 E Edit function on MCP 204 Editing global variables with the MCP 204 EJI to Amp cable installation 86 EMC Test Information 264 Emergency situation whattodo 41 Emergency stop button on MCP 211 circuit 165 from MCP 203 switch 75 Enable Power description of process 112 End Effector dowel pin 153 grounding 153 Environmental requirements 47 Errors displaying system on MCP 207 E Stop button and switch checks 181 E Stop circuit Customer Safety Barrier switch specifications 114 mute function in Customer Safety Barrier 111 schematic 117 voltage free contacts 115 Ethernet connection setting up the TCP IP interface 130 Ethernet connections 157 Extended Digital I O signals 177 Extended length CIP to AWC cable 80 Eyebolts lifting robot with 61 F Facility overvoltage protection 48 Facility requ
119. Procomm or Procomm for Windows available from many computer stores include software emulation for the Wyse 75 This type of interface is not suitable for any graphics based programming graphics based application programs such as AIM or systems equipped with the vision option Recommended Terminal for Text Based Systems The recommended terminal for use with the Adept MV controller is the Wyse WY 60 You must also specify the Wyse ANSI VT100 style keyboard Wyse p n 900127 02 or 900128 02 Note The WY 60 is also available with ASCII and IBM Enhanced PC keyboards These are not Adept compatible You must make sure you order the correct keyboard The WY 60 is available in both 220V and 110V versions Installation Procedure 128 1 Make sure the controller is turned off before making any connections 2 Verify the voltage range marked on the terminal is compatible with your local voltage source Connect the AC power cord to the terminal then plug it into an appropriate voltage source 3 Connect a suitable serial cable between the terminal and the RS 232 TERM connector on the AWC board If you need to fabricate this cable see the Adept MV Controller User s Guide for the RS232 TERM pin location and description 4 If the terminal is a Wyse 60 use the setup mode to set the personality to WY 75 If you are using terminal emulation software on a computer set the software to WY 75 emulation If WY 75 is not
120. R1 2 4 USER1 2 5 USER1 3 5 USER1 3 5 USER1 3 6 USER1 3 6 USER1 3 6 USER1 3 7 USER1 4 7 USER1 4 7 USER1 4 8 USER1 4 8 USER1 4 8 USER1 4 9 USER1 5 9 USER1 5 9 USER1 5 10 USER1 5 10 USER1 5 10 USER1 5 11 USER1 6 11 USER1 6 11 USER1 6 12 USER1 6 12 USER1 6 12 USER1 6 13 Not used 13 Not used 13 Not used 14 Not used 14 USER2 1 14 Not used 15 Not used 15 USER2 1 15 Not used SHLD FOR USER1 16 USER2 2 SHLD FOR USER1 17 USER2 2 USER2 J225 9 Pin 18 USER2 3 USER2 15 Pin Pin No Signal 19 USER2 3 Pin No Signal 1 USER2 1 20 USER2 4 1 USER2 1 2 USER2 1 21 USER2 4 2 USER2 1 3 USER2 2 22 Not used 3 USER2 2 4 USER2 2 23 Not used 4 USER2 2 5 USER2 3 24 Not available 5 USER2 3 6 USER2 3 25 Not available 6 USER2 3 7 USER2 4 SHLD FOR USER1 amp 2 7 USER2 4 8 USER2 4 8 USER2 4 9 Not used 9 10 Not available SHLD FOR USER2 11 15 Not used SHLD FOR USER2 140 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Joint 5 Wiring 7 2 2 Adept XL Joint 5 Wiring 7 3 Wiring is provided for an optional Joint 5 axis Contact Adept RDA services group for specifications on the Adept XL series Joint 5 option see How Can I Get Help on page 41 NOTE The Adept Joint 5 used with non XL series AdeptOne robots is not compatible with the AdeptOne XL robot CAUTION The Joint 5 wiring is designated to be used only for that purpose and should not be used to drive peripheral device
121. Ras a dilate she ne tile nee b ie eG e lc 212 Joint Axis Control BUTO sri eor a RANG 212 STEP BUTTON oras td e ta ls doe feds hia ade ia 212 Speed BOIrs s runde eae oat i o ans HC e Bos e od a 212 In World Tool and Joint Mode cerir rer r eero TEOR aA 212 In Comp Modes ous due ee Sk RE nea s SET 212 SIOW BUTTON sex eunt ihe cde em ee ENERO ed EROR sr EORR Rc Ur Rs UAR 213 ROBOT STONSS CPI 213 Word ST elle in alc anh teo AAA a 213 TOOL STON dr aa rm 214 JOINT SIGS 2 ea eera Matias ois A oda be ae eee 216 EROS OIG it E 218 Controlling More Than One ROBOT ces 219 Robots With Fewer Than Six Joints aaa 220 Robots With More Than Six JOINTS eee 220 LO Maintenance snnm RR 221 10 1 Testing the MMSP Hardware 00 cee ee nne 222 10 2 Robot Lubrication 0 0 ccc nn 222 Recommended Grease for the Adept XL ROBOT ees 222 Joint l Encoder Orta Parentes e De ro 222 Joint 3 Upper and Lower Quill Shaft lisse 222 Manufacturer s Safety Data Sheets MSDS 6 000 eee 222 Lubricating Joint 1 Encoder Gear Adept XL Robot 0 eee 223 Lubricating Joint 3 Upper Quill Shaft Adept XL Robot 0 6 cee 225 Lubricating Joint 3 Lower Quill Shaft Adept XL RObOt 0 0 0 0 228 10 3 Check Robot Mounting Bolt Tightness ooooooommomoo 228 10 4 Maintenance and Inspection of Air Filters ooo 228 Draining Moisture From Adept
122. Robot Lubrication Lubricating Joint 3 Upper Quill Shaft Adept XL Robot CAUTION Lubrication of the robot must be performed with the PA 4 power chassis power turned OFF Use the Brake Release button located on the underside of the inner link to release the brake allowing manual quill movement See section 3 2 on page 62 for instructions on using the Brake Release button CAUTION When the brake release button is pressed the quill if holding a payload will drop to the bottom of its travel To prevent possible damage to the equipment make sure that the quill is supported while releasing the brake and verify that installed tooling is clear of all obstructions 1 Turn off power to the PA 4 power chassis 2 Using an M4 Allen wrench remove the six socket head cap screws that hold the quill cover to the outer link Remove the quill cover See Figure 10 2 on page 226 3 Press the Brake Release button and move the quill to its fully retracted or raised position Inspect the upper quill shaft and remove any excess or accumulated grease with a clean cloth 4 Apply Mystik SynGuard SX 6 grease to the axial and spiral grooves on the joint 3 upper quill shaft Extend and retract the joint 3 quill several times Inspect the upper quill and wipe off any excess lubricant with a clean soft cloth AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 225 Chapter 10 Maintenance Joint 3 Upper Quill Shaft Cover M6
123. Sub female connector see Figure 4 10 on page 78 for location There are 12 inputs and 8 outputs each optically isolated from the circuitry of the CIP The connector also provides access to a single channel emergency stop circuit E Stop input and Passive E Stop output To access this connector a user supplied cable with a 50 pin male D Sub connector at one end is required Note that with the MMSP option input signal 1012 and output signals 1 thru 5 are not available The remaining I O signal lines are available on terminal blocks at the MMSP See Table 5 8 DIO Input Specifications for TB1 and TB2 on the Security Panel on page 121 and Table 5 10 DIO Output Specifications for TB3 on page 123 Input Signals The JSIO connector handles input signals 1001 to 1012 On systems with the MMSP option input channel 1012 is used by the MMSP and is not available for users Each channel has an input and a corresponding return line See Table 7 12 for input specifications The connector pinouts are shown in Table 7 14 Table 7 12 DIO Input Circuit Specifications JSIO Connector Operational voltage range 0 to 24 VDC Off state voltage range 0 to 3 VDC On state voltage range 10 to 24 VDC Typical threshold voltage Vin 8 VDC Operational current range 0 to 6 mA Off state current range 0 to 0 5 mA 1 These signals are also available at the Security Panel on systems with the MMSP option See Table
124. TBS for Passive E Stop Contacts 0 0 0 oo 116 Description of Numbers in the MMSP 3 E Stop DrawinQ 0 o 120 DIO Input Specifications for TBI and TB2 on the Security Panel 121 Digital Input Signal Assignments on Terminal Blocks TB and TB2 122 DIO Output Specifications for TB3 lisse nnn 123 Digital Output Signal Assignments on Terminal Block TB3 123 Pinouts for User Connectors een 140 Nyon Tubing Lengte Htc ues est AO A LASA 142 User Air Line Command Summary 0 enn 147 Pin Assignment on 9 Pin Connector J240 for Gripper Solenoid Signals 148 AdeptOne XL Initial Payload and GAIN SET Tuning Values for Joint 4 154 AdepltThree XL Initial Payload and GAIN SET Tuning Values for Joint 4 155 JCOM Connector Pin Assignments iiis isses 158 RS 232 Term Connector Pin Assignments isis es 159 RS 422 485 Connector Pin Assignments 0 00 00 ces 160 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 23 List of Tables Table 7 10 Table 7 11 Table 7 12 Table 7 13 Table 7 14 Table 8 1 Table 9 1 Table 10 1 Table 10 2 Table 10 3 Table 10 4 Table 10 5 Table 10 6 Table 11 1 Table 11 2 Table 11 3 Table 11 4 Table 11 5 Table 11 6 Table 11 7 Table A 1 Table A 2 24 Contacts Provided by the JUSER Connector 2 es 161 Remote MCP Connections on the JUSER Connector sahanan isses 162 DIO Input Circuit Specifications JSIO Connector saaa aaaea 173 DIO O
125. Technical Specifications 11 3 AdeptOne XL Robot Specifications All specifications subject to change without notice Table 11 1 AdeptOne XL Robot Performance Specifications Maximum Payload including end effector 12 kg 26 5 Ib Rated Payload including end effector 5 kg 11 Ib Reach Maximum radial 800 mm 31 5 in Minimum radial 278 mm 10 9 in Vertical clearance bottom of base to end effector flange with maximum Joint 3 retraction 876 3 mm 34 5 in with maximum Joint 3 extension 356 mm config 520 7 mm 20 5 in with maximum Joint 3 extension 203 mm config 673 0 mm 26 5 in Vertical Stroke Z direction Joint 3 356 mm 14 0 in Joint Rotation Joint 1 300 Joint 2 280 Joint 4 540 Inertia About Joint 4 axis maximum 3 181 kg cm 1 087 Ib in Force Joint 3 downward force without payload 45 kg 100 Ib Cycle Time 12 in 305 mm Burst Sustained No payload 0 54 sec 0 64 sec 5 0 kg 11 0 Ib payload Rated 0 60 sec 0 73 sec 12 kg 26 5 Ib payload Max 0 69 sec 0 85 sec Resolution Joint 1 0 00078 Joint 2 0 00078 Joint 3 vertical Z 0 0067 mm 0 00026 in Joint 4 tool rotation 0 025 Repeatability X Y plane 0 025 mm 0 001 in Joint 3 vertical Z 0 038 mm 0 0015 in Joint 4 rotational 0 05 260 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adep
126. VAC 106 requirements for controllers 48 requirements for MMSP option 108 requirements for power chassis 49 to the Adept components checks 179 voltage current ratings power chassis 49 AC power cord from power chassis specifications 93 107 specifications for power chassis 93 107 Accelerometer 184 Accelerometer Test 187 Acceptable modifications 37 Additional safety information 31 Address controller IP 133 Adept Control System applying power 182 Adept Controller Interface Panel CIP dimensions 250 Adept equipment compatibility 27 Adept equipment unpacking the 49 Adept hardware and software compatibili ty for MMSP systems 27 Adept MV controller fan filter inspection and cleaning 229 fuse holder 233 fuse ratings 233 installation 65 power cord specifications 88 power entry board 87 Index power requirements 48 Adept MV 10 and Adept MV 5 controller dimensions 248 controller and PA 4 power chassis 26 Adept PA 4 fan filter inspection and cleaning 229 power chassis dimensions 249 fan filter inspection and cleaning 229 power requirements 49 specifications 264 Adept robot grounding 93 Adept shipment specifications 49 Adept shipping crate specifications 49 AdeptOne XL dimensions 243 external equipment mounting area 245 initial payload and gainset tuning val ues forJ4 154 Joint 1 motion 257 Joint 2 LEFTY RIGHTY configurations 258 Joint 3 and Joint 4 motions 259 Joint 5 wiring Optional 141 softstop and hardstop s
127. XL Robot Instruction Handbook Rev C 57 Chapter 3 Robot Installation 58 Top Plate Wy M12 x 60mm or 1 2 13 UNC x 2 5 in Hex Head Bolt With Lock and Flat Washers 3 places Robot Base M12 or 1 2 13 UNC Robot To Plate Tapped Holes 3 places OLLI M12 x 100mm or 1 2 13 UNC x 4 in Hex Head Bolt With Lock and Flat Washers 4 places 16 mm 5 8 in Spool to Floor Through Hole 4 Places og i P a o Q Y a gt gt 90mm e 0 Concrete Floor Q 3 5 inch um ME TN Expansion Bolt Anchor n ME gem jq ER Thread End Down FS ou d 4 Places d g e a Drawing Not to Scale 22 mm 7 8 in Diameter Floor Holes 4 Places Figure 3 5 Mounting Spool to Floor Installation Detail Installing a Mounting Plate The following sequence details the installation of a robot mounting plate to the floor NOTE You can substitute M12 bolts of correct length in place of 1 2 13 UNC bolts to install the mounting plate and robot Drill and tap three M12 or 1 2 13 UNC 2B mounting holes as shown in Figure 3 2 for robot to plate attachment Drill four 16 mm 5 8 inch diameter through holes as shown in Figure 3 1 for plate to floor anchoring Place the plate exactly where the robot is to be installed Ensure that the plate is positioned so that the footprint for the robot is properly oriented relative to
128. _UTL utility as described earlier There is one test in addition to the tests performed at the time of commissioning the dual brake solenoid valve test When SAFE_UTL is started after the system has been successfully commissioned the utility program displays the following menu and prompts the user to select an option Adept MMSP Test Programs Version 13 0 Copyright c 1998 by Adept Technology Inc Robot 1 XXX XXXX gt EXIT gt All Tests gt Accelerometer B Amp Voltage Restrict gt CIP Switches and Buttons gt MCP E STOP Functions gt Brake Holding Force gt Dual Brake Valve YOO BWNE OO ll V Enter Selection AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 193 Chapter 8 Verifying the System Installation 194 WARNING In order to perform tests on the dual brake valve some access covers must be removed The PA 4 power chassis should be switched off These tests should be performed only by trained personnel Required Tools The following tools are required to perform the tests e M6 Allen wrench e Flat bladed common screwdriver Testing the Dual Brake Valves With MMSP WARNING The robot will move all joints to their midrange position If the robot is in its workcell make sure the robot will not contact other tooling and or fixtures causing damage to the robot tooling and or fixtures Select the brake vale test option 7 gt Dual Brake
129. ach side near the back of the chassis Use the screws and washers from the accessories kit see Figure 4 6 and Figure 4 7 Rack Mounting Use the mounting brackets screws and washers from the accessories kit to rack mount the Adept PA 4 power chassis joined to an Adept MV controller in a standard 19 inch equipment rack The brackets can be installed in two positions for rack mounting flush and set back see Figure 4 6 and Figure 4 7 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Rack or Panel Mounting M4 x 25mm pan head screws two places To Install Mounting Brackets on an co Adept MV Controller n e Remove and discard three existing countersunk screws from the chassis side at locations shown in drawing o o e Place bracket in desired position and secure with indicated M4 screws and washers from the accessories kit MY e Repeat process for the other side of the controller If the controller is M4 x 10mm joined to an Adept PA 4 power o o pan head chassis see Figure 4 7 for the screw location of the screws on the PA 4 power chassis Note See Figure 11 11 on page 252 Panel Mount for dimensions of the controller and mounting brackets MCN M4 x 25mm pan head screws two places each rack mount M4 x 10mm pan head screw one place each m rack mount i Rack Mount Flush Rack Mount Set
130. al real variables in system memory When a variable has been selected the LCD will display var name XXX CHANGE TRUE FALSE 1 If the variable being edited is from an array an additional soft button is displayed that allows you to specify the index of the variable to edit 204 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C MCP Predefined Functions Press the TRUE soft button to set the variable to the Boolean value of true 1 Press FALSE to set the variable to false 0 To change the value of the variable press the CHANGE soft button The LCD displays var name CHANGE TRUE FALSE The typing cursor replaces the variable value Use the data entry buttons to input a new value and complete the entry by pressing REC DONE Loc Press the LOC soft button and the LCD displays SELECT LOCATION VARIABLE TO EDIT locl loc2 loc3 loc4 lt MORE gt Press the soft button under the variable name to edit that variable The lt MORE gt soft button is shown only when there are more than five global location variables in system memory When a variable has been selected the LCD will show loc name X 500 CHANGE NEXT HERE If a precision point is selected the LCD will show loc name Jtl 210 CHANGE NEXT HERE Press the CHANGE soft button to change the displayed component of the location variable The value will
131. alve 2 on port B DO CLOSEI In World Tool or no pressure at valve 1 on port or Joint state press T1 B SIGNAL 3001 3002 and minus speed bar Open option option option Pressure at valve 3 on port B DO OPENI In World Tool or no pressure at valve 4 on port or Joint state press T1 B SIGNAL 3003 3004 and plus speed bar Closed option option option Pressure at valve 4 on port B DO CLOSEI In World Tool or no pressure at valve 3 on port or Joint state press T1 B SIGNAL 3003 3004 and minus speed bar Relaxed No pressure at either valves 1 2 DO RELAXI In Free state press T1 3 or 4on or port B SIGNAL 3001 3002 3003 3004 Pneumatic action on port A will be the opposite of port B No pressure indicates that the valve is connected to the return exhaust AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 147 Chapter 7 Optional Equipment Installation Compressed Air Lines In the Adept XL Robot Extra User Air Lines IE Port A Valves i Optional Solenoid Assembly Normally Plugged Under Joint 2 Cover ne Seed EE 1 User Connector on rni a _ Tower Bracket Air Line Feed for TERO EE cdi Solenoid Valves u Spare Air Line Connected at Outer Link Bracket and Electrical Bulkhead Optional Open Close User Air Lines Port B Valves
132. amming of the robot system Use of cables other than those supplied or use of modified components in the system Failure of a second device in a redundant safety circuit Take precautions to ensure that these situations do not occur see Chapter 10 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C What to Do in an Emergency Situation For Systems Without MMSP Option The following situations may result in risks that cannot be avoided Purposely defeating any aspect of the safety E Stop system Improper installation or programming of the robot system Unauthorized use of cables other than those supplied or use of modified components in the system Defeating interlock so that operator can enter workcell with High Power ON Take precautions to ensure that these situations do not occur see Chapter 10 What to Do in an Emergency Situation 1 18 Press any E Stop button a red push button on a yellow background field and then follow the internal procedures of your company or organization for an emergency situation If a fire occurs use CO to extinguish the fire WARNING Do not disconnect the compressed air supply to the robot unless you are sure that nobody is trapped near the robot Disconnecting the air supply will prevent the brake release function from operating This function may be required to release or gain access to a person trapped in the workcell How Can Get Help Refer to the Ho
133. and Figure 11 17 on page 257 256 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Joint Motions 150 150 Figure 11 16 AdeptOne XL Joint 1 Motion Figure 11 17 AdeptThree XL Joint 1 Motion AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 257 Chapter 11 Technical Specifications Joint 2 Joint 2 also referred to as the elbow 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 link Travel of joint 2 is also limited by software to the value set by the softstop The softstops are set to 150 degrees AdeptThree XL and 140 degrees AdeptOne XL from the zero position extended straight out This motion is similar to an elbow that can act in either a left hand or right hand configuration see Figure 11 18 and Figure 11 19 The robot can reach a given location in either a right hand Righty or left hand Lefty configuration This configuration is not stored when a location value is saved When V moves the arm to a location it might return to that location in either configuration depending on the starting configuration of the arm If the robot must always return to a location with a specific configuration the programmer must specify within the program RIGHTY or LEFTY configuration LEFTY Joint 2 Hardstops LEFTY Joint 2 Hardstops Figure 11 19 AdeptThree XL Joi
134. anual and an Automatic AUTO operating mode While in Automatic Mode personnel are not allowed in the workcell In Manual Mode operators with additional safety equipment see section 1 13 on page 40 are allowed to work in the robot workcell if the MMSP option incorporated For safety reasons the operator should whenever possible stay outside of the robot work envelope to prevent injury The maximum speed and power of the robot is reduced but it could still cause injury to the operator Before performing maintenance in the working envelope of the robot High Power must be switched off and the power supply of the robot must be disconnected After these precautions a skilled person is allowed to maintain the robot See section 1 12 on page 39 for the specifications AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Qualification of Personnel The Adept XL robot can work in Automatic Mode at high speeds and accelerations and can trap persons or crush them The impact of a robot can kill a person WARNING Electrical Hazard Impact Hazard Never remove any safeguarding and never make changes in the system that will decommission a safeguard 1 12 Qualification of Personnel This manual assumes that all personnel have attended an Adept training course and have a working knowledge of the system The user must provide the necessary additional training for all personnel who will be working with the system As noted in t
135. are located inside the robot The hardstops for joint 2 are mounted externally on the inner link The joint 2 hardstops are the hard rubber half cylinders that the large eyebolts pass through The hardstops for joint 3 are mounted at the top and bottom of the quill Joint 2 and 3 hardstops must not be modified in any way or damage to the robot could occur AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Limiting Joint Travel Cartesian Limit Stops V can detect collisions between the robot end effector and static Cartesian obstacles V tests for collisions between the robot s tool tip or its tool mounting flange and specified obstacles NOTE Collisions between other structural elements of the robot and the obstacles or between two robots are NOT detected For fixed structural elements of the workcell the system automatically detects possible collisions in the following circumstances When planning the end point for a straight line or joint interpolated motion When executing a straight line motion but not during a joint interpolated motion When moving the robot in tool world or joint manual control Rectangular solids boxes cylinders and spheres can be defined Objects can be placed in any position and orientation relative to the base of the robot Four user obstacles can be defined and modified by the end user The SPEC utility see SPEC V2 in the Instructions for Adept Utility Programs is used to defin
136. ated on the front of the chassis near the On Off switch The robot ID label is located on the right side of the robot base toward the rear You should always have this serial number available when you call Adept Customer Service for technical support AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Installation 3 1 Mounting the Robot Adept robots must always be installed on a base The base can be a mounting plate or a mounting spool see Mounting Surface Specifications on page 45 WARNING You must not install a robot directly on the floor Tool and Equipment Requirements Common hand tools plus the following items are required to install the robot and any options or end effectors Power Drill Motor 12 mm 1 2 inch capacity minimum Masonry drill bit 22 mm 7 8 inch Ratchet handle 1 2 inch drive Socket 3 4 inch Device for measuring mounting surface level that exceeds the level requirements described in Table 2 1 on page 45 Torque wrench 1 2 inch drive Vacuum cleaner Pallet jack or forklift Hydraulic lift with dual leg sling both rated for 320 kg 700 pounds minimum Mounting plate or spool WARNING The installation procedures in this chapter should be performed only by skilled persons as defined in section 1 12 on page 39 Do not attempt the installation without proper tools including a torque wrench and a device for measuring level An improper installation could caus
137. ation 4 6 Robot and Control System Cable Installation This section covers the installation of all required power and signal cables for the robot and controller If you have the MMSP option there are additional cables that must be installed For MMSP equipped systems complete the installation steps in this chapter up to section 4 10 on page 92 then move to Chapter 5 for details on installing the MMSP option and completing cable installation Figure 4 13 shows the cabling between the robot and the control system Table 4 1 lists the lengths of all cables EJl to Amp Cable Controller Power Chassis CLERI s Te g C e 8 per Oo E aU p au PME MlajO 0 7 7 il I Arm Power E Lr E A Cable Adept XL Robot Ee ALL CIP to Controller Interface User 1 1 0 AWC Panel CIP User 2 Security Panel Cable JAWC 82 MCP LJ Figure
138. ative label over the existing label below the circuit breaker on the front of the chassis to show the new voltage configuration 7 Reconnect the controller and Security Panel to the AC power source Part 3 Moving Blue Wire on Security Panel 1 Locate the blue wire labeled Neutral that is installed on the neutral terminal on the Power Rail X2 N 2 Remove that wire from the neutral terminal and install it in the L2 position on contactor AP1 X2 AP1 L2 next to the wire that is already installed there See Figure 5 5 on page 101 100 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option Connect Blue Wire Here for 220 240 VAC ii Power Rail X2 z B ojojo 900 000 E ape J H AP1 F1 OO0O0 ooo ry ojojo 7 a BEER EEE EERE X Blue Wire Labeled Neutral From 24 VDC Supply Figure 5 5 Moving Blue Wire From Neutral to AP1 L2 200 240 VAC Adept PA 4 Power Chassis with Front Air Intake Grill Removed adept O technology inc D 380 415 V rS 380 415 V 200 240 V Voltage Selector Voltage Selector Plug in Socket 380 415 Position Figure 5 6 Changing Voltage in Power Chassis AdeptOne
139. available try VT102 or VT100 you will not be able to use all of the function keys 5 Set the terminal baud rate to 9600 the default rate for the Adept system To change the baud rate refer to the information on CONFIG_C in the Instructions for Adept Utility Programs AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Graphical Interface Using AdeptWindows PC 6 3 Graphical Interface Using AdeptWindows PC The AdeptWindows PC Microsoft Windows based program allows full programming and control of the robot from an IBM compatible personal computer The computer can be connected to the Adept controller using a serial cable or an Ethernet link This section details the simple connection of one PC to one Adept controller AdeptWindows software allows for more complex installations on a network For instructions on installing and configuring more complex installations see the AdeptWindows User s Guide The following instructions assume that the configuration DIP switches and network section of the Adept system configuration have been left as delivered Installing an AdeptWindows PC based user interface involves the following steps Install the AdeptWindows PC software on the customer supplied PC e If you are using an Ethernet connection Setup the TCP IP interface Connect the Adept controller to the PC using a customer supplied network hub or an Ethernet crossover cable A crossover cable can be pu
140. ay a blinking error message and light the LED on the CLR ERR button shown in Figure 9 8 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 207 Chapter 9 Using the Manual Control Pendant MCP 208 EXTERNAL E STOP Figure 9 8 CLEAR ERROR Function Button The CLR ERR button must be pressed for operation to continue Pressing the CLR ERR button will clear the error message from the display and return the MCP to the state it was in before the error The CMD Function The CMD function button displays the options AUTO START CALIBRATE STORE ALL CMD1 and CMD2 as shown in Figure 9 9 AUTO STORE START CALIB ALL CMD1 CMD2 OLOLOLO JO Figure 9 9 Command CMD Function Button The AUTO START CALIB CMD1 and CMD2 functions require the MCP to be in Auto mode If one of these function buttons is pressed while the MCP is in Manual mode the MCP prompts you to place the keyswitch in the Auto position The operation is halted and you must press the function button again The programs started by these buttons may include a WAIT START instruction in which case the program will pause and the MCP will display START and CANCEL buttons over the two right soft buttons Pressing START allows the program to continue Pressing CANCEL halts program execution The programs started by these functions run in task 0 Therefore High Power must be enabled and the robot must be calibrated Auto Start When AUT
141. ay use these contacts to control other mechanisms e g conveyor linear modules etc when MANUAL mode is selected The load on the contacts should not exceed 40 VDC or 30 VAC at a maximum of 1A Remote High Power Control The CIP also provides a connection for an additional user supplied High Power enable circuit see Figure 7 14 Figure 7 15 Figure 7 16 Table 7 10 and Table 7 11 for the customer High Power circuitry The CIP has two different methods of remote operation of the High Power push button located on the CIP These connections are optional The first method allows relocating the push button switch to a more convenient location The second allows the start up of multiple robots from a central control computer that can communicate with the robot controllers Implementation of either method must conform to EN standard recommendation The European standard EN 775 Ind Robots Part 6 Recommendations for Safety Item 7 2 5 Emergency Stop reads Each robot system operator station shall have a readily accessible emergency stop device The manual intervention and reset procedure to restart the robot system after an emergency stop shall take place outside the restricted space AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 167 Chapter 7 Optional Equipment Installation Thus it is important that the remote High Power push button be located outside of the protected space of the robot Pins 1 and 20 2 and
142. bels PA 4 ID Label z O TT N adept technology Inc San Jose CA Model PA 4 Part No Serial No VOLTAGE AMPERAGE FREQUENCY 39 200 240V 8 5 AIPHASE 50 60 Hz 39 380 415V 8 5 AIPHASE 50 60 Hz tT TT O O O O O A E M AdeptOne XL Cleanroom ID Label adept technology Inc San Jose CA Model AdeptOne XL Cleanroom Robot ID 860 1234 0 14D 5 Weight 255kg 585 Ibs Air 0 48 0 76 MPa 70 110 psi T V Rheinland 2 MED in 05 1998 Made in U S A S AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 267 Chapter 11 Technical Specifications AdeptOne XL IP 54 ID Label MMSP AdeptThree XL IP 54 ID Label MMSP rr N f adept technology Inc adept technology Inc San Jose CA San Jose CA Model AdeptOne XL IP 54 Model AdeptThree XL IP 54 Robot ID 860 1234 0 149 5 w MMSP Robot ID 862 1234 0 15B 5 w MMSP Weight 255kg 561 Ibs Weight 266kg 585 Ibs Air 0 48 0 76 MPa 70 110 psi Air 0 48 0 76 MPa 70 110 psi zJ MFD in 05 1998 2 T V Rheinland EM Made in U S A rbv Rheinland VL EMS MFD in 05 1998 Made in U S A EMV EMC J J CIP ID Label a adept technology Inc D San Jose CA Model CIP Serial No 350 00138 Part No 30350 10350 Made in U S A Manufactured in 1998 B1 CE 0197 TUV Rheinland 2 o EMC 3j 2
143. cludes support for turning on and off system power to the controller If you use this switch you must provide an AC contactor with the following electrical characteristics e 12V or 24V AC or DC coil limited to less than 500 mA The user connection for system power is at the JUSER connector pins 6 and 24 You will need to provide a power supply to match the coil voltage of the external contactor In addition the system power switch has a second pole that is wired through the 25 pin cable to the Manual Mode Safety Package Access to this pole is at TB5 pins 5 and 6 on the E Stop PCA of the MMSP You can wire to whichever contact is more convenient See Figure 7 17 for details on wiring through the CIP See Figure 7 18 for details on wiring through the Security Panel AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 169 Chapter 7 Optional Equipment Installation 170 1 8 m 6 ft SCSI Interface Cable Controller Interface Panel Side View Adept MV Controller User Supplied 24V Power Supply i 5 pees Coil User Supplied Contactor L AC Supply CN 100 240 VAC PE Figure 7 17 System Power Switch Circuit AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP 24VDC Available at TB1 To Pins 5 and 6 of Pins 1 and 2 Terminal Block TB5 on
144. control button can be selected STEP Button When the CIP keyswitch is set to Manual V programs cannot initiate motions unless you press the STEP button and speed bar on the MCP To continue the motion once it has started you can release the STEP button but must continue to press the speed bar Failure to operate the STEP button and the speed bar properly results in the following error message Speed pot or STEP not pressed Once a motion has started in this mode releasing the speed bar also terminates any belt tracking or motion defined by an ALTER program instruction Motions started in this mode have their maximum speeds limited to those allowed in Manual mode AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Moving a Robot or Motion Device With the MCP Programs designed to allow moving the robot in Manual mode should read the status of the STEP button and speed bars before starting the move The program should prompt the user as required Speed Bars In World Tool and Joint Mode The speed bars are used to control the robot s speed and direction The joint s that will move when the speed bars are pressed depends on the state selected with the MAN HALT button Press the speed bars with your left thumb Pressing the speed bars near the outer ends will move the robot faster pressing the speed bar near the center will move the robot slower See Robot States below for details on positive and ne
145. controller If the slot has a blank panel installed loosen the captive screws at the top and bottom of the panel and remove it Verify that the intended slot for the module is ready to accept the module Align the module with the card guide slots at the top and bottom of the card cage Slide the module in slowly Apply straight forward pressure to the top and bottom handles until it is firmly seated in the rear power connector and the face of the module is flush with the other modules Do not use excessive pressure or force to engage the connector If the board does not properly connect with the rear power connector remove the module and inspect the connector and guide slots for possible damage or obstructions Tighten the captive screws at the top and bottom of the module WARNING There is an interlock circuit that prevents enabling power if the amp module screws are not tightened securely This also applies to any blank panel cover s There are dangerous voltages present inside the power chassis Do not attempt to operate without blank panel cover s installed in any unused slots AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 239 Chapter 10 Maintenance 10 10 Spare Parts List MV 5 MV 10 Part numbers and specifications are subject to change Contact Adept Customer Service for ordering information for items in Table 10 1 on page 221 or for items not listed see section 1 18 on page 41 Tabl
146. cord An incorrect installation can injure or kill anybody who touches the equipment in the robot workcell AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 87 Chapter 4 Adept MV Controller Installation Connect each conductor of the power cord securely to your AC power source using the color code below You must provide a suitable plug or other facility connection in accordance with all applicable local and national standards and regulations See section 4 11 on page 93 for important information on system grounding Table 4 2 Adept MV Controller Power Cord Specifications Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 10 amps Number and size of 3 x 1 00 mm conductors Color code line brown neutral blue ground green yellow System Grounding Information 4 8 The detachable three wire power cord is used for connection to both the power source and protective ground The protective ground conductor colored green yellow in the power cord is internally connected to the exposed metal parts of the Adept MV controller To ensure electrical shock protection the protective ground conductor must be connected to a properly grounded power source See section 4 11 on page 93 for proper grounding procedures WARNING Ensure that a proper protective ground connection exists before turning on the power Manual Mode Safety Package Installation 88 If you are installing a system that
147. cts AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 165 Chapter 7 Optional Equipment Installation Two pairs of pins on the JUSER connector pins 13 32 and 14 33 provide voltage free contacts one for each channel to indicate whether the E Stop chain as described above on that channel is closed Both switches are closed on each of the redundant circuits in normal condition no E Stop You may use these contacts to generate an E Stop for other equipment in the workcell The load on the contacts should not exceed 40 VDC or 30 VAC at a maximum of 1A These voltage free contacts are provided by a redundant cyclically checked positive drive safety relay circuit for EN 954 1 Category 3 operation see Figure 7 14 Figure 7 15 and Table 7 10 for the customer emergency stop circuitry Muted Safety Gate E Stop Circuitry WARNING The Adept XL series of robots are Category 3 robots and they require a Category 3 E Stop on all workcell guarding if a teach restrict interface such as the MMSP option is not installed The muted safety gate functionality is not compatible with a Category 3 E Stop and must not be used on systems that do not include the MMSP option To use the muted safety gate function with the MMSP option see Chapter 5 JSIO E Stop Circuitry Six pins provide two single channel E Stop inputs and a single channel output The output relay contact Passive E Stop Output is different from the E Stop outputs describ
148. d should incorporate twisted pair wires of a minimum of 0 08 mm 28 AWG size The connectors should be wired so that pin 1 goes to pin 1 pin 2 goes to pin 2 and so on The twisted pairs in the cable must be wired to physically opposing contacts in the connector That is the first twisted pair goes to pins 1 and 26 the second to pins 2 and 27 and so on A shielded Micro D50 male connector should be used on both ends The entire cable must be shielded with a foil and drain wire See the Adept MV Controller User s Guide for the connector pin descriptions and locations Connecting the MCP to the CIP 80 The MCP is connected to the system at the pendant connector on the CIP The controller does not have to be turned off to connect or disconnect the MCP Note that if the MCP or the MCP bypass plug is removed High Power will be turned off The JUSER connector allows you to install a remote MCP connector See Connecting User Supplied Digital I O Equipment on page 173 and the Adept MV Controller User s Guide for details WARNING The CIP has two key switches Before the MCP can be used in the workcell the operating key switch must be set to MANUAL and the NET switch to LOCAL O This will prevent program execution from being started from keyboard or terminal AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C MCP Cradle CAUTION The coiled cable on the MCP III has been tested to withstand 500V of repetitive electrical bu
149. d slow button are used primarily to move the robot when it is in Manual mode These options are described in Moving a Robot or Motion Device With the MCP on page 210 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C MCP Predefined Functions In some cases application programs will make special use of the speed bars See the documentation for any application program for details on how it uses these buttons Emergency Stop From the MCP To immediately halt program execution and turn off High Power press the E Stop button on the MCP This switch has the same effect as pressing the E Stop button on the controller To reenable High Power after pressing the MCP E Stop button turn the E Stop button to the right clockwise The switch is spring loaded and will return to its normal position Depress the enabling switch High Power can now be reenabled by pressing the COMP PWR button mode control group or by entering the ENABLE POWER command from the keyboard and then pressing the white High Power push button lamp on the CIP Background Mode 9 3 The pendant is in background mode when the USER LED is not lit and none of the predefined functions are being used The USER LED is lit whenever an application program is making use of the MCP The MCP will not return to background mode until the program completes execution or is aborted The LEDs above the predefined function buttons indicate whether the functions are being used
150. d through capacitors to the blue wire of the PA 4 power chassis power cord If you change the voltage setting from 200 240 VAC to 380 415 VAC you must add additional insulation to the blue wire according to the directions provided below Failure to do this could result in injury or death Turn off the power chassis and controller Disconnect the controller and the optional Security Panel from the AC power source Verify that power remains off during all parts of this procedure Remove and discard the 19 mm 3 4 inch shrink tubing from the end of the power cord Remove and discard the 7 mm 1 4 inch shrink tubing from the end of the blue wire in the power cord see Figure 5 9 on page 104 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 103 Chapter 5 MMSP Installation and Configuration 4 Locate the 19 mm 3 4 inch piece of shrink tubing in the accessory kit 5 Place the 19 mm 3 4 inch piece of shrink tubing from the accessory kit over the end of the power cord Use a heat gun to apply the shrink tubing 6 Reconnect the 5 wire power chassis power cord at the power source from the AP2 T1 T2 T3 neutral and protective earth terminals on the Security Panel 7 Reinstall the power chassis power cord at the Security Panel according to the 380 415 VAC section in Figure 5 10 on page 106 also see Figure 5 1 on page 96 Power Cord From 19 mm 3 4 inch Power Chassis Shrink Tubing Don aR Blue Wire
151. dequate safeguards according to applicable local and national standards Installations in EU and EEA countries must comply with EN 775 1SO 10218 sections 5 6 EN 292 1 and EN 60204 section 13 28 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Precautions and Required Safeguards Maximum Robot Forces and Torques Adept robots are computer controlled mechanisms capable of exerting considerable force Like all robot and motion systems and most industrial equipment they must be treated with respect by the user and the operator See Table 1 2 and Table 1 3 Table 1 2 Maximum Torques and Forces AdeptOne XL Robot Torque Force Joint 1 maximum static torque 330 Nem 244 ft lb Joint 2 maximum static torque 255 Nem 188 ft lb Maximum static force applied by the robot in XY plane 1187 N 267 lb measured at the tool flange joint 2 fully tucked Table 1 3 Maximum Torques and Forces AdepiThree XL Robot Torque Force Joint 1 maximum static torque 330 Nem 244 ft lb Joint 2 maximum static torque 255 Nem 188 ft lb Maximum static force applied by the robot in XY plane 1179 N 265 lb measured at the tool flange joint 2 fully tucked Safety Barriers Safety barriers must be an integral part of robot workcell design Adept systems are computer controlled and may activate remote devices under program control at times or along paths not anticipated by personnel
152. dule on the left hand side called Amp 1 drives the motor for joint 1 The A amp module on the right hand side called Amp 2 drives the motor for joint 2 Connectors and Indicators 11 Status LEDs When an LED is turned on it indicates the following conditions High Volts On indicates the high voltage to the amps is turned on PWM On indicates that current servo is on It does not go on until calibration is complete DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY EXTINGUISHED O torreon Low Volts On indicates the low voltage supply in the power O rios chassis is on O LowvoLTs ON O OPENCKT FAULT s de O wsisoien Tew Open Ckt Fault indicates that an open circuit in the motor O A PHASE SHORT FAULT Cy arise suci eat leads has been detected O C PHASE SHORT FAULT HV Sag Over Temp indicates that the input voltage has dropped below the specified level or an over temperature fault has been detected on an amp module Phase A B C Short Fault indicate that an over current in the motor leads to one of the phases has been detected TODAZOO DM N VES o9 Amplifier Control connector the EJI to Amp cable connector is installed here Motor Power Output connector the Arm Power cable is installed here ACUACO PMEOV DOJOZ 6 D Figure 4 2 A Amplifier AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 67 Chapter 4 Adept MV Contr
153. e 10 3 Controller Spare Parts List From Adept n Adept Part z Description Number Quantity General Comments Fan Filter 40340 00030 1 Front Panel Bypass plug 10330 01040 User can build their own see the 1 Adept MV Controller User s Guide for details E Stop test plug for JSIO port 10330 01075 1 on CIP Table 10 4 Controller Spare Parts List From Third Parties Description Specification Quantity General Comments Fuse F1 5 AT 250V 5x20mm 1 AC line fuse at power IEC 127 style entry board Fuse F2 5 AT 250V 5x20mm 1 AC line fuse at power IEC 127 style entry board These items are not available from Adept 240 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Spare Parts List PA 4 Amplifier Chassis 10 11 Spare Parts List PA 4 Amplifier Chassis Part numbers and specifications are subject to change Contact Adept Customer Service for ordering information for items in Table 10 5 Table 10 5 PA 4 Spare Parts List ore Adept Part Description Number Quantity General Comments Fan Filter 40330 11200 1 10 12 Spare Parts List Adept XL Robot Part numbers and specifications are subject to change Contact Adept Customer Service for ordering information for items in Table 10 6 Table 10 6 IP 54 and Adept XL Clean Room Robot Spare Parts List eure Adept Part Description Number Quantity Genera
154. e B Tube D Figure 7 4 Solenoid Valve Assembly 13 Route tubes A1 A4 along the outer link inside wall so that the tubing will not interfere with existing wiring Use the 4 inch cable ties P N 27300 00023 as required to hold the tubing together see Figure 7 5 144 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Robot Solenoid Kit M Valve Harness D sub Connector Outerlink Cable Track Entry is Under This Pneumatic A Jupe P Fitting for ee Routing Tube E Figure 7 5 Tube and Cable Routing 14 Remove the 1 4 inch plug from the pneumatic fitting on the left bulkhead Insert tube E into the fitting and make a loop that will allow the outer link cover to be installed without interference from tube E 15 Connect tubes A1 A4 to the B ports of the four valves Group the tubes by pairs so that they are in adjacent valves Adjust the tubing lengths as needed by pushing the tubes out through the tower bracket see Figure 7 6 on page 146 16 Connect the D sub connector on the solenoid valve harness to the connector on the outer link left bulkhead see Figure 7 5 Route the harness along the four 5 32 inch pneumatic tubes Secure the captive screws on the D sub connector 17 Route tube D as shown in Figure 7 5 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 145 Chapter 7 Optional Equipment Installation 146 18 Verify that none of the existing connect
155. e Erklarung bezieht mit den folgenden Normen auquel se r f re cette d claration est conforme aux normes We declare that the machine in the form delivered by us subject to the usage conditions specified below complies with the relevant and fundamental safety and health requirements defined in EU Directive 89 392 EEC Annex I and the following standards The machine must not be put into operation until all of the machinery into which it is incorporated has been declared in compliance with the provisions of the effective versions of the directives This includes all supplementary equipment and protective devices EU EEA IEC ISO EN 55011 1991 Class A EMC Emissions CISPR 11 1990 EN 50082 2 1995 EMC Immunity EN 292 1 1991 amp EN2922 A1 1995 Safety of machinery EN 60204 1 1997 IP20 Electrical safety TEC 204 1 1992 EN 775 1992 Robot safety ISO 10218 1992 EN 954 1 1996 Safety related parts of control systems EN 1050 1996 Risk assessment EU Directives EG Richtlinien Directives Communautaire Direttiva CE 89 392 91 368 93 44 93 68 Machinery 89 336 92 31 93 68 EMC 73 23 93 68 Electrical Equipment Usage and installation conditions The product must be installed and used strictly in accordance with the AdeptOne AdeptThree XL Robot Instruction Handbook document p n 00862 00100 In particular the robot system must be installed with user supp
156. e an Adept MV series controller and a PA 4 power chassis see Figure 1 3 on page 26 The robot is programmed and controlled using the Adept MV controller and PA 4 amplifier control system The optional Manual Mode Safety Package MMSP provides additional safety features see Figure 5 1 on page 96 Specifications for the Adept XL series of robots are provided in Chapter 11 oo Cm om im T Cm JJ AdeptThree XL Robot AdeptOne XL Robot Figure 1 1 Adept XL Robots Selective Compliance Assembly Robot Arm AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 25 Chapter 1 Safety 26 Joint 3 MV Controller With Adept PA 4 Power AWC Board Chassis Figure 1 3 Adept MV 10 Controller and PA 4 Power Chassis AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Definition of a Manipulating Industrial Robot An automatically controlled reprogrammable multipurpose manipulative machine with several degrees of freedom which may be either fixed in place or mobile for use in industrial automation applications is called a manipulating robot ISO 10218 1992 E Adept Equipment Compatibility This instruction handbook describes the installation and commissioning of Adept XL robots with and without the Manual Mode Safety Package The optional Manual Mode Safety Pac
157. e e Signal 1010 USER n NO cate 1 NT 121 1 a Signal 1011 eS 2 T Sinking Eile 123 1 Signal 1012 TO Figure 7 19 Digital Input Wiring Examples JSIO Connector Output Signals The JSIO connector handles output signals 0001 to 0008 On systems with the MMSP output channels 0006 to 0008 are used by the MMSP and are not available for users Refer to Table 7 13 for output specifications The locations of the signals on the connector are shown in Table 7 14 The JSIO connector provides separate positive and negative connections for each channel no internal common connections This allows the choice of wiring for current sourcing or current sinking modes Table 7 13 DIO Output Specifications JSIO Connector Operating voltage range 0 to 24 VDC Operational current range per channel I out lt 100 mA short circuit protected Vdrop across output in on condition V drop 2 7 V at 100 mA V drop 2 0 V at 10 mA Output off leakage current I out 600 pA Turn on response time hardware 3 psec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time Turn off response time hardware 200 usec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 175 Chapter 7 Optional Equipment Installation 176 The following drawing shows two examples of different connections
158. e inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or unusable for any reason order a new air filter The Adept MV controller fan filter part number is 40340 00030 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 229 Chapter 10 Maintenance CAUTION If the fan stops working or the filter becomes dirty the controller could overheat and cause a thermal failure This applies to all models of Adept MV controllers 1 Turn off the controller 2 Loosen the two screws on the fan filter cover to gain access to the filter 3 Pull the air filter out and inspect for dust or dirt particles If cleaning is required use compressed air to clean the filter Follow all appropriate safety procedures regarding the use of compressed air 4 Replace the cleaned air filter and secure the filter holder 10 5 Changing the Lamp on the CIP High Power Enable Switch 230 The system is equipped with circuitry to detect the potentially dangerous condition of a burned out CIP HIGH POWER push button lamp If this lamp is burned out you cannot enable High Power until the lamp has been replaced To replace the High Power indicator lamp 1 Turn off the controller and disconnect system power 2 Remove all cables from the back and side of the CIP WARNING Make sure that the cables connected to JDIO1 through JDIO4 are properly labeled The two input cables
159. e obstacles AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 63 Adept MV Controller Installation The Adept XL robots are delivered with either an Adept MV 5 controller or an Adept MV 10 controller The dimensions installation and cabling requirements of both controllers are identical The Adept MV 10 controller allows for additional option boards The following sections apply whether you have an Adept MV 5 or Adept MV 10 controller The same PA 4 power chassis is used with both controllers The controller chassis holds the backplane power supply and cooling fans required by the various processor boards All systems include an AWC system processor see Figure 4 1 and an EJI motion interface board see Figure 4 15 These boards are delivered with the configuration specified on your order and you should not have to perform any setup or initialization of these boards If you need to alter the delivered configuration or are installing additional boards not supplied with the original order see the Adept MV Controller User s Guide for complete details on installing and configuring boards Your system may contain additional optional boards that were included as part of your sales order These boards also will be configured as ordered and you should not have to perform any additional setup or configuration For a complete description of all Adept processor boards see the Adept MV Controller User s Guide The optional boards that mi
160. e packing slip or are damaged do not sign the receipt Contact Adept as soon as possible If the items received do not match your order please contact Adept immediately Inspect each item for external damage as it is removed from its container If any damage is evident contact Adept see How Can I Get Help on page 41 Retain all containers and packaging materials These items may be necessary to settle claims or at a later date to relocate equipment AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 51 Chapter 2 Installation Overview 2 10 Repacking for Relocation 2 11 If the robot or other equipment needs to be relocated reverse the steps in the installation procedures that follow this chapter Reuse all original packing containers and materials and follow all safety notes used for installation Improper packaging for shipment will void your warranty Before unbolting the robot from the plate or spool fold the outer arm against the joint 2 hardstops to help centralize the center of gravity The robot must always be shipped in an upright orientation Specify this to the carrier if the robot is to be shipped Robot and Controller ID Labels 52 Identification ID labels are located on the left or back side of the controller and power chassis On the label you will find the model and serial numbers and the voltage and current ratings see Figure 4 18 on page 90 Smaller serial number labels are loc
161. e serious damage or possible fatal injury AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 53 Chapter 3 Robot Installation Installing a Base for the Robot Adept recommends that you use a mounting plate or a mounting spool The following sections detail preparing and installing a plate or a spool The plate or spool must meet the specifications detailed in Mounting Surface Specifications on page 45 Robot Installation Dimension Drawings Figure 3 1 shows the dimensions for drilling the holes to mount the plate or spool to the floor Figure 3 2 shows the hole pattern for drilling the holes to mount the robot to the plate or spool Figure 3 3 shows the clearance required at the rear of the robot for the power and signal cables Figure 3 4 shows mounting plate installation details Figure 3 5 shows mounting spool installation details V4 559 mm 22 0 in Y 610 mm 24 0 in Figure 3 1 Mounting Hole Pattern Plate Spool to Floor 54 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Mounting the Robot 353 1 mm ins 13 90 in 2 176 5 mm 6 95 in gt A A Clearance holes 3 in robot base 47 14 2 mm 0 56 in os Y A A 128 3 mm 541 0 mm in 21 3 in Y A A 346 5 mm 13 64 in 2 mm 9 in 241 8 mm 9 52 in v_ y Y Y A Center of Column column 23 6 mm diameter is 0 93 in 179
162. e the last 4 decimal digits of the AWC board s serial number AWC Board Serial Number 6000030542 yy Default IP Address 172 16 105 142 Figure 6 3 The Controller IP Address NOTE The AWC board serial number is located on the top front of the AWC board and on a bar code label attached to the bus connectors at the rear of the board As shown in Figure 6 3 if the AWC board serial number is 6000030542 the Adept controller s default IP address will be 172 16 105 142 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 133 Chapter 6 User Interface Installation Connecting One PC and One Controller As shown in Figure 6 4 there is one PC networked to one Adept controller The AWC board can be connected to the PC using one of the three cabling options shown below IP 172 16 200 1 SM 255 255 0 0 AWC Board Using Factory Default Settings Ethernet or Network Serial Cable Crossover Hub Cable Figure 6 4 One PC One Controller To create the network shown in Figure 6 4 complete the following steps 1 Install the AdeptWindows software on the PC See Installing the AdeptWindows Software on page 129 2 If you are making an Ethernet connection a Connect the Adept controller to your PC using a network hub or a crossover cable b Install a TCP IP protocol on the PC using the IP address and subnet mask shown in Figure 6 4 See Setting Up the TC
163. each Restrict cable to the Security Panel User 2 connector on the robot Arm Signal cable Tighten the two captive screws securely 4 Connect the 9 pin D Sub male plug labeled TRS1 to the D Sub connector TRS1 on the Teach Restrict Interface board Tighten the two captive screws securely 5 Connect the square plug to the square connector J4 on the E Stop Board CAUTION Verify that all components are fully inserted and screwed down Connecting the Security Panel to the Adept PA 4 Power Chassis For speed limiting of joints 3 and 4 in Manual mode the Teach Restrict to B Amp cable must be installed between the Adept PA 4 power chassis and the Teach Restrict Interface board on the control rail Installation procedure for the Teach Restrict to B Amp cable see Figure 5 1 and Figure 5 3 1 Turn off the PA 4 power chassis and Adept MV controller AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option 2 Plug the 15 pin high density D Sub male connector of the Teach Restrict to B Amp cable into the Teach Restrict socket on the B Amplifier board in the power chassis Tighten the two captive screws securely Plug the 9 pin D Sub connector labeled TRS2 into the socket TRS2 on the Teach Restrict Interface board Tighten the two captive screws securely Plug the 9 pin D Sub connector labeled TRS3 into the socket TRS3 on the Teach Restrict Interface board Tighten the two captive screws
164. ed above This contact closes only when High Power is on not when the E Stop circuit is closed CAUTION These are single channel contacts and are not suitable for EN 954 1 Category 3 operation The two pairs of pins on the JSIO connector pins 41 42 and 43 44 provide connections for user and auxiliary emergency stop circuitry see Figure 7 14 Table 7 10 and Table 7 11 for the customer emergency stop circuitry NOTE These pins must be jumpered closed if not used The High Power On contacts and JSIO connector pins 45 and 46 are called the Passive E Stop Output because they are compatible with older Adept equipment The load on the contacts should not exceed Maximum Voltage 40 VDC 30 VAC Maximum Current 1A Category 3 E Stop If your system does not include the MMSP option it must be protected by a Category 3 dual channel cross checked interlocked barrier system The system must disconnect the AC power supply to the PA 4 power chassis if any person enters the workcell See Risk Assessment Category 1 on page 34 166 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP Remote Manual Mode Control The CIP also provides a connection for a user supplied Manual Mode circuit see Figure 7 14 Figure 7 16 Table 7 10 and Table 7 11 for the customer Manual Mode circuitry This circuitry must be incorporated into the robot workcell t
165. ematic Sheet 2 of 2 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 119 Chapter 5 MMSP Installation and Configuration The following table describes the components referred to by the numbers in Figure 5 16 on page 118 and Figure 5 17 on page 119 Table 5 7 Description of Numbers in the MMSP 3 E Stop Drawing No Description of Numbers in the Schematic 1 Front Panel MANUAL AUTOMATIC select key switch MANUAL Normally Open 2 Customer Manual Mode 1 and 2 OUT Voltage Free Contacts 3 V Manual Mode Input Contacts 4 Customer E Stop IN 1 and 2 Contacts 5 Customer Safety Barrier 1 and 2 Contacts 6 Customer Safety Barrier Mute 1 and 2 Contacts 7 Teach Restrict Cyclic Check Contacts 8 Joint 1 Joint 2 Accelerometer Contacts 9 Joint 3 B Amplifier Speed Cutoff Contacts 10 Joint 4 B Amplifier Speed Cutoff Contacts 11 V User External E Stop Input Contacts to the CIP passive E Stop circuit 12 Customer E Stop 1 OUT Voltage Free Contacts 13 Customer E Stop 2 OUT Voltage Free Contacts 14 V High Power Enable Passive E Stop 15 CIP High Power ON Remote PUSH Button MOM 16 Customer Safety Relay IN N C Feedback Contacts 17 PA4 Power Amplifier Chassis Contactors 18 Power Chassis 19 Robot RSC Brake Release Enable Driver 20 Robot Brake Release Enable Solenoids 21 USER Computer Control Hi Power ON 22 USER Remote High Pow
166. emory with the command LOAD c util safe_utl v2 3 Start execution of the program with the command EXECUTE 1 a safe_utl The following menu is displayed Adept MMSP Test Programs Version 13 0 Copyright c 1996 1998 by Adept Technology Inc Language Selection gt EXI English Deutsch gt Francaise D 0ND GO ll V gt Italiano Enter Selection After a language selection is made the following is displayed Warning A personnel should be outside the safety barrier A safety gates should be installed and closed Note Adept recommends that all end of arm tooling be removed from the robot prior to testing Some tests may require a second person 8 6 Tests Performed at Time of Commissioning NOTE There are no tools required for these tests NOTE Some actual display screens may vary slightly from the displays shown in this handbook The utility program displays the following menu and prompts the user to select an option 1 The SAFE_UTL programs can be loaded from the D drive from the A drive or from a remotely mounted NFS drive by substituting the correct drive letter and path 186 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Tests Performed at Time of Commissioning Adept MMSP Test Programs Version 13 0 Copyright c 1996 1998 by Adept Technology Inc Robot 1 xxx xxxx Not Commissioned
167. ence describes the installation of the robot to the mounting plate or spool NOTE You can substitute M12 bolts of correct length in place of 1 2 13 UNC bolts to install mounting spool and robot Connect the hydraulic lift to the eyebolts at the top of the robot by means of a dual leg sling see Figure 3 6 Take up any slack but do not lift the robot WARNING Impact Hazard Do not attempt to lift the robot at any points other than the eyebolts provided Failure to comply could result in the robot falling and causing either personnel injury or equipment damage AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Mounting the Robot Spreader Width pa Nominal 19 8 mm o 7 7 in Lift Robot Only From Two Eyebolts WARNING Eyebolts Must Not Be Removed Robot Calibration Will Be Affected Figure 3 6 Lifting Robot With Eyebolts Remove the three bolts securing the robot base to the pallet Retain these bolts for possible later relocation of the equipment WARNING Do not extend the inner or outer links of the robot until the robot has been secured in position With the inner and outer links extended an unsecured robot will tip and fall causing either personnel injury or equipment damage Lift the robot and position it directly over the floor plate or spool WARNING Impact Hazard The robot may swing free if not lifted straight up Stand clear of the robot at all times while it is su
168. end of the blue wire in the power cord and use a heat gun to apply it see Figure 5 4 Fold the blue wire back Place the 19 mm 3 4 inch shrink tubing over the end of the blue wire and the power cord insulation Use a heat gun to apply it see Figure 5 4 Reinstall the power chassis power cord at the Security Panel according to the 200 240VAC section in Table 5 11 on page 106 also see Figure 5 1 on page 96 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 99 Chapter 5 MMSP Installation and Configuration Power Cord From 19 mm 3 4 in Power Chassis Shrink Tubing Blue Wire 7 mm 1 4 in Shrink Tubing Figure 5 4 Insulating Blue Wire in Power Cord 200 240 VAC Part 2 Rotating Voltage Selector in Power Chassis 1 Open the front air intake grill on the power chassis by loosening two screws and swinging the grill out 2 Inspect the voltage setting it is marked on the front of the voltage selector plug To change the voltage setting remove the selector rotate it 180 degrees so the required setting is shown and replace it see Figure 5 6 on page 101 3 Close the grill and secure the two screws 4 Clearly mark or alter the ID label on the side of the PA 4 power chassis to show the new voltage configuration 5 Clearly mark or alter the ID label on the side of the Security Panel to show the new voltage configuration see Figure 5 7 on page 102 6 Clearly mark or paste an altern
169. eptOne XL AdeptThree XL Robot Instruction Handbook Rev C 261 Chapter 11 Technical Specifications 11 4 AdeptThree XL Robot Specifications All specifications subject to change without notice Table 11 3 AdeptThree XL Robot Performance Specifications Maximum Payload including end effector 25 kg 55 lb Rated Payload including end effector 9 kg 19 8 Ib Reach Maximum radial 1066 8 mm 42 0 in Minimum radial 279 5 mm 11 0 in Vertical clearance bottom of base to end effector flange with maximum Joint 3 retraction 876 3 mm 34 5 in with maximum Joint 3 extension 520 7 mm 20 5 in Vertical Stroke Z direction Joint 3 356 mm 14 0 in Joint Rotation Joint 1 300 Joint 2 300 Joint 4 540 Inertia About Joint 4 axis maximum 14 600 kg cm 5000 Ib in Force Joint 3 downward force without payload 45 kg 100 lb Cycle Time 12 in 305 mm Burst Sustained No payload 0 62 sec 0 73 sec 9 kg 20 lb payload Rated 0 69 sec 0 89 sec 25 kg 55 lb payload Max 0 99 sec 1 24 sec Resolution Joint 1 0 00078 Joint 2 0 00078 Joint 3 vertical Z 0 0067 mm 0 00026 in Joint 4 tool rotation 0 025 Repeatability X Y plane 0 038 mm 0 0015 in Joint 3 vertical Z 0 038 mm 0 0015 in Joint 4 rotational 0 05 262 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev
170. er ON P B MOM 23 CIP JMMSP TB1 6 USER ground Timing gt 0 1 1 second 120 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Digital Signals on the Category 3 E Stop Board 5 5 Digital Signals on the Category 3 E Stop Board The digital input and output signals available to the CIP JSIO connector are wired to terminal blocks TB1 TB2 and TB3 on the security panel see Figure 5 15 Eleven input and five output channels are available You can wire these signals using either the JSIO connector on the CIP see section 7 11 or terminal blocks TB1 TB2 and TB3 See section 7 11 on page 173 and section 7 12 on page 177 for details on wiring to the CIP digital I O connectors Wiring to the security panel is described in the following sections NOTE The CIP JSIO supports 12 input and eight output channels However one input and three outputs are used by the MMSP option and are not available to users Input Signals See Figure 7 19 on page 175 for a typical input signal circuit The terminal blocks TB1 and TB2 handle the digital input signals 1001 to 1011 Each channel has an input and a corresponding return line refer to Table 5 8 for input specifications The locations of the signals on the terminal blocks are given in Table 5 9 Table 5 8 DIO Input Specifications for TBI and TB2 on the Security Panel Operational voltage range 0 to 24 VDC Off state voltage range 0
171. er chassis fan filter 229 recommended schedule 221 robot compressed air filter 228 robot lubrication 222 228 Man Halt button on MCP 211 Manipulating Industrial Robot defined 27 Manual Control Pendant basics 199 CMD function 208 CMD1 209 CMD2 209 connector 76 dimensions 253 how touse 199 220 mode control buttons 210 operator s model 199 predefined function buttons 210 Manual mode High Power enable process 112 how to use 112 197 robot speed limited 112 197 user supplied circuit 167 Manual Mode Safety Package 203 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 283 Index connector on CIP 77 171 installation 88 95 Manual operating mode 197 Manual states free 218 joint 216 tool 214 world 213 Manual Automatic mode switch 75 Manufacturer s Safety Data Sheets MSDS 222 Maximum Adept XL robot joint velocities in runaway situations 30 Maximum torques and forces AdeptOne XL Robot 29 AdeptThree XL Robot 29 MCP bypass plug 81 connection 81 connector 76 cradle 81 dimensions 254 installation 81 Enabling switch 184 E Stop functions 191 layout 201 predefined function buttons 204 predefined functions 203 viewing angle on MCP 203 Mechanical checks before using the robot 179 Mechanical installation of the CIP 79 Micro style connector pinouts for DeviceNet 157 MMSP installation and configuration 95 security panel dimensions 251 Mode control and joint axis control buttons 202 butto
172. er cord securely to your AC power source using the color code shown in Table 4 3 The installation must meet all applicable European international and national standards and regulations AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept Robot Grounding Table 4 3 AC Power Cord Specifications for Power Chassis Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 25 amps Number and size of 5 x 2 5 mm conductor size Color code 380 415VAC line 1 black line 2 black line 3 brown neutral blue ground green yellow Color code 200 240VAC line 1 black line 2 black line 3 brown no connection blue must be insulated see page 89 ground green yellow WARNING Electrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord An incorrect installation can injure or kill anyone that touches the equipment in the robot workcell The protective ground conductor colored green yellow of the Adept PA 4 power chassis is internally connected to the accessible metal parts of the power chassis To ensure electrical shock protection this must be connected to a properly grounded power source WARNING Ensure that a proper protective ground connection exists before turning on the power The Adept PA 4 power chassis and the Adept MV controller must be connected to the same earth gr
173. erated as described in this handbook meets the stringent requirements of the Category 3 level of safety specified in EN 954 The MMSP has also been designed to meet relevant standards referenced in EN 954 including ISO 10218 EN 775 Manipulating Robots Safely Also see the Manufacturer s Declaration on page 5 Adept has performed a risk assessment based on intended applications of this product Our assessment indicates that a Category 3 safety system as defined in EN 954 is required to protect the operator and programmer This protection may take two forms 1 If a programmer may need to enter the cell with High Power on then Adept s optional MMSP should be installed The system must be installed so that no one can enter the workcell when the robot is in AUTO mode 2 Ifno one will enter the workcell with High Power ON not even to teach robot locations then the user must provide a Category 3 dual channel and cross checked interlocked barrier system The system must disconnect the AC power supply to the robot if any person enters the workcell Intended Use of the Robots The installation and use of Adept products must comply with all safety instructions and warnings in this manual Installation and use must also comply with all applicable local and national requirements and safety standards see section 1 8 on page 38 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 35 Chapter 1 Safety 36 The AdeptOne XL
174. eries with the number 1 contacts of the E Stop switches on the CIP and the MCP It is the same for the 2 contacts The customer E Stop IN 1 and 2 signals should be from a two pole switch or multiple two pole switches These contacts are for additional customer E Stop switches or circuitry for example light curtains or pressure sensitive mats They would open the E Stop circuit and shut down High Power when activated The customer Safety Barrier 1 and 2 connectors should be from one or more two pole switches All the switches that are mounted on safety barriers and safety gates should be installed in series making two separate loops Then they are connected to the customer Safety Barrier 1 and 2 input terminals on TB4 Between the customer Safety Barrier 1 and 2 Mute connectors the same type of switch should be installed as between the connectors described above In Automatic mode this switch or series of switches has the same function as the normal customer Safety Barrier 1 and 2 connectors but in Manual mode they are not connected to the chain of E Stops In Manual mode these connectors are muted bypassed by the control system This allows you to open an access door to the robot workcell in Manual mode if these limit switches are installed to the customer Safety Barrier 1 and 2 Mute contacts Voltage Free Contacts for Monitoring E Stop Circuitry Passive E Stop Adept provides voltage free contacts passive E Stop on TB
175. f the cable 7 If you are using the AdeptWindows PC user interface connect a shielded Ethernet cable from the hub or server to the shielded RJ45 connector on the AWC board Unshielded cables will degrade the integrity of the AdeptWindows PC link particularly when power is applied to the robot or mechanism Use straight cables to a hub or a crossover cable to a stand alone PC Cable Connection Summary All Systems Check to make sure all the following cables are correctly installed Robot to power chassis Arm Power Cable CIP to MCP install bypass plug if not used e CIP AWC to AWC board 180 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation Check List Robot to controller Arm Signal Cable Controller to power chassis EJI to Amp Cable JUSER to user supplied equipment install jumper plug if not used Cable Connection Summary MMSP Systems Check to make sure all the following cables are correctly installed Robot to Security Panel Controller to Security Panel Power chassis to Security Panel e CIP JMMSP to Security Panel User Supplied Safety Equipment on JUSER and JSIO Connector Checks Check the following safety equipment connected to the JUSER and JSIO connectors on the CIP 1 There are eight pairs of contacts that must be connected on the JUSER connector see Table 7 10 Contacts Provided by the JUSER Connector on page 161 to ensure proper continuity
176. f the controller Whenever this switch is released High Power is removed from the motion device When the MCP is not being used the operator must place it in the special cradle provided or remove it from the controller and install the pendant jumper plug The cradle retaining clip will keep the enabling switch depressed when the pendant is not in use Figure 9 2 shows how to place the pendant in its cradle To operate the MCP put your left hand through the opening on the left hand side of the pendant and use your left thumb to operate the pendant speed bars Use your right hand for all the other function buttons The various button groupings of the pendant are reviewed in this section O a USER WORLD TOOL JOINT FREE DEV e Depress the palm activated enabling switch Figure 9 1 Holding the MCP AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 199 Chapter 9 Using the Manual Control Pendant MCP 200 OJGICIOIS e Cees OQOWOO NI MCP cradle retaining clip Figure 9 2 Cradling the MCP WARNING The cradle for the pendant MUST be mounted
177. from the center of the quill increases Inertias for the commonly used shapes of a cylinder and rectangular bar are given by the following AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 153 Chapter 7 Optional Equipment Installation uo I Cylindrical Payload Inertia Rectangular Payload Inertia 1 2 m r2 m 12 12 w m mass in kilograms m mass in kilograms r radius in centimeters 1 length in centimeters w width in centimeters The formulas for the inertia for other common shapes as well as the formula for an off axis mass can be found in many mechanical engineering textbooks Adept XL Initial Payload and GAIN SET Tuning Values for Joint 4 Table 7 5 AdeptOne XL Initial Payload and GAIN SET Tuning Values for Joint 4 Joint 4 Inertia GAIN SET Value Payload Value 0 880 kg cm 0 default 14 default 0 300 Ib in 881 2053 kg cm 1 46 301 700 Ib in2 2054 3188 kg cm 2 82 701 1087 Ib in Example GAIN SET 2 2 PAYLOAD 50 4 154 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installing End Effectors on an Adept XL Robot Table 7 6 AdepiThree XL Initial Payload and GAIN SET Tuning Values for Joint 4 J4 Inertia GAIN SET Value Payload Value 0 2933 kg cm 0 default 10 default 0 1000 Ib in2 0 880 kg cm 1 3 0 300 Ib in 881 2933 kg cm 2 13 301 1000 Ib in 2934 5865 kg cm 3
178. g plate in the previous section apply to the top plate of the mounting spool The recommended design for a manufactured spool is a welded assembly consisting of three steel parts top and bottom plates welded to a center column as detailed in Figure 2 1 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 45 Chapter 2 Installation Overview 610 mm dia 24 0 in gt Y Top Plate PLLLAL LLL ELL ALLL LLL od zr 25 mm 1 0 in Top and CAM Bottom Don in 457 mm max Column 18 0 in Y Bottom Plate gt S gt 5555959595900I0U00D0 ooooo5oo5050 25 mm 1 0 in A 10mm 0 40 in ue 305 mm dia E 12 in Schedule mne 808 3 x x mm mm oq FORS Or egu 3 8 in min 12 in View A A View A A Option 1 Option 2 Material Carbon Steel Material Surface Flatness 0 5 mm 0 02 in Mounting Surface Level within 0 25 degrees 2 5mm 0 1 in over 610 mm 24 in Figure 2 1 Mounting Spool Specifications See Figure 3 2 on page 55 for the robot mounting hole pattern 46 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Environmental Requirements 2 3 Environmental Requirements The Adept robot system installation must meet the operating environment requirements shown in Table 2 2 See Table 2 3 on page 48 for the Adept MV controller electrical requirements and Table 2 4 on page 49 for the PA 4 amplifier chassis electrical
179. g on the sales order The boxes have different dimensions and weights The following table gives an overview Table 2 5 Adept Shipping Crate Specifications Product in Crate Length Width Height Weight AdeptOne XL Robot 0 74 m 29 in 1 20 m 47 in 2 00 m 79 in 265 kg 583 Ib AdeptThree XL Robot 0 74 m 29 in 1 20 m 47 in 2 00 m 79 in 266 kg 585 Ib Adept MV Controller and 0 89 m 35in 0 64m 25 in 0 96 m 38 in 66 kg 145 lb PA 4 Power Chassis Monitor 0 54 m 21in 0 51 m 20in 0 51 m 20 in 23 kg 50 lb AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 49 Chapter 2 Installation Overview WARNING The center of gravity of the robot shipping crates is not in the middle of the boxes Pay attention when you transport the crates 2 7 Transport and Storage Shipping and Storage This equipment must be shipped and stored in a temperature controlled environment within the range 25 C to 55 C The recommended humidity range is 5 to 90 percent non condensing It should be shipped and stored in the Adept supplied packaging which is designed to prevent damage from normal shock and vibration You should protect the package from excessive shock and vibration Use a forklift pallet jack or similar device to transport and store the packaged equipment see Figure 2 2 on page 51 WARNING Heavy load
180. gative directions In Comp Mode See the description of the STEP Button on page 212 Fast Slow EN U n Fast Figure 9 12 Speed Bars Slow Button The slow button selects between the two different speed ranges of the speed bars When the slow button LED is lit the slower speed range is selected This slower speed is 25 of the normal MCP speed Robot States World State When world state is selected movement in the X Y or Z direction is parallel to an axis of the world coordinate system Before the speed bars will move the robot an axis of motion must be selected from the manual control buttons The world coordinate system for a SCARA robot is shown in Figure 9 13 If X1 is selected pressing the speed bar will move the robot tool flange in the positive X direction Pressing the speed bar will move the flange in the negative X direction AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 213 Chapter 9 Using the Manual Control Pendant MCP ANS X direction Z Y direction ES Z direction RZ CCW Rotation Toning Gripper activity Bit X Figure 9 13 WORLD State Four Axis SCARA The T button cycles the gripper solenoids Press anywhere on the side of the speed bar to open the gripper on the side to close the gripper NOTE This is the most common gripper setup The gripper solenoids ma
181. ght be in your system are Additional AWC boards used as auxiliary processors EVI board for the AdeptVision system VGB board for the standard Adept graphical user interface SIO board for additional hard and floppy drives and additional serial ports e MI6 MI3 boards for controlling non Adept robots DIO for supplying additional digital input and out signals The amplifier chassis holds the backplane power distribution and cooling fans required by the amplifiers An amplifier chassis for an Adept XL series robot contains two single channel amplifiers described in A Amplifier Module Overview on page 67 and one dual channel amplifier described in Dual B Amplifier Module Overview on page 68 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 65 Chapter 4 Adept MV Controller Installation IMZIMIAM YONOD VONOD mwmws0m AdeptWindows Controller AWC Board Connectors and Indicators An AWC board 040 or 060 is required in every system This section describes the basic features of the AWC board 11 Status LEDs Six bicolor LEDs indicate diagnostic test power control and communication status The right column of LEDs gives the following status information LED Label Red LED Green LED SF OK System Fault System O K ES HPE E Stop open High Power Enabled HD LAN Read Write from CF Ethernet access o e o
182. h Power High Power On Off Switch Lamp On Off switch above See Remote High Power Control on page 167 for current limits 3 22 User Supplied 24 VDC for Central Active only in AUTO and Control High Power on off REMOTE NET 1 modes Table 7 11 Remote MCP Connections on the JUSER Connector Pin JUSER Pin MCP Description 37 1 9 Logic GND 17 3 MCP TXD 18 2 MCP RXD 19 5 12 VDC max 350mA 36 8 12 VDC max 50mA 4 23 Note 1 6 7 MCP E Stop PB CH 1 5 24 Note 2 11 12 MCP E Stop PB CH 2 6 25 Note 2 13 15 MCP Enable CH 1 Hold to run 7 26 Note 2 14 16 MCP Enable CH 2 Hold to run Note 1 Must be used in User E Stop circuit Note 2 Must be used in User Enable circuit NOTE There is an E Stop loop on the robot outerlink that may be useful in wiring E Stop switches to end of arm tooling for example to detect a break away gripper Information on the AmpLoop emergency stop circuitry is available from the FAXBack number listed in How Can I Get Help on page 41 162 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP JUSER 37 pin D sub Controller Interface Panel E Stop and MANUAL AUTO Controls Cyclic check circuit for ES1 and ES2 emergency stop relays CIP Internal connectors Channel 1 F ESTOPSRC Channel 2 User Supp
183. h is in the improper position the following message is displayed Accelerometer Test Switch the MANUAL AUTO keyswitch to MANUAL and NETWORK keyswitch to OPEN position When the key switches are in the proper position the following message is displayed AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 187 Chapter 8 Verifying the System Installation 188 Loc 2 Program controlled move xpect E Stop assert The default test locations are with Joint 1 at 15 degrees from midrange and all other join Do you want to use the default test locations ts at midrange Y N WARNING Responding Y causes the robot to move joint 1 to the positions shown in Figure 8 1 If the robot is in its workcell make sure the robot will not contact other tooling and or fixtures causing damage to the robot tooling and or fixtures dues lae 2 2 l Gates PS At dn WS val ge NO YN hel fu a Sys P2 a y B N l n y N Default Test Locations Example Test Locations Figure 8 1 Adept XL Robot Test Locations Responding N allows new test locations to be defined The test locations must be defined so that joint 1 is driven at least 30 degrees see Figure 8 1 The robot will make a quick move during the test causing the accelerometer to activate the E Stop The robot may overshoot slightly To ensure the robot does not crash i
184. hapter 6 User Interface Installation 6 1 Graphical User Interface Using the VGB Board If you ordered this type of interface the VGB board is already installed There is no hardware or software configuration You simply install the monitor keyboard and pointing device The user interface will be available as soon as you turn on the system NOTE The keyboard and monitor supplied by Adept are intended for use in light industrial conditions In more severe conditions they should be protected with a suitable enclosure Installation Procedure Connect the color monitor and extended keyboard with built in trackball to the VGB board see Figure 6 1 e VGB Ox oco omo lt zo4 zoz 1 2m4z ov 1 126 B Keyboard Trackball LI CLEYEEIL TET IL yr titi E ILL sa a E LI 111 PITITITTTriiriiia FERH II I 111 oO um e O pe Color Monitor Figure 6 1 Connecting the A Series Monitor and Keyboard Make sure the controller is turned off before making any connections Connect the monitor signal cable to the MONITOR connector on the VGB board See the Adept MV Controller User s Guide for monitor specifications for user supplied monitors Verify that the voltage range marked on the monitor is compatible with your local voltage
185. he controller and the PA 4 chassis from the AC power source Verify that power remains off during all parts of this procedure If a 5 wire plug has already been installed remove the plug Locate the two pieces of shrink tubing in the accessory kit one is 7 mm 1 4 inch diameter the other is 19 mm 3 4 inch Place the 7 mm 1 4 inch shrink tubing over the end of the blue wire in the power cord and use a heat gun to apply it see Figure 4 17 Fold the blue wire back see Figure 4 17 Place the 19 mm 3 4 inch shrink tubing over the blue wire and the power cord insulation and use a heat gun to apply it see Figure 4 17 Install a 4 wire plug or wire directly to an appropriate service disconnect according to the 200 240VAC section in Table 4 3 on page 93 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 89 Chapter 4 Adept MV Controller Installation Power Cord From 19 mm 3 4 in Power Chassis Shrink Tubing Blue Wire 7 mm 1 4 in Shrink Tubing Figure 4 17 Insulating Blue Wire in Power Cord 200 240VAC Part 2 Rotating Voltage Selector in Power Chassis 1 Open the front air intake grill on the power chassis by loosening two screws and swinging the grill out 2 Inspect the voltage setting it is marked on the front of the voltage selector plug To change the voltage setting remove the selector rotate it 180 degrees so the required setting is shown and replace it See Figure 5 6 o
186. he robot and power chassis cyclic checking 4 The CIP High Power push button lamp starts blinking NOTE The system waits until the High Power push button lamp is pressed If the button has not been pressed in a user configurable time the system does not enable High Power and returns an error message 5 The operator must press the CIP High Power push button lamp 6 The contactors close on the Security Panel and the power chassis amplifiers to supply High Power to the robot motors While in Manual mode the robot speed is limited to 250 mm per second 10 inches per second The motors also run at reduced torque This is to protect a person who is in the workcell teaching points with the MCP during program development It is important to remember that the robot speed is not limited when the robot is in Automatic mode 112 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Category 3 Emergency Stop and Teach Restrict Equipment 5 3 Category 3 Emergency Stop and Teach Restrict Equipment Systems equipped with the MMSP option have two methods of installing emergency stop circuitry The first method is to use the JUSER connector on the CIP This method is detailed in Chapter 8 The second method is to use the TB4 and TB5 connectors on the security panel see Figure 5 15 Both methods will yield functionally equal results as the state of the circuit on the Security Panel is forwarded to the CIP circuit see item 11 on F
187. he user must supply the following minimum hardware Your system may include additional user supplied equipment as described in Chapter 7 All Systems Mounting plate or spool see Mounting Surface Specifications on page 45 Installation tools see Tool and Equipment Requirements on page 53 End effector see Installing End Effectors on an Adept XL Robot on page 153 Safety barrier see Safety Barriers on page 29 Ground wire for robot see Adept Robot Grounding on page 93 Ground wire for robot mounted equipment see Robot Mounted Equipment Grounding on page 94 Optional AC 10A contactor AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 43 Chapter 2 Installation Overview Systems Without MMSP Option Optional 24VDC power supply see System Power Switch on page 76 Systems With MMSP Option 5 wire power cord for security panel see Changing the Power Chassis Voltage Setting on page 89 Ground wire for security panel see Grounding an MMSP Equipped System on page 110 2 2 Facility Requirements Compressed Air Requirements The Adept XL robot requires clean dry oil free compressed air at 4 8 7 6 bar 70 110 psi with a flow rate of 28 liters per minute 1 SCFM This compressed air is used to release the robot brakes and optionally to provide air to the User air lines End effectors attached to the robot may require additional air flow Insufficient air press
188. her equipment The two independent normally open contacts on this switch come out of the User connector and out of a terminal block on the MMSP They are for customer use only See Connecting the System Power Switch to the CIP on page 169 for details on using these connections NET Switch This switch should be left in the O position Side Connectors See Figure 4 9 on page 77 for the location of the following connectors AWC Interface JAWC Connects the CIP to the AWC board The JAWC connector accepts a standard 50 pin SCSI cable see Figure 4 11 on page 80 Note that the CIP does not communicate in SCSI format See Connecting the CIP to the AWC on page 79 for details User Connector JUSER All switch functions on the CIP can be duplicated external to the CIP using signals from this connector For example an external E Stop can be connected to the User connector this will behave exactly like the E Stop on the CIP Similarly there is an output on the User connector that can be used to stop external equipment when the CIP E Stop is pressed see Remote E Stop Circuit on page 172 for details See the Adept MV Controller User s Guide for details on the other remote functionality available through this connector AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Back Panel Connectors CIP SCSI Cable Connector JUSER Connector Figure 4 9 Controller Interface Panel CIP Side View Back Panel
189. hile the button is flashing After pressing ENTER the High Power push button must be pressed If the test fails the main menu is displayed If the test passes the E Stop Button test is performed and the following messages are displayed EMERGENCY STOP Button test Press the EMERGENCY STOP on the CIP AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Tests Performed at Time of Commissioning Release the EMERGENCY STOP Press and then release the E Stop button on the CIP If the test fails the main menu is displayed If the test passes the following messages are displayed CIP test passes Press ENTER to continue Press ENTER to continue with the next test or return to the main menu MCP E STOP Functions The Enabling switch on the MCP is tested to ensure that it is operational The following messages are displayed MCP Enable Hold to run Switch Test 1 Release the Enable Hold to run switch on the MCP Is the red ES LED on the AWC Board on Y N When the Enabling switch opens the red ES LED on the AWC board should turn on If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Attempting to enable HIGH POWER with the MCP Enable switch released The test attempts to enable High Power and expects an E Stop error If High P
190. his handbook certain procedures should be performed only by skilled or instructed persons For a description of the level of qualification Adept uses the standard terms Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers electrical and or mechanical Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers electrical and or mechanical All personnel must observe sound safety practices during the installation operation and testing of all electrically powered equipment To avoid injury or damage to equipment always remove power by disconnecting the AC power from the source before attempting any repair or upgrade activity Use appropriate lockout procedures to reduce the risk of power being restored by another person while you are working on the system WARNING The user must get confirmation from every entrusted person before they start working with the robot that the person 1 Has received the instruction handbook Has read the instruction handbook Understands the instruction handbook and A WO N Will work in the manner specified by the instruction handbook AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 39 Chapter 1 Safety 1 13 Safety Equipment for Operators 1 14 Adept advises operators to wear extra safety equipment in the workcell For safety reasons operators must wear the followi
191. ier modules If you do need to remove and reinstall a module follow the instructions below The four slots in the chassis are not interchangeable Some slots have special control signals The amplifier modules are factory installed in the correct slots Contact Adept Customer Service if you need to relocate any modules see section 1 18 on page 41 for details on contacting Adept WARNING Do not attempt to install or remove any amplifier modules without first turning off the power to the power chassis and all related external power supplies Failure to observe this warning could cause injury or damage to your equipment 238 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C PA 4 Power Chassis Circuit Breaker and Fuse Information Removing Amplifier Modules 1 2 3 4 Turn off the PA 4 power chassis and the Adept MV controller Note the location of any cables connected to the module then disconnect them Loosen the captive screws at the top and bottom of the module Using both the top handle and bottom handle pull the module straight out of the chassis Remove the module from the chassis and store it in a safe place CAUTION Do not expose the amplifier modules to electrostatic discharge ESD while you are handling or storing them Adept recommends using an antistatic ground strap on your wrist when handling modules Installing Amplifier Modules 1 2 Turn off the PA 4 power chassis and the Adept MV
192. ignal Pin Signal Pin Signal 1 Input 1001 2 1001 return 27 Output 0002 28 Output 0002 3 Input 1002 4 1002 return 29 Output 0003 30 Output 0003 5 Input 1003 6 1003 return 31 Output 0004 32 Output 0004 7 Input 1004 8 1004 return 33 Output 0005 34 Output 0005 9 Input 1005 10 1005 return 35 Output 0006 36 Output 0006 11 Input 1006 12 1006 return 37 Output 0007 38 Output 0007 13 Input 1007 14 1007 return 39 Output 0008 40 Output 0008 15 Input 1008 16 1008 return 41 Auxiliary 422 External E Stop input E Stop input 17 Input 1009 18 1009 return 43 Auxiliary 44 External E Stop input E Stop input 19 Input 1010 20 1010 return 45 Passive 46 Passive E Stop output E Stop output 21 Input 1011 22 1011 return 47 Not used 48 Not used 23 Input 1012 24 1012 return 49 Not used 50 Not used 25 Output 26 Output 0001 0001 Pins 41 42 43 and 44 See Figure 7 16 on page 165 for more information 7 12 Extended Digital I O Signals The extended digital I O signals are 64 optically isolated digital I O channels 32 input and 32 output They are wired to connectors JDIO1 through JDIO4 which are located on the back of the CIP see Figure 4 10 The electrical specifications for the inputs are similar to the JSIO inputs but have a different wiring configuration In addition they may not be used for REACTI programming high speed interrupts or vision triggers The outputs have a higher current carrying capac
193. igure 5 16 Wiring to the TB4 and TB5 connectors is mechanically simpler and two additional sets of contacts for customer safety barriers are provided Wiring to the CIP is covered in Chapter 8 Wiring to the TB4 and TB5 connectors on the security panel is covered in the following sections The Category 3 emergency stop and teach restrict equipment is located on the Control Rail on the Security Panel Figure 5 15 shows the Category 3 E Stop board and the Teach Restrict Interface TRI board NOTE Removable terminal block connectors for TB1 to TB5 on the Category 3 Emergency Stop board are supplied in the accessory kit Use these connectors to install customer wiring Adept recommends using crimp on ferrules on all wires that are installed into terminal blocks Teach Restrict Interface Board TRI Category 3 E Stop Board TRS2 TRS4 TRS1 J4 en J3 7 BH J2 Ge LE dl 1 12 1 1 Figure 5 15 Category 3 E Stop Board and Teach Restrict Interface TRI Board on Control Rail The Control Rail contains the terminals for customer supplied safety equipment The terminal blocks TB4 and TB5 are for customer E Stop connections The terminal block TB4 supplies the terminals for three additional user supplied E Stops These switches are two pole switches that a
194. ink XL PC Card 3C575 TX AOL Adapter Dial Up Adapter IEITIBVE PIGBETHES Client for NetwW are Networks AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 131 Chapter 6 User Interface Installation 4 Click on Protocol and then click on the Add button and the following window is displayed Select Network Protocol Y Fast Infrared Protocol 4 IFX SPX compatible Protocol 5 Click on Microsoft in the left scrolling window and then scroll down the right scrolling window until you can click on TCP IP Click on the OK button The network parameters window is redisplayed Click on the TCP IP protocol that you have just added and then click on Properties When the TCP IP Properties windows is displayed select the IP Address tab The following window is displayed TCP IP Properties m 132 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Graphical Interface Using AdeptWindows PC 6 Click on Specify an IP address and then enter the numbers shown above Click on the OK button 7 Restart your computer See the documentation provided with your PC for further details on installing a TCP IP protocol and setting the network address and sub net mask The IP address for the AWC board is already set based on the board s serial number the board serial number is not the same as the controller s serial number The default IP address will be 172 16 1xx lyy where xx and yy ar
195. ion The vacuum system maintains enough air velocity and pressure differential so that no particles escape Because the volume contained by the bellows changes when joint 3 moves up and down the system has been designed to accept this pumped air volume without allowing a positive pressure to develop across the bearing at the bottom of the quill or at the gap between the inner and outer links The seal between the inner and outer links allows air to flow freely from the outside of the robot toward the negative pressure inside the robot pulling any particles into the arm AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 269 Appendix A Adept XL Robot Factory Installed Options Vacuum requirements are defined in terms of a required level of vacuum at the base of the robot and the flow required to create this level of vacuum These requirements are listed below Minimum input vacuum 17 inches of water column W C Maximum input vacuum 30 inches of water column W C Minimum air flow 49 SCFM A practical requirement is that a minimum vacuum be maintained at the quill even during the fastest possible motions of joint 3 It is possible to adjust the amount of vacuum being applied to the system provided the following minimum vacuum level is met when the robot is running at its fastest joint 3 motion Minimum arm vacuum 1 0 inch W C measured at the tool flange These specifications result in sufficient vacuum t
196. ion Handbook Rev C 273 Appendix A Adept XL Robot Factory Installed Options Gaskets and seals should be inspected periodically and replaced immediately after finding damage Table A 2 IP 54 Hardware Upgrade Kit Nomenclature Adept Part Number Gasket Kit Joint 1 Upper Joint 2 Upper 90862 00800 Joint 2 Lower and Quill Covers Joint 1 Drive Tube Seal 40862 10660 Gasket Adhesive 87333 00404 O ring Grease 85304 00000 Baffle and Blower Plate Gasket 40862 10650 Blower Fitting Gasket 40862 10430 Customer Requirements While the IP 54 hardware upgrade kit provides most of the hardware needed to achieve an IP 54 protection level customers must provide a way of sealing the tool flange and pressurizing the robot through the blower attachment fitting located at the base of the Adept XL robot These two requirements sealing the tool flange and pressurizing the robot are critical to achieving the IP 54 level of protection Sealing the Tool Flange The tool flange must be sealed so that the robot shell can be positively pressured The positive pressure reinforces the sealing properties of the gaskets and seals provided in the IP 54 kit Joint 2 has no seal or gasket and achieves IP 54 protection levels through positive pressure alone This fact is critical when selecting a blower to pressure the robot Pressurizing of the Robot The robot is pressurized through the blower attachment fitting located a
197. irements 44 Fan filter cleaning in controller 229 in power chassis 229 Fast input signals 1001 to 1004 174 Fixed seals 234 Freestate 218 Free state four axis SCARA 219 Front switches and indicators 75 Function buttons on MCP 202 Fuse holders MV 10 233 Fuse information MV 10 233 Fuse ratings MV 10 233 Fuses amplifier chassis 238 amplifier module 238 G Graphical User Interface using AdeptWindows PC 129 using the VGB board 126 Gripper solenoid drivers 148 Gripper solenoids connector locations 143 Grounding Adept robot system 93 an MMSP equipped system 110 protective system information MV 10 88 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 281 Index system information 93 H Hardstops 62 Hardware to be provided by user 43 Harting connector Arm Power 265 motor winding resistance check 267 pin identification 266 pinout 265 Hazards from attached tooling 30 from expelling a part 30 High Power enable process description of 112 enabling switch lamp 76 Holding the MCP 199 How Can I Get Help 41 I Impact and trapping points 30 Information shipping 50 storage 50 Input signals JSIO 173 security panel 121 Installation 24V valve assembly 141 AC power 90 102 AC power MV controllers 87 AdeptWindows PC 129 Adept XL robot solenoid kit 141 check list 179 Cleanroom robot 269 dialog box Windows 95 program 130 floor requirements 45 graphical user interface with the VGB 126 in a rack
198. isplayed on MCP 205 Predefined function buttons on MCP 203 Pressurizing of the robot 274 Preventive maintenance recommended schedule 221 Priming a new program on MCP 209 Prog Set function on MCP 209 Program installation dialog box Windows 95 130 starting execution on MCP 210 Program cycles setting on MCP 209 Program Step selecting starting 209 Protection against unauthorized operation 40 facility overvoltage 48 Q Qualification of personnel 39 R Rack mounting the controller 72 Rack or panel mounting the controller 71 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 285 Index REACT input signals 1001 to 1012 174 Real MCP function 204 Real variables editing with MCP 204 REC DONE button 202 Recommended grease for the Adept XL robot 222 preventive maintenance schedule 221 terminal for S series systems 128 terminal for text based systems 128 vendors for mating cables and connectors 156 Related manuals 42 Relocation repacking for 52 Remote E Stop circuit 172 High Power control 167 High Power On Off Lamp 168 Manual mode control 167 MCP connections 172 on the JUSER connector 162 sensing of CIP MCP and user emer gency stop push button switches 165 user panel connections 172 Remote control of the AUTOMATIC MANUAL switch 167 Remote Enable switch connections 172 Removing amplifier modules 239 and installing amplifier modules 238 the bellows 236 the end effector for cleaning 234 Re
199. ital outputs available on the CIP See Connecting User Supplied Digital I O Equipment on page 173 for details Additional digital I O can be added using DIO boards See the Adept MV Controller User s Guide for details JSIO This connector includes 20 signal pairs eight digital outputs 100 mA max and 12 digital inputs including four fast inputs the first four input signals on this connector are the only input signals that can be configured as fast inputs The digital outputs are short circuit protected The single channel E Stop input and passive E Stop output are also included on this connector NOTE With the MMSP option input signal 1012 and output signals 1 through 5 are not available The remaining signals from the JSIO connector are also available at terminal blocks on the Security Panel see Digital Signals on the Category 3 E Stop Board on page 121 These signals can be wired from either the CIP or the Security Panel JDIO 1 4 These four connectors duplicate the function of one DIO board with 32 inputs and 32 outputs 700 mA max a total of 64 I O points The digital outputs are short circuit protected and protected from thermal overload Note that if a DIO board is installed and addressed as DIO board 1 the JDIO connectors on the CIP are inactive In order to use the JDIO signals the first DIO board must be addressed as DIO board 2 See the Adept MV Controller User s Guide for details on DIO boards Reserved Do n
200. itry on page 117 If one of these switches or contacts is open High Power will be turned off The Security Panel also supplies voltage free contacts that are closed when High Power is on and open when High Power is off These contacts can be used to switch additional equipment depending on the status of the emergency stop circuit The Security Panel also supplies voltage free contacts to signal that the robot is in Manual mode These contacts can be used by the customer to disconnect input devices or other external peripherals turntables conveyors etc Description of Mute Capability There are two pairs of terminals see Table 5 5 on the Security Panel for customer safety barriers that can be muted in Manual mode Input to these terminals from a safety barrier is muted not active in Manual mode but the input is active in Automatic mode That means that an interlock switch on a workcell access door can be connected to these terminals and the door can be left open in Manual mode This is useful for a person who is teaching points in the workcell during program development There is a second pair of terminals for a second barrier This pair of inputs is always active even in Manual mode This feature can be used for an inner barrier safety mat or light curtain These two safety gate circuits can be wired to the CIP or to the E Stop board on the security panel See Table 5 5 on page 114 and Table 5 5 on page 114 for details on wiri
201. ity than the JSIO See the Adept MV Controller User s Guide for details on using extended digital I O NOTE The signals on the JDIOx connectors can be superseded by a DIO board that is installed and addressed as DIO board 1 To use both the JDIOx signals and DIO boards address the first DIO board as DIO board 2 See the Adept MV Controller User s Guide for details on DIO boards AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 177 Verifying the System Installation Verifying that the system is correctly installed and that all safety equipment is working correctly is a three step process This chapter covers the first two steps Step one covers starting the control system for the first time and verifying that all components have been correctly installed Once the safe initialization of the control system has been verified the second step referred to as commissioning the system is to verify that all safety equipment is working properly The last step is to verify that the robot moves correctly The Manual Control Pendant is used for this step and is covered in Chapter 9 WARNING After installing the robot you must test it before you use it for the first time Failure to do this could cause death or serious injury or equipment damage 8 1 Installation Check List Before using the robot make the following checks to ensure that the robot and controller have been properly installed Mechanical Checks Ve
202. kage MMSP provides a Category 3 level of safety as specified in EN 954 in section 1 3 on page 33 The Adept robot system as described in this handbook must consist of the hardware and software listed in the following table All new systems shipped from the factory will include the correct equipment as shown If you have existing Adept equipment this table can help distinguish new equipment from older equipment especially since some of it is visibly similar See the product data label for the robot controller and power chassis for model number or part number information For information on the V operating system refer to the V Operating System User s Guide Table 1 1 Adept Hardware and Software Compatibility for MMSP Systems Product Required Model Part or Version Number AdeptOne XL robot Model Number 860 203 mm 8 in quill option part number 30862 10301 356 mm 14 in quill option part number 30862 10304 AdeptThree XL robot Model Number 862 part number 30862 10300 Adept MV 10 controller part number 30340 40000 Adept MV 5 controller part number 30340 10000 Adept PA 4 power amplifier chassis part number 30336 31000 A power amplifier part number 10337 15200 Dual B power amplifier part number 10338 51000 Manual Mode Safety Package MMSP Option consisting of Category 3 Security Panel part number 30335 00000 B power amplifier with voltage restrict part number 90338 51010 Controller Interface Pane
203. ke sure that workcell components have been properly interlocked to avoid hazards when the robot motion system is operated in Manual Mode Per ISO 10218 Manipulating Robots Safety the robot control system must employ a single point of control when operated in Manual Mode E Stop Button and Switch Checks 1 Verify that the red E Stop push buttons on the CIP MCP and User Panel if installed are in the normal unlatched electrically closed position AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 181 Chapter 8 Verifying the System Installation 2 Verify that the MCP is mounted on a rack that holds the MCP Enable switch in the ON position Verify that the user panel enable contacts are closed that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Inadvertent connection between the channels will short the E Stop power supply making it impossible to apply High Power to the robot 8 2 Applying Power to the Adept Control System 182 After you have made the checks listed above you are ready to turn on system power WARNING All safety systems must be in place and operating before applying power to the system Extra care should be taken during the initial tests of the robot system Turn the AC power switches on the Adept MV controller and PA 4 power chassis to the ON I position Turn the System Power switch on the C
204. l CIP part number 30350 10350 Category 1 part number 30350 10350 Category 3 Manual Control Pendant III part number 90332 48050 MCP III V operating system software Version 13 0 or later AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 27 Chapter 1 Safety 1 1 Notes Cautions and Warnings There are four levels of special notation used in this instruction handbook 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 WARNING If the WARNING is indicated with a lightning bolt instead of an exclamation mark an electrical danger or shock is possible for personnel working with the system 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 1 2 Precautions and Required Safeguards This manual must be read by all personnel who install operate or maintain Adept systems or who work within or near the workcell WARNING Adept Technology strictly prohibits installation commissioning or operation of an installation with an Adept robot without a
205. l Comments Gasket Kit 90862 00800 1 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 241 Technical Specifications 11 1 Robot Dimension Drawings Additional drawings of Adept products in DXF format are available on the Manuals on CD ROM that ships with each system and on the Adept Web site www adept com 800 mm 31 49 in 344mm 425mm 375mm 13 56 in 16 73 in 14 76 in ES Co 447 0 mm ERA 17 60 in de C E is 586 0 m 23 08 in 356 mm 14 in 203 mm 8 in See Figure 3 3 for Configuration Configuration required clearance x at rear of robot 1 497 8 mm 345 4 mm 19 6 in 13 6 in k 1726 mm 68 in fo up 1302 0 mm l gt 51 26 in p E F r ij 356 0 mm 1152 9 mm NE y 45 4 in 845mm 1074mm f 4 dn UE i i IN 0 in 33 2 in 423 in 5 mm ll 20 5 in y Y L Y Y Y v Y 28 mm 11 1 in 242 mm 9 52 in Figure 11 1 AdeptOne XL Robot Top and Side Dimensions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 243 Chapter 11 Technical Specifications 1485 mm 344 mm I 13 56 in 447 0 mm 17 60 in 58 47 in 558 8 mm 22 00 in
206. l Equipment 1 9 Additional equipment used with the Adept XL robot grippers conveyor belts etc must not reduce the workcell safeguards All emergency stop switches must always be accessible If the robot is to be used in an EU or EEA member country all components in the robot workcell must comply with the safety requirements in the European Machine Directive 89 392 EEC and subsequent amendments and related harmonized European international and national standards For robot systems these include EN 775 ISO 10218 sections 5 6 EN 292 1 3 71 and EN 60204 section 13 For safety fences see EN 294 In other countries Adept strongly recommends in addition to complying with the applicable local and national regulations that a similar level of safety be obtained In the USA applicable standards include ANSI RIA R15 06 and ANSI UL 1740 In Canada applicable standards include CAN CSA Z434 Sound Emissions 1 10 The sound emission level of the Adept XL robot depends on the speed and payload The maximum value is 90dB This is at maximum AUTO mode speed Thermal Hazard WARNING Thermal Hazard You can burn yourself Do not touch the robot base or outer link shortly after the robot has been running at high ambient temperatures 40 50 C 104 122 F or at fast cycle times over 60 cycles per minute The robot skin surface temperature can exceed 70 C 158 F Working Areas 38 Adept robots have a M
207. l down on the bellows until the bellows are fully compressed See Figure 10 3 on page 227 4 Apply Mystik SynGuard SX 6 grease to the axial and spiral grooves on the lower quill shaft 5 Move joint 3 slowly from the bottom to top and top to bottom travel positions several times Then move joint 3 to a middle travel position and wipe away any excess grease from the shaft with a clean soft cloth 6 Carefully pull bellows up around the lower quill shaft on the outer link Hold bellows in place and secure the top clamp 7 Reposition joint 3 to the bottom travel position and install the quill cover Tighten the six socket head cap screws with an M5 Allen wrench 10 3 Check Robot Mounting Bolt Tightness The robot mounting bolts including spool mounting bolts should be checked periodically to make sure they are not loose Also check the tightness of all access cover screws and all the captive screws of the cables NOTE The Adept XL robot generates high torque inertia forces 10 4 Maintenance and Inspection of Air Filters Draining Moisture From Adept XL Robot Compressed Air Filter The air filter on the compressed air inlet at the robot base has a moisture trap that should be emptied periodically depending on the quality of the air supply and the frequency of use The trap is emptied with the air supply connected To empty the trap use a rag to push up on the bottom of the air filter see Figure 4 14 on page 84 The co
208. ld be level Due to the high torque 405 Nem 432 ft Ib at the base transmitted by the robot it must be mounted to an extremely rigid structure Any mounting structure vibration or flexing will seriously degrade robot performance Adept recommends using either a mounting plate or a mounting spool Both have proven reliable over extended periods of use If another type of mounting structure is used it must adequately resist vibration and flexure Plate Using a flat steel plate is mandatory if the robot is to be mounted directly to the facility floor The mounting plate should conform to the following specifications Table 2 1 Mounting Plate Specifications Material carbon steel Diameter minimum 610 mm 24 0 inches Thickness minimum 25 mm 1 0 inch Mounting surface flatness within 0 5 mm 0 02 inch Mounting hole pattern as shown in Figure 3 2 Mounting surface level must be level to within 0 3 degrees 2 5 mm 0 1 in for a 610 mm 24 in spool For MMSP equipped systems the mounting surface must be level to within 0 25 degrees WARNING The specification for leveling the mounting surface is critical on MMSP systems The Teach Restrict sensor in the outer link will not function properly if the robot is not level Spool Another method of mounting uses a steel spool See Figure 2 1 on page 46 for the specifications and dimensions of a robot spool All of the specifications for the mountin
209. le clearance See Figure 4 14 on page 84 Connect the other end of the Arm Power cable to the matching connectors on the A and B Amplifier boards see Figure 4 13 on page 82 NOTE The user must add adequate strain relief for the Arm Power cable connectors at the amplifier boards a Connect the plug labeled A Amp 1 to the connector marked Motor Power Output on the A amp at the left side of the chassis b Connect the plug labeled A Amp 2 in the connector marked Motor Power Output on the second A amp to the right hand side of the first A amp AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 83 Chapter 4 Adept MV Controller Installation c Connect the plug labeled B Amp 1 in the connector marked Motor Power Output on the B amp d The fourth connector on the motor power cable is used only for the Adept XL Fifth Axis option not available for robots with the MMSP option WARNING Verify that all connectors are secure and fully inserted Failure to do this could cause unexpected robot motion eee Harting Arm Power Cable Connector Fan Filter Housing a gt Compressed Air gt Inlet With Filter Arm Power Cable Connectors a _ Robot Spare Air Line Base e DeviceNet Connector Harting Arm Signal Cable Connector a Arm Signal Cable Figure 4 14 Adept XL Robot Connector Locations
210. ler end of the bellows over the outer race of the user flange bearing Clamp the bellows onto the bearing using the bottom bellows clamp Put your fingers between the first and second of the top convolutions and push the top bellows cuff up and around the clamping diameter of the outer link housing It must wrap smoothly around the diameter Tighten the clamp around the bellows cuff The bellows cuff must make full contact with the clamping diameter AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Clean Room Robot Bellows Replacement Joint 3 Upper Quill Shaft Cover Joint 3 Upper Quill Shaft Outer Link Cutaway Quill Bellows Joint 4 Joint 3 Lower Quill Shaft Figure 10 8 Adept XL Quill Bellows Further Instructions The vacuum must now be tested refer to Testing the Vacuum on page 272 If the vacuum test fails check the bellows for leaks and correct them if found After the vacuum has been tested the end of arm tooling can be put back in place and the robot can be returned to normal use AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 237 Chapter 10 Maintenance 10 9 PA 4 Power Chassis Circuit Breaker and Fuse Information NOTE The SSER LVON HPON and ILMT labels on the lower right corner of the front of the power chassis are for diagnostic LEDs that can be viewed behind the front grill These LEDs are for Adept Field Service use only Chassi
211. lied Connections 24V midi ov Test Front Panel 1 7 7 7 call Ves q Pinay ES2 7 ES2 MOP n Z GE User E Stop and Gate Interlock ESTOPSRC Jumper closed when not used MUST open both ES Z SS D channels independently if 2200 uF used CIP will malfunction if one channel is jumpered and the other is opened ES1 ES2 V S s ESTOPSRC User E Stop Indication User Enable Jumper closed when Y N A not used MCP Enable Switch E F 1 User Manual Auto indication DM1 v Manual open MM1 MM1 c Muted Safety Gate A Active in auto mode only Jumper closed when Af 9 not used EsTOPsSRC 24V VeIN1 V IN4 V IN2 Manual 1 to AWC board Manual Auto Keyswitch Manual gt lt 250mm s See Figure 7 16 for details on the V IN coils ye Auto 1 Auto 2 Manual 2 User Manual Auto Switch Manual Open Jumper closed when not used Manual Open f Mo Auto gt 100 Figure 7 14 JUSER 37 Pin D sub Connector AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 163 Chapter 7 Optional Equipment Installation H High Power on off 77777 V High Power VREF 0 24V diode forward voltage drop V burned out bulb notify prevent High lt Power enable Manual Auto F
212. lied perimeter barrier interlocks The design of the barrier interlocks must provide a Category 3 level of control per EN 954 If the system has the EN 954 Category 1 Control System option The barrier interlocks must interrupt the AC supply to the PA 4 Power Chassis in the event of personnel attempting to enter the workcell You must teach the robot from outside the barrier or with arm power off The system must incorporate only those plug in modules and accessories listed in Table 1 or Table 2 If modules or accessories listed in Table 2 are installed the user must verify conformance to the EMC Directive after installation This Declaration applies only to those Adept product part numbers specifically listed in this declaration The following changes may result in the system not complying with the applicable Directives and would void this declaration unless additional testing and or evaluation is performed by the user unauthorized user modifications substitution or addition of Adept parts not listed on this declaration addition of user supplied parts and accessories 23 November 1998 Richard J Casler Jr Vice President Engineering San Jose California USA AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 5 DEUTSCH Hiermit erkl ren wir daf die nachstehende Maschine in der von uns gelieferten Ausf hrung den einschl gigen grundlegenden Sicherheits und Gesundheitsanforderungen der EG Richtlinie 89 39
213. ling setpoint That is set the switch for this point apply more vacuum then gradually reduce the amount of vacuum until the switch trips This helps compensate for switch hysteresis The extra 1 1 2 inches of vacuum allows for the normal swing of vacuum roughly 1 inch as joint 3 is moved up and down Reset the vacuum supply to the normal setting CAUTION The vacuum supply to the Adept XL Cleanroom robot must be on 24 hours per day to maintain the Class 10 Cleanroom rating Failure to supply vacuum to the robot 24 hours per day can void the warranty and contaminate the cleanroom environment AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C A 2 Adept XL Robot IP 54 Option IP 54 means dust protected and protection against water splashing Dust Resistance protection of the equipment inside the robot shell against ingress of solid foreign objects Specifically for IP 54 Dust Protection Ingress of dust is not totally prevented but dust shall not penetrate in a quantity to interfere with the satisfactory operation of the robot or impair safety Water Resistance protection of the equipment inside the robot shell against harmful effects due to the ingress of water Specifically for IP 54 Water Protection Water splashed against the robot enclosure from ANY direction shall have no harmful effects The factory installed IP 54 option kit provides an improved level of dust and water protection
214. ll connectors are fully inserted and screwed down Failure to do this could cause unexpected robot motion Also a connector could be pulled out or dislodged unexpectedly 86 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Power Entry Board 4 7 Connecting AC Power to the Adept MV Controllers The Adept MV controllers have auto ranging power supplies that operate at either 100 120VAC or 200 240VAC single phase The power supply must meet the requirements detailed in Table 2 3 Adept MV Controller Power Requirements on page 48 Power Entry Board The power entry board is located on the front of the controller It contains e On Off power switch On O Off Fuse holder containing the two incoming AC line fuses The spare fuses are stored in the fuse holder see Figure 4 16 AC power cord socket On Off Switch Fuse Holder WARNING FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE AC Power Cord Socket 5AT 7100 240 50 60HZ Serial Number Fan Filter Cover Figure 4 16 Adept MV Controller Power Entry Board Connecting AC Power Cord The AC power cord is included in the accessory kit The controller end of the power cord is fitted with an IEC 320 connector WARNING Electrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the
215. lying power to the Adept control system 182 Arm Power cable installation 83 Arm Signal cable installation 85 A Series controller installation 126 Auto start 208 from the MCP 208 AUTO V2 208 Automatic mode how touse 198 AUX JEXT 77 AWC interface JAWC 76 system processor board 66 user communication connectors 159 B B Amp Voltage Restrict Test 189 B Amplifier module connections indicators 68 overview 68 B Amplifier voltage restrict 184 Back panel connectors 77 Background mode on MCP 203 Bellows replacement Cleanroom robot 236 Board and cable installation checks 180 Bolt Resealing detail drawing on Adept XL IP 54 robot 235 procedure on Adept XL IP 54 robot 235 torque specs on Adept XL IP 54 robot 235 Brake release button 62 Brake Holding Force Test 192 Brakes 62 description 62 C Cable connection summary allsystems 180 MMSP systems 181 installation without MMSP option 82 Calculating payload inertia 153 Calib MCP function 208 Calibrating the robot from the MCP 208 Camera bracket mounting pattern dimensions 246 Cartesian limit stops 63 Category 3 278 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Index emergency stop and teach restrict equipment 113 emergency stop circuitry 117 equipment compatibility 27 E Stop 166 schematic E Stop board and Teach Restrict Interface TRI board on control rail 113 location of connectors 113 list of security panel functions 111 risk assess
216. ment 33 robot components 184 Changing from 200 240 VAC to 380 415 VAC 90 from 380 415 VAC to 200 240 VAC 89 the lamp on the CIP High Power En able switch 230 the power chassis voltage setting 89 from 200 240 VAC to 380 415 118 119 VAC 90 102 from 380 415 VAC to 200 240 VAC 89 99 voltage in power chassis 101 Chassis and Amplifier module fuses 238 circuit breaker 238 power requirements PA 4 power 49 Checking robot mounting bolt tightness 228 Checks after applying power 183 CIB JSLV 77 CIP dimensions 250 front panel screws 231 operating modes 197 side connectors 76 switch and button test 190 switches and buttons 184 Circuit breaker on power chassis 238 Clean Room robot bellows replacement 236 Cleaning procedure Adept XL IP 54 robot 234 Clear error button on MCP 208 Clear error function on MCP 207 CMD function 208 CMD1 and CMD2 209 Command CMD function button 208 Commissioned vs Not Commissioned 185 Comp mode 212 COMP PWR button 211 Compatibility Category 3 equipment 27 Components of a Category 3 E Stop system 96 Compressed air installation at robot 44 requirements for Adept XL 44 Compressed air lines in the Adept XL robot 148 Connecting AC power Adept MV controllers 87 Adept PA 4 power chassis 92 105 cord 87 security panel MMSP option 109 Adept MV controller to the power chassis 86 A Series monitor and keyboard 126 CIP tothe AWC 79 80 compressed air supply to the robot 44 cus
217. midity ranges WARNING The instructions for operation installation and maintenance given in this Instruction Handbook must be strictly observed Non intended use of an Adept XL robot can Cause injury to personnel Damage the robot or other equipment Reduce system reliability and performance All persons that install commission operate or maintain the robot must Have the necessary qualifications Read and follow exactly the instructions in this Instruction Handbook If there is any doubt concerning the application ask Adept to determine if it is an intended use or not AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Modifications 1 6 Robot Modifications It is sometimes necessary to modify the robot in order to successfully integrate it into a workcell Unfortunately many seemingly simple modifications can either cause a robot failure or reduce the robot s performance reliability or lifetime The following information is provided as a guideline to modifications Acceptable Modifications In general the following robot modifications will not cause problems but may affect robot performance Attaching 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
218. mm e Nes lo L 2 66 in o E a 6 35 mm 149 86 mm 5 90 in gt 0 25 in 78 23 mm 289 56 mm 11 40 in 3 08 in 71 58 mm 2 82 in 7 62 mm 304 80 mm 12 00 in 0 30 in 50 E 2 9 A HO au 106 68 mm 8 e 2 E 1 a lef 4 20 in so fi 58 j i2 T ES ES sa 1 E loz ij v m 1 g 0 d o o 12 70 mm 0 50 in 274 32 mm 10 80 in gt s mm 10 99 in 12 70 mm 0 50 in Figure 11 9 Adept Controller Interface Panel CIP Dimensions 250 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Dimension Drawings Dimensions of the MMSP Security Panel 482 6 mm gt 19 0 in gis A D e i Parr par s JE ohm 399 2 mm Esesscocococ bossssscococ poscsces 99 a 15 7 in L 420 6 mm 4 75 in E OOO OOO al ila I 101 6 mm L ooo foco slalo 4 0 in J 5 Y Y 14 7 mm PE 0 58 in 0 27 in A 150 mm 5 9 in Figure 11 10 MMSP Security Panel Dimensions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 251
219. mounted gasket not included Manual Automatic Switch Manual Control Pendant Connector Manual Mode Auto Mode Arm Power Emergency Stop MCP cde Network Switch System Power Switch Figure 4 8 Controller Interface Panel CIP Panel Switches and Indicators Emergency Stop Switch The E Stop is a dual channel passive E Stop that supports Category 3 CE safety requirements It supports a customer programmable E Stop delay that maintains motor power for a programmed time after the E Stop is activated This allows the motors to assist in stopping the robot The programmable E Stop is described in a paper available through Adept On Demand see How Can I Get Help on page 41 Manual Automatic Mode Switch In Automatic AUTO Mode programs running on the system control the mechanism and the mechanism can be run at full speed In Manual Mode the system limits mechanism speed and torque so that an operator can safely work in the cell Manual mode initiates software restrictions on robot speed commanding no more than 250 mm sec as required by RIA and ISO standards For Category 3 mechanisms such as the Adept XL safety regulations require that the software speed and torque limiting be enforced by hardware This hardware must be redundant and self testing The Manual Mode Safety Package MMSP available for the Adept XL robots implements this functionality see Figure 4 8 for the location of the Manual Automatic Mode switch on the C
220. mpressed air filter part number is 30440 03200 If you have to empty water from the filter housing frequently check the water content in your compressed air supply and consider using an air dryer Moisture inside the robot can cause damage to mechanical electrical and pneumatic components 228 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Maintenance and Inspection of Air Filters Adept XL Robot Fan Filter Inspection and Cleaning The fan filter on the Adept XL robot is located on the base see Figure 4 14 on page 84 The fan filter must be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must be inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or unusable for any reason you will need to order a new air filter The part number for the filter is 40320 20232 1 Turn off power to the PA 4 power chassis 2 Lift the filter up by the tabs on the top edge 3 Inspect the filter for dust or dirt particles If cleaning is required use compressed air to clean the filter Follow all appropriate safety procedures regarding the use of compressed air 4 Replace the cleaned air filter NOTE A robot equipped with the IP54 option has positive air pressure throughout the interior of the robot Air is continually being exhausted from under the base of the robot This means that a cooling fan and filter are not
221. n p 201 mm 5 479 7 91 in 221 mm 8 70 in Figure 11 13 MCP Cradle Dimensions 254 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Joint Motions 11 2 Joint Motions AdeptOne XL Robot Working Envelope Maximum Intrusion Maximum Radial Contact Radius Reach Functional Area 873 8 mm 34 4 in 9 B In Maximum Radial Reach Inner Link Inaccessible Area Radius 277 62 mm 424 9 mm 10 93 in 16 7 in Joint 2 Limit 140 Joint 1 Limit j b Joint 1 Limit 4150 BL 150 Figure 11 14 AdeptOne XL Robot Working Envelope AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 255 Chapter 11 Technical Specifications AdeptThree XL Robot Working Envelope Maximum Intrusion Contact Radius Maximum Radial 1140 7 mm Reach Functional Area 44 91 in 1066 8 mm 42 0 in Maximum Radial Reach Inner Link Inaccessible Area Radius 279 4 mm 558 8 mm p Aum M 11 0 in 22 0 in Pp LH Mee a Joint 2 Limit s N s y s N y s y B 4 x E 2 150 Joint 1 Limit 24 CT y Joint 1 Limit 150 150 Figure 11 15 AdeptThree XL Robot Working Envelope Joint 1 Joint 1 also referred to as the shoulder provides the rotational movement of the inner link and the column Travel of the inner link is limited by software to 300 degrees see Figure 11 16
222. n Review the checklist items above to resolve the problem If the problem persists call Adept Customer Service AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Checks After Applying Power LED Status Indicators on the AWC The LEDs on the front of the AWC indicate the following conditions O off G green R red Table 8 1 LED Status Indicators LED Display Error Description O O O 0 No error O O R 1 System clock is dead or too fast Clock interrupts are not being received O R O 2 Hardware configuration error Address switches SYSCTL wrong O R R 3 Graphics board failure VGB not responding R O O 4 Memory test failure Free storage error R R O 6 Software serial I O configuration error G O O C Uninitialized trap G O G D Bus error detected If the AWC displays any of the above errors contact Adept Customer Service see How Can I Get Help on page 41 8 3 Checks After Applying Power 1 Verify that High Power can be enabled a Enter the following command at the monitor window ENABLE POWER Or press the COMP PWR button on the MCP b When the High Power push button light on the CIP begins flashing press and hold the push button for 1 2 seconds When you release the push button the light should remain lit continuously indicating that High Power has successfully been enabled c If the light does not stay on the High Power enable process ha
223. n D sub Connector JSIO Emergency Stop Circuit System Power Switch Circuit System Power Switch Circuit MMSP Option Digital Input Wiring Examples JSIO Connector Digital Output Wiring for JSIO Connector Adept XL Robot Test Locations Brake Solenoid Valve Electrical Connectors Holding the MCP Cradling the MCP AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C List of Figures Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 Figure 9 9 Figure 9 10 Figure 9 11 Figure 9 12 Figure 9 13 Figure 9 14 Figure 9 15 Figure 9 16 Figure 9 17 Figure 9 18 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 11 1 Figure 11 2 Figure 11 3 Figure 11 4 Figure 11 5 Figure 11 6 Figure 11 7 Figure 11 8 Figure 11 9 Figure 11 10 Figure 11 11 Figure 11 12 Figure 11 13 Figure 11 14 Figure 11 15 Figure 11 16 MGPEGIVOUIT ir star o eene x Bil e dfe ere e Bere ep e RO Rt 201 DANEM KEYS E sri dos Se t treten Face rins vete qt cod e ER Rod etis 202 MCP Predefined Function Buttons aoaaa aaa a 204 EDIT Function BUTTON 1 cente c ese sb eese s 204 DISPLAY Function BUTTON 5e iod kei be RA Ee TES 206 CLEAR ERROR Function Button iiie 207 Command CMD Function Button isse 208 Program Set Function Buffon wo es EARE AEA NE 209 Mode Control BUMONS vestidas Fr e ee b ede bate sn 210 SPEEA BOTS tantas Cum PT 2
224. n page 101 3 Close the grill and secure the two screws 4 Clearly mark or alter the ID label on the side of the PA 4 chassis to show the new voltage configuration see Figure 4 18 o Em E 00 0 tetta EPI E E E adept technology Inc adept technology Inc San Jose CA San Jose CA Model MV 10 Part No Model PA 4 Part No Serial No Serial No VOLTAGE AMPERAGE FREQUENCY VOLTAGE AMPERAGE FREQUENCY mo 20 soa soso ne o AREER ancon eee PT O O O J J Figure 4 18 Power Labels Changing From 200 240 VAC to 380 415 VAC To change the AC voltage setting from 3 phase 200 240VAC to 3 phase 380 415VAC follow the two part procedure below Also see Connecting AC Power to the Adept PA 4 Power Chassis on page 92 90 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Changing From 200 240 VAC to 380 415 VAC WARNING Electrical hazard Changing the voltage setting in the power chassis must be done by a skilled person The power supply can injure or kill a person who does not perform this procedure correctly Part 1 Rotating Voltage Selector in Power Chassis 1 Open the front air intake grill on the power chassis by loosening two screws and swinging the grill out Inspect the voltage setting it is marked on the front of the voltage selector plug To change the voltage setting remove the selector rotate it 180 degrees so the required
225. n procedures V Operating System User s Guide 00963 02300 Describes the V operating system including disk file operations monitor commands and monitor command programs V Language User s Guide 00963 013000 Describes the V language and programming of an Adept control system 42 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 2 1 Installation Overview This chapter covers the facility electrical and mechanical specifications and other general installation requirements The next several chapters cover the installation of the robot the robot control system optional Adept supplied equipment and optional user supplied equipment In general a complete installation will proceed as described in the following chapters Chapter 3 covers installing the robot Chapter 4 covers installation of the control system and power amplifiers Chapter 5 covers installation and configuration of the optional Manual Mode Safety Package MMSP Complete the installation instructions in this chapter only if you have the MMSP option Chapter 6 covers selection and installation of a user interface Chapter 7 covers installation of optional equipment Once the physical installation is complete the installation must be verified and the system must be commissioned Chapter 8 covers verifying that the installation is correct and commissioning the system Hardware to Be Provided by User T
226. nal equipment installation 137 Output signals 122 175 Overvoltage protection facility 48 MV controllers 48 P PA 4 power chassis power requirements 49 PA 4spare partslist 241 Panel CIP switches and indicators 75 Panel mounting controller or power chassis 72 Partial list of worldwide robot and machin ery safety standards 33 Passive E Stops 115 Payload inertia calculating 153 Pin assignment on 9 pin connector J240 for gripper solenoid signals 148 Pinouts for TB1 and TB2 122 for TB3 123 for TB4 114 for TB5 116 for user connectors 140 Pipe fitting flow equivalents 271 size 271 Plate mounting 45 Plate to floor installation detail mounting 57 Power chassis AC power requirements 49 changing voltage setting From 200 240 VAC to 380 415 VAC 90 102 changing voltage setting From 380 415 VAC to 200 240 VAC 89 99 circuit breaker 238 circuit breaker and fuse information 238 connecting to controller 86 connecting to robot 83 dimensions 249 fuses 238 interlock circuit 239 joining to controller 69 panel mounting 72 power requirements PA 4 49 rack mounting 72 Power consumption for PA 4 power chassis 264 Power cord from power chassis specifications 109 Power entry board on Adept MV controller 87 Power labels 90 Power Rail connecting power cord from power chassis 107 drawing of components 108 Power requirements MV controller 48 PA 4 power chassis 49 Precautions and required safeguards 28 Precision point d
227. nce a month Record the results and produce a schedule appropriate to the particular system its environment and use NOTE For the Adept XL IP54 Robot plan on lubricating every three months To check for adequate lubrication at the Joint 3 upper quill remove the upper quill cover and run a finger along the quill A thin film of grease should be present If the shaft is dry it needs lubrication Recommended Grease for the Adept XL Robot Joint 1 Encoder Gear LUBRIPLATE MO LITH No 2 a molybdenum disulfide based grease USDA H2 Molybdenum grease Adept part number 85151 00003 Joint 3 Upper and Lower Quill Shaft Mystik SynGuard SX 6 5448 or equivalent NLGI 2 high temperature lithium complex EP grease CATO Oil and Grease Co Oklahoma City OK Adept part number 85114 31680 CAUTION Using improper lubrication products on the Adept XL robot may cause damage to the robot Manufacturer s Safety Data Sheets MSDS The manufacturer s safety data sheets for the greases used in the Adept XL robots are available from the Adept FAXback system at the numbers listed in How Can I Get Help on page 41 222 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot Lubrication Lubricating Joint 1 Encoder Gear Adept XL Robot CAUTION Lubrication of the robot must be performed with PA 4 power chassis power turned OFF Use the Brake Release button located on the underside of the inner link to release
228. nd controller at the top and bottom as described in the following paragraphs NOTE Joining the chassis and controller allows rack mount of the chassis and controller in a 19 inch rack AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 69 Chapter 4 Adept MV Controller Installation 70 Joining at the Top 1 Turn off power to each unit and disconnect the power cord Place the two units next to each other Remove the top cover from both see Figure 4 4 Locate the C shaped bracket in the accessory kit Slip the bracket under the lip of the top edge of the unit on the right hand side and into the two slots in the edge of the chassis Install two M4 x 8 mm flat head screws into the lip and down into the bracket Install the other two M4 x 8 mm flat head screws into the chassis on the left hand side Replace the cover on each unit Top view with covers removed Adept MV Controller Adept PA 4 Power Chassis Jo o lo o o o Jo o 1et o ol M4 x 8mm four each flat head Phillips screws Figure 4 4 Joining the Power Chassis and Controller at the Top AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Space Around the Chassis Joining at the Bottom 1 Turn the two units over so you have access to the bottom side 2 Locate the cutout bracket in the accessory kit 3 Place the bracket ove
229. ndbook Rev C Installation of the MMSP Option Category 3 Teach Restrict E Stop Board Interface Board TRI Control gt Rail X1 E Cable Trays S90090000000 090900000000 09090000 oo Jl Ground L E DIN Power oToTo Rail X2 OOO O00 AP 1 AP 2 Hee O00 OOo O O O SS Cable Tie Anchor Circuit External 24 VDC Contactors Breaker Power Supply Terminals Figure 5 2 Security Panel Connecting the Security Panel to the CIP Communication between the external CIP and the Security Panel is through two cables the CIP to Cat3 E Stop cable and the JSIO to Cat3 E Stop cable Installation procedure for the CIP to Cat3 E Stop Cable see Figure 5 1 1 Turn the Adept MV controller off 2 Connect the male plug of the CIP to Cat3 E Stop cable to the connector J3 on the Category 3 Emergency Stop board See Figure 5 3 on page 98 Tighten the two captive screws securely Connect the female connector of the cable to the connector JMMSP on the CIP Tighten the two captive screws
230. nects to the AWC through the JAWC connector The AWC to CIP cable is a 1 8 m 6 ft SCSI 2 50 wire cable with a male Micro D50 pin shielded connector on each end The Micro D connector has two rows of 25 pins spaced at 1 27 mm 0 050 inches apart To connect the CIP to the AWC see Figure 4 11 on page 80 1 Turn off the Adept MV controller power switch and disconnect main power 2 Plug one end of the CIP interface panel cable into the CIP connector on the AWC board Plug the other end into the SCSI connector JAWC on the left side of the CIP Be sure the spring latches are engaged 3 When not using the MCP install the optional MCP bypass plug into the MCP connector on the face of the CIP If an MCP is being used see Connecting the MCP to the CIP on page 80 for more information 4 In order to enable High Power plugs with appropriate jumpers or contacts must be attached at the JSIO and JUSER connectors AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 79 Chapter 4 Adept MV Controller Installation 1 8 m 6 ft SCSI Interface Cable MV Controller With AWC Board Controller Interface Panel CIP Figure 4 11 Connecting the CIP to the AWC Extended Length CIP to AWC Cable 4 5 A custom cable not to exceed 10 m 33 ft may be fabricated It should be made to the ANSI SCSI Parallel Interface 2 SPI 2 standard an
231. ng High Power to be disabled B Amplifier Voltage Restrict Circuitry in the B amplifier measures the voltage applied to the joint 3 and 4 motors If the voltage exceeds a preset limit the emergency stop circuit is opened causing High Power to be disabled This will prevent excessive speed and acceleration while operating in Manual mode CIP Switches and Buttons After the user requests that High Power be enabled the High Power lamp flashes Before High Power is turned on this button must be pressed If the button is not pressed within 10 seconds it will stop flashing and High Power will not be turned on Tests are also performed on the key switches MCP Enabling Switch The Enabling switch on the Manual Control Pendant must be pressed for High Power to remain on see Figure 9 1 on page 199 for the location of the MCP Enabling switch If the Enabling switch is released High Power is disabled If the MANUAL AUTO key switch is in the manual position the Enabling switch must be cycled before High Power will be enabled This is to confirm before enabling High Power that the Enabling switch is operational The following instructions are displayed on the system monitor Release then press the MCP Enable button Press the HIGH POWER button when it blinks The Manual Control Pendant displays the following messages Release then press the MCP Enable button Press the HIGH POWER Power button to enable power 18
232. ng to the E Stop board on the security panel See the Adept MV Controller User s Guide for details on wiring the safety gate feature to the CIP Per EN954 Category B refers to a component that meets the requirements of its environment voltage current temperature Such components are not necessarily fault tolerant AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 111 Chapter 5 MMSP Installation and Configuration 24 VDC Category 3 39 Power Relay Power Supply E Stop with Cyclic Relay Board Checking Controller Interface Panel CIP Teach Restrict Interface Board Figure 5 14 Main Components of the Safety System Operating in Manual Mode The most important function of the Security Panel is to protect the operator in Manual mode To work in Manual mode the operator switches the lower key switch on the CIP to the O position and the operating mode key switch upper switch to the MANUAL position Then the operator gives the instruction to enable High Power either through an ENABLE POWER monitor command or by pressing the COMP PWR button on the MCP The system starts the process to enable High Power The sequence to enable High Power in Manual mode is as follows takes about 20 25 seconds 1 The system checks all E Stops including customer non mute safety barrier 2 The operator must release and then close and hold the MCP Enable switch 3 The system tests the Teach Restrict sensors in t
233. ng when they are in the robot workcell Safety glasses Protective headgear hard hats Safety shoes Install warning signs around the workcell to ensure that anyone working around the robot system knows they must wear safety equipment 14 Protection Against Unauthorized Operation 1 15 The system must be protected against unauthorized use Restrict access to the keyboard and the Manual Control Pendant by locking them in a cabinet or use another adequate method to prevent access to them 15 Safety Aspects While Performing Maintenance 1 16 Only skilled persons with the necessary knowledge about the safety and operating equipment are allowed to maintain the robot controller and power chassis WARNING During maintenance and repair the power of the Adept PA 4 power chassis and the Adept MV controller must be turned off Unauthorized third parties must be prevented from turning on power through the use of fail safe lockout measures Turn off the circuit breakers lock the cabinet and remove the key Risks That Cannot Be Avoided 40 For Systems with MMSP Option The Manual Mode Safety Package MMSP Category 3 Adept XL robot control system implementation has a series of electromechanical devices that disable High Power if a system failure occurs The following situations may result in risks that cannot be avoided Purposely defeating any aspect of the safety E Stop system Improper installation or progr
234. ns 210 Modifications acceptable 37 unacceptable 37 Monitor installation 126 speed setting on MCP 210 Mounting arobot ona base 60 and connecting the External Front Panel 75 the Controller Interface Panel CIP 79 the MV controller and power chassis 69 the robot 53 Mounting bolts checking tightness 228 Mounting brackets install positions controller 73 power chassis 74 installation 71 Mounting hole pattern plate or spool to floor 54 robot to plate or spool 55 Mounting plate installation 58 specifications 45 Mounting plate to floor installation detail 57 Mounting spool installation 59 specifications 45 46 Mounting spool to floor installation detail 58 Mounting surface specifications 45 Mounting user equipment on robot arm 151 Moving a robot or motion device with the MCP 210 Moving blue wire from AP1 L2 to neutral 380 415 VAC 103 from neutral to AP1 L2 200 240 VAC 101 Mute function in Customer Safety Barrier 111 Muted safety gate E stop circuitry 166 MV controller power requirements 48 N NET switch 76 Notes Cautions and Warnings descrip tion of 28 Numbers in the MMSP 3 E Stop drawing description of 120 Nylon tubing lengths for 24V solenoid 142 284 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Index O Operating environment specifications controller and power chassis 47 Operating in Manual mode 112 Operating modes Automatic 198 Manual 197 Optio
235. ns for the digital inputs and outputs on the CIP JSIO are different from the specifications for a DIO board Specifically the CIP JSIO output current is limited via short circuit protection to 100 mA per channel whereas the DIO output is rated at 400 mA See the Adept MV Controller User s Guide for details on wiring DIO boards Table 5 11 Digital Output Signal Assignments on Terminal Block TB3 es Pg Terminal Signal Terminal Signal TB3 1 24V 1 Amp 2 24 V return TB3 3 Output 0001 4 Output 0001 TB3 5 Output 0002 6 Output 0002 TB3 7 Output 0003 8 Output 0003 TB3 9 Output 0004 10 Output 0004 TB3 11 Output 0005 12 Output 0005 NOTE Digital Output signals 0006 to 0008 from the CIP JSIO connector are not available because they are used by the MMSP option AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 123 User Interface Installation There are three different user interface options for the Adept MV controllers An ASCII interface using a Wyse terminal or equivalent A graphical user interface using the Adept VGB board an SVGA monitor a standard PC style keyboard and a serial pointing device e A graphical user interface using the AdeptWindows PC software running on a PC Windows959 Windows98 Or WindowsNT Installing the three different operator interfaces is covered in this chapter You need to read only the sections that cover the ty
236. nsion bolt anchor into each of the four holes in the floor Ensure that the threaded end of each bolt anchor is toward the bottom of each hole as shown in Figure 3 5 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 59 Chapter 3 Robot Installation 60 7s Reposition the spool over the anchor holes in the floor taking care to align the four spool to floor holes with the anchor holes Ensure that the spool is positioned so that the footprint for the robot is properly oriented to the workcell Verify that the top mounting surface of the plate is level ensure that the accuracy of the device used to level the plate exceeds the required leveling tolerances The surface must be horizontal within 0 25 degrees MMSP or 0 3 degrees no MMSP If the spool is not level insert shims between the spool and the floor to bring the spool within specifications The shims should be at least 75 mm 3 inches in diameter and have cutouts provided to fit around the anchor bolts Insert a M12 x 100 mm or 1 2 13 UNC x 4 inch bolt fitted with a lock washer and a flat washer through the holes in the spool into each of the four spool to floor anchor holes Tighten the bolts to 55 Nem 40 ft lb of torque 10 Recheck the robot mounting surface of the spool and reinsert shims as required to bring the mounting surface horizontal within 0 25 degrees or 0 3 degrees without MMSP Mounting a Robot on a Base The following sequ
237. nt 9 Push the CIP front panel into the CIP body taking care to align all of the plug type connectors 10 Replace the six front panel screws and the MCP bypass plug retainer screw 11 Reinstall the CIP in its mounting 12 Reconnect the CIP cables Ensure that the JDIO1 through JDIO4 cables are cor rectly reinstalled AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Controller Fuse Information 10 6 Controller Fuse Information The two fuses F1 and F2 at the power entry board on the front panel are for the incoming AC power lines See Table 10 2 for ratings WARNING Only skilled or instructed personnel should attempt to change any fuses Always replace blown fuses with new fuses of the same type and rating To remove the fuse holder 1 Turn off AC power to the controller and disconnect the power cord from the AC power source 2 Remove the AC power cord from the socket on the power entry board 3 To remove the fuse holder insert a small flat blade screwdriver into the slot between the fuse holder and the power cord socket then lift up to release the fuse holder see Figure 10 6 Spare fuses are stored in the sliding compartments 4 To reinstall the fuse holder insert it in place then press down firmly until the entire holder snaps into position Table 10 2 Adept MV Controller Fuse Ratings Fuse Rating Type F1 AC Line fuse at Power 5 AT 250V IEC 127 style Entry board 5x20mm F2
238. nt 2 LEFTY RIGHTY Configurations Joint 3 The AdeptOne XL robot joint 3 range of motion see Figure 11 20 is 356 mm 14 0 in for the 356 mm quill configuration and 203 mm 8 0 in for the 203 mm quill configuration The AdeptThree XL robot joint 3 range of motion see Figure 11 21 is 356 mm 14 0 in 258 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Joint Motions Joint 4 Joint 4 also referred to as the wrist provides rotation of the quill over a range defined by the softstop This motion is similar to that of the human hand involved in tightening a bolt or unscrewing a bottle cap see Figure 11 20 and Figure 11 21 The rotational limit is set by software to plus or minus 270 degrees from the zero wrist position Joint 3 Joint 3 x ke mm Stroke ir 14 oum 203 mm X ory gt 8 0 in d DENS E A EX 16009 Joint 4 Rotation Joint 4 Rotation 270 270 356 mm 14 in 203 mm 8 in Configuration Configuration Figure 11 20 AdeptOne XL Joint 3 and Joint 4 Motions Joint 3 Stroke 356mm 14 0 in k TY Se LA Joint 4 Rotation 270 Figure 11 21 AdeptThree XL Joint 3 and Joint 4 Motions AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 259 Chapter 11
239. nts 2 Installation Overview 2 0ccccceccececcecseceecceuees 43 2 1 Hardware to Be Provided by User 0 0 cc eee eee eee 43 AISYS EMS t sete do dad BA ok eel ME Kui o A hak de to els c Aie EA Ee e bt 43 Systems Without MMSP Option lisse ns 44 Systems With MMSP Option 00 0c es 44 2 2 Facility Requirements 000 ec eee 44 Compressed Air Requirements 000 eee eee eens 44 Mounting Surface Specifications 0 ees 45 PIGS usc Sel a gt oh s obs anna anon fee Manes fon comin ss fM foris 45 fele 45 2 3 Environmental Requirements 0 0 00 eee ees 47 2 4 Power Requirements 0 0 ce eee eee eee 48 Adept MV Controller Power Requirements oo 00 ce ee 48 Facility Overvoltage Protection sasaaa aaa eee 48 PA 4 Power Chassis Power Requirements eee 49 2 5 Before Unpacking the Adept Equipment 0 000 cece eee eee 49 2 6 Adept Shipment Specifications 0 0 0 ees 49 2 7 Transport and Storage 2c cee eee 50 Shipping and Storage o da ir deo eh Re e re CT OR ena 50 2 8 Lifting and Handling 0 ccc ees 50 Before UNPACKING gum aa Ea atid m aa Peces kt reel ae S 50 2 9 Unpacking and Inspecting the Adept Equipment L 51 USON UN PACKING rer intct Am SO Pe a ea ache RAT EST s 51 2 10 Repacking for Relocation 0 0 cece ees 52 2 11 Robot and Controller ID Labels 1 0 0 0 cece eee 52 3 Robo
240. o ensure that an installed functioning robot will be clean even at full speeds The plug covering the bottom of the tool flange has a 1 8 or 1 4 N P T tapped hole You can install a low pressure differential pressure meter at this point to measure the vacuum Cover Seal Seal Y Y between Cover SS outer link and Seal quill cover i EL Xd e Quill S Bellows 1 1 4 inch fitting A Figure A 1 Adept XL Cleanroom Features 270 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Vacuum Installation Vacuum Supply Pump The vacuum supply pump must be sized based on the pipe size and the distance between the robot and vacuum pump Pipe Size The pipe sizes required when hooking up the robot to a vacuum source are a function of several factors air flow requirements of the system distance from the vacuum pump to the robot vacuum pump used Due to its low cost ease of installation good flow characteristics and availability most installations use PVC pipe The following sections assume the use of PVC pipe The first consideration in pipe size is the location of the vacuum pump with respect to the robot Given the location of the pump a diagram displaying the pipe layout should be drawn This allows the counting of fittings and their conversion to equivalen
241. o provide a Single Point of Control the operator when the controller is placed in Manual mode Certain workcell devices such as PLCs or conveyors may need to be turned off when the operating mode switch is set to Manual mode This is to ensure that the robot controller does not receive commands from devices other than from the MCP the single point of control The two channel Manual Automatic Mode select circuit is designed to fail to the highest safety condition If either channel is open the controller will be in Manual mode This requires that the User Remote Manual Mode Control electrical contacts be in series with the contacts on the CIP Auto Manual mode selector switch To select Automatic mode both the Remote Manual Mode Control and the CIP Auto Manual Switch must be in Automatic mode both switches must be closed The CIP provides connections for a remote user panel circuitry that allows a second user panel at another location see Figure 7 14 Figure 7 15 Table 7 10 and Table 7 11 for the customer remote user panel circuitry Two separate inputs on the JUSER connector 10 29 and 11 30 provide connections for remote MANUAL AUTOMATIC functionality MANUAL Open e AUTOMATIC Close NOTE These pins must be jumpered if not used Two pairs of pins on the JUSER connector pins 15 34 and 16 35 provide a voltage free contact to indicate whether the CIP and or remote AUTOMATIC MANUAL switches are closed The customer m
242. o sets of digital I O connections on the CIP The JSIO connector accesses the first set a group of 12 inputs and 8 outputs The signals are numbered 1001 through 1012 for the inputs and 1 through 8 for the outputs In the JSIO group all the signals have independent source and ground connections This group of inputs contains the four high speed inputs that are used by the system for interrupts and latching The outputs although independent have a lower current rating of only 100mA compared to 700mA for the extended outputs described in the next section The second group of digital I O connections or extended DIO uses four connectors 32 inputs on JDIO1 and JDIO2 and 32 outputs on JDIO3 and JDIO4 The signals are numbered 1033 through 1064 for the inputs and 33 through 64 for the outputs The extended DIO are arranged in groups of eight signals with a common ground connection for each group and a common source for each output group However the groups are independent of each other and do not share sources or grounds The electrical characteristics of the inputs are similar to the JSIO signals but the outputs have a higher voltage rating 30 VDC vs 24 VDC and a higher current rating than the JSIO outputs See the Adept MV Controller User s Guide for details on wiring extended DIO signals See the V Language User s Guide for information on digital I O programming JSIO Connector The JSIO connector on the CIP is a 50 pin standard density D
243. ogram progresses B Amp Voltage Restrict Test Joint 3 Program contro d move expect E Stop to assert The default test locations are with Joint 3 at 50 mm from midrange and a ot Do you want to use her joints at midrange the default test locations Y N WARNING Responding Y may cause the robot to move joints 3 and 4 to the positions described below Make sure the robot will not contact other tooling and or fixtures causing damage to the robot tooling and or fixtures Respond N to define new test locations The test locations must be defined so that joint 3 moves a minimum of 50 mm and joint 4 moves a minimum of 90 degrees The robot will make a quick move during the test causing the sensor to activate the E Stop The robot may overshoot slightly To ensure the robot does not crash it should be able to move slightly beyond the defined locations in both directions After the new test locations are defined joint 3 is tested first The following messages are displayed as the program progresses Testing Joint 3 on the monitor The test prompts will be displayed on the MCP as well as here AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 189 Chapter 8 Verifying the System Installation 190 Release then press the Enable Hold to run button on the MCP Press the High Power button when the button blinks Press the CMP PWR button
244. oller Installation Dual B Amplifier Module Overview The Dual B amplifier module is a plug in module that contains the circuitry and ampli fying components to drive two robot motors In this type of robot system there is one Dual B amplifier module in the Adept PA 4 power chassis This amp module located to the right of the A amp modules drives the motors for joints 3 and 4 Connectors and Indicators 11 Status LEDs The left hand column of LEDs is for the first S 2 motor controlled by this module the right hand column is Dual B AMP for the second motor controlled by this board When an LED e e is turned on it indicates the following conditions A High Volts On indicates the high voltage to the amps is turned on rica PWM On indicates that current servo is on It does not go on O O Hon voLTs on O O Pwmon O Otowvorrs on until calibration is complete O Q orencer rauer Low Volts On indicates the low voltage supply in the power O O tv sacioven eue OO siorr rair chassis is on B1 B2 Note the three LED pairs below indicate faults and are visible momentarily before the system turns off Open Ckt Fault indicates that an open circuit in the motor leads has been detected HV Sag Over Temp left hand LED when lit indicates that the fault was caused by a sag in voltage The right hand LED when lit indicates the fault was caused by an over tempera ture condition on the amplifier heat sink
245. ontroller Interface Panel CIP ss nho cer rac ane ii 75 Controller Interface Panel CIP Side View suauu 77 Controller Interface Panel CIP Back Panel View suana 78 Connecting the CIP to the AWC Lo cents 80 MER CODFIGGHODA naaa Darro dla a ga ae ves ar te Bae 81 Cable Installation Without MMSP Option 0 eee 82 Adept XL Robot Connector Locations 2 1 eee 84 Robot to EJI Cable Installation noana aaa 85 Adept MV Controller Power Entry Board ow ieee 87 Insulating Blue Wire in Power Cord 200 240VAC oo ees 90 PowerlaBels ci ago t at ager iG aon alae deed ee a eae Saws 90 Insulating Blue Wire in Power Cord 880 415 VAC oo ces 92 Adept XE Robot Ground Point erre ri ned RRA wae Bad 94 Components of a Category 3 E Stop System aaan aa 96 Security Panel omar eee os eee Sela UR SET een BE 97 Connectors on the Control Rail ow eee 98 Insulating Blue Wire in Power Cord 200 240 VAC cc ee 100 Moving Blue Wire From Neutral to AP1 L2 200 240 VAC 06 eee 101 Changing Voltage in Power Chassis 2 0 ccc tees 101 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 19 List of Figures Figure 5 7 Figure 5 8 Figure 5 9 Figure 5 10 Figure 5 11 Figure 5 12 Figure 5 13 Figure 5 14 Figure 5 15 Figure 5 16 Figure 5 17 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure
246. oordinate system will be offset and rotated by the value of the TOOL transformation Any motion in tool state will now be relative to the offset coordinate system and not the center of the tool flange See the V Language Reference Guide for details on TOOL transformations X direction Y direction Z direction Rotation about Tool Z axis n 4RZ 4X Keyway Gripper activity Z Figure 9 14 TOOL State Four Axis SCARA AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 215 Chapter 9 Using the Manual Control Pendant MCP Rotation about TOOL X axis Rotation about TOOL Y axis Rotation about TOOL Z axis Gripper activity Figure 9 15 TOOL State Six Axis Robot Joint State When joint state is selected movement is about the axis of the specified joint Figure 9 16 shows an Adept SCARA robot with three rotational joints joints 1 2 and 4 and one translational joint joint 3 Positive rotation of joints 1 and 2 is counterclockwise as viewed from above Positive rotation of joint 4 is clockwise as viewed from above Positive movement of joint 3 is downward Before the speed bars will move a joint the correct joint must be selected from the manual control buttons Different robots or motion devices will have the different joint numbers assigned to their joints When you first move an unfamiliar robot using joint state set the monitor speed to 10 or lowe
247. operator by limiting the speed of the robot MCP Layout The major areas of the MCP are shown in Figure 9 3 Liquid Crystal Display LCD User LED Speed Bars MCP Enable Switch I TOOL JOINT FI e REE Programmable Function Buttons Figure 9 3 MCP Layout Soft Buttons Soft Buttons Predefined Function Buttons Manual State LEDs Emergency Stop Switch Mode Control Buttons Joint Axis Control Buttons Disable Power Button The soft buttons have different functions depending on the application program being run or the selection made from the predefined function buttons Whenever a soft button is active its function is shown on the bottom line of the pendant display Because these buttons do not have fixed labels the labels are defined by the program using the buttons they are referred to as soft buttons Programming the MCP is covered in the V Language User s Guide Figure 9 3 shows the soft buttons AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 201 Chapter 9 Using the Manual Control Pendant MCP 202 Function Buttons The predefined function buttons have specific system wide functions assigned to them These functions are covered in MCP Predefined Functions on page 203 The programmable function buttons are used in custom application programs and their functions will var
248. or Pin Out AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 265 Chapter 11 Technical Specifications Arm Power Connector Pin Identification Table 11 6 Arm Power Harting Connector Pin Identification Pin No Color Function 1 BRN Jt3A 2 ORG Jt3B 3 BLU Jt3C 4 GRN YEL Frame Ground 5 Not used 6 Not used 7 ORG Jt 1 Outer C 8 RED Jt 1 Outer B 9 VIO Jt 1 Outer A 10 RED Jt4A 11 VIO Jt4B 12 YEL Jt4C 13 Not used 14 BLU Jt 1 Inner C 15 BLK Jt 1 Inner B 16 WHT Jt 1 Inner A 17 BRN Jt5A 18 ORG Jt5 B 19 BLU Jt5C 20 Not used 21 BLU Jt 2 Inner C 22 BLK Jt 2 Inner B 23 WHT Jt 2 Inner A 24 BLK Fan 25 BLK Fan 26 Not used 27 GRN YEL Frame Ground 28 Not used 29 Not used 30 ORG Jt 2 Outer C 31 RED Jt 2 Outer B 32 VIO Jt 2 Outer A 266 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Robot ID Labels Table 11 7 Motor Winding Resistance Check Motorand Phas perd an J1 Outer A J1 Inner A 1 3 1 7 Jl Outer B J1 Inner B 1 3 1 7 J1 Outer C J1 Inner C 1 3 1 7 J2 Outer A J2 Inner A 1 4 1 8 J2 Outer B J2 Inner B 1 4 1 8 J2 Outer C J2 Inner C 1 4 1 8 J3A J3B 4 4 5 6 J3B J3C 4 4 5 6 J3C J3A 4 4 5 6 J4A J4B 4 4 5 6 JAB JAC 4 4 5 6 JAC J4A 4 4 5 6 J5A J5B J5C 11 7 Robot ID La
249. orientation and attached payload all contribute to the total amount of energy available to cause injury Hazards From Expelling a Part or Attached Tooling The maximum joint tip speeds that can be achieved by the Adept XL robot in a runaway situation are listed in Table 1 4 Any tooling fixtures end effectors etc mounted to the user flange outer link or inner link of the robot must be attached by sufficient means to resist being expelled from the robot Additionally any payload must be held by the end effector in a manner that prevents the payload from being expelled accidentally Table 1 4 Maximum Adept XL Robot Joint Velocities in Runaway Situations Joint Max Angular Linear Velocity AdeptOne XL AdeptThree XL Joint 1 maximum angular velocity 1118 degrees second 920 degrees second Joint 1 maximum linear velocity 10 4 meters second 10 7 meters second Joint 2 maximum angular velocity 1869 degrees second 1670 degrees second Joint 2 maximum linear velocity 31 8 meters second 35 3 meters second These velocities can occur only in a runaway or mechanical failure situation These are not performance specifications see Chapter 11 for robot performance specifications The safety fence or barrier constructed around the robot must be designed to withstand the impact of any item expelled accidentally from the robot Projectile energy can be calculated using the formula E 1 2mv Here are two examples
250. ors on the printed circuit board have been disconnected 19 Carefully lower the joint 2 upper cover into place and secure the cover with the original hardware Use Loctite 242 on the fasteners 20 Move joint 3 all the way to the lower hard stop Ensure that the four air lines do not have an excessively sharp bend radius top of the radius is 1 to 2 inches above the top of the ball spline as shown in Figure 7 6 Cut tubes A1 A4 so that the air lines are 1 to 2 inches below the face of the user flange and replace the wire markers 21 Install a cable tie on each pair of 5 32 inch air lines above the tower bracket see Figure 7 6 22 Install the four 5 32 inch tube unions P N 42066 92000 23 Install the four 5 32 inch plugs P N 42055 12000 Figure 7 6 Tower Bracket Tubing Cable Tie Installation AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Adept XL Robot Solenoid Kit Test the Gripper Valves As part of the commissioning process described in Chapter 8 test the operation of the hand valves by issuing the following V monitor commands and verifying that the results listed in Table 7 3 are correct Table 7 3 User Air Line Command Summary State Pneumatic Action on Port B V Command MCP Procedure Open Pressure at valve 1 on port B DO OPENI In World Tool or no pressure at valve 2 on port or Joint state press T1 B SIGNAL 3001 3002 and plus speed bar Closed Pressure at v
251. ot use DEVICENET JDVC 16 INPUTS GROUP 1 2 JDIO1 16 OUTPUTS 16 OUTPUTS GROUP 3 4 JDIO4 1 0 12 IN 8 OUT AUX ESTOP JSIO g 7222222222222 9 a e ex a gt o d e O 16 INPUTS GROUP 3 4 JDIO2 AUX JEXT RS232 4 JCOM oye e e Reserved Do not use Figure 4 10 Controller Interface Panel CIP Back Panel View 78 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Location of the CIP 4 3 Mounting the Controller Interface Panel CIP All the user connections to the AWC except for the serial ports and the Ethernet connectors are made through the CIP The CIP provides connections for digital I O fast inputs one RS 232 serial port DeviceNet and the user interface to the E Stop circuitry See Connecting Customer Supplied Safety and Power Control Equipment to the CIP on page 161 for details on connecting user E Stop circuitry See the Adept MV Controller User s Guide for details on the other connections Location of the CIP 4 4 The CIP contains features that prevent dangerous motions while an operator is in the workcell In order for the installation of the CIP to conform with RIA and European standards for power control functions the CIP must be mounted outside the robot enclosure Mount the CIP on the same enclosure as the controller or on a separate protected enclosure see section 11 1 for CIP dimensions Connecting the CIP to the AWC The CIP con
252. ote High Power lamp current limitations are Maximum current 300 mA at 5V Minimum current 100 mA if JP2 is installed Otherwise there is no minimum current The third pair of pins which provides for more restricted operation complying with the EN 775 recommendation will prevent the use of the Central Control High Power On Off when the system is in Manual Mode This function will work only when the keyswitches on the CIP are in the following positions Operating keyswitch is in the Automatic Mode Network keyswitch is in the position The user supplied voltage to provide a Central Control High Power On Off function drives a relay in the CIP with the following electrical characteristics Coil 24 VDC at 1440 O including a parallel flyback diode Timing the High Power signal transition will be seen only if the signal is off at least 32 milliseconds followed by on for at least 32 milliseconds After a positive transition there must be no positive transitions for at least 2 seconds before another positive transition will be recognized 168 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting Customer Supplied Safety and Power Control Equipment to the CIP Connecting the System Power Switch to the CIP The CIP also provides a connection for a user supplied system power circuit see Figure 7 14 Figure 7 15 Table 7 10 and Table 7 11 for the customer system power switch circuitry The CIP in
253. ound 4 11 Grounding the Adept Robot System Proper grounding is essential for safe and reliable robot operation Follow these recommendations to properly ground your robot system Adept Robot Grounding The major structural parts of the robot are connected to the ground point on the base of the robot see Figure 4 20 The user must install a ground wire to the robot Make sure to remove all paint from the surface under the screw at the ground point and use a star washer to ensure a proper ground connection AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 93 Chapter 4 Adept MV Controller Installation Robot Mounted Equipment Grounding The following parts of an Adept XL robot are not grounded to protective earth the joint 3 quill the tool flange and all access covers If hazardous voltages are present at any user supplied robot mounted equipment or tooling you must install a ground connection from that equipment tooling to the ground point on the robot base Hazardous voltages can be considered anything in excess of 30VAC 42 4VAC peak or 60VDC See also Figure 11 6 on page 247 for the grounding point on the tool flange WARNING Failing to ground robot mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end effector when an electrical fault condition exists User Supplied Ground Wire for End of Arm Tooling
254. outside of the robot or motion device work envelope Connecting the MCP The MCP is connected to the 16 pin connector marked MCP on the CIP see Connecting the MCP to the CIP on page 80 The pendant E Stop button and the palm activated enabling switch are wired into the emergency stop circuitry Therefore either the pendant or the optional pendant bypass plug must be attached to this connector If neither one is connected you cannot enable High Power If the pendant or bypass plug is removed High Power is turned off NOTE The CIP design allows for an external MCP connection If this connection is installed and used the MCP bypass plug must be installed on the CIP MCP connector CAUTION Do not modify or extend the MCP cable Doing this will void the warranty on the MCP and the CIP CAUTION Use only the MCP III P N 10332 11000 Assy 90332 48050 with a CIP Other MCPs will not work with the CIP because they do not incorporate the dual E Stop channels Damage may result if an MCP III is plugged into older Adept controller systems that contain a VME Front Panel VFP Damage may also result if older MCPs part numbers other than 10332 11000 are plugged into a CIP AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Manual Control Pendant Basics WARNING The Auto Manual keyswitch on the CIP must be set to Manual if the MCP is to be used inside the robot workcell This enables important safety features to protect the
255. ower can be switched on the test fails and an error message is displayed If High Power cannot be switched on the test passes MCP Enable Hold to run Switch Test 2 Press and hold the MCP Enable switch Is the red ES LED on the AWC Board off Y N When the Enabling switch closes the ES LED on the AWC board should turn off If you respond N the test fails and an error message is displayed If you respond Y the system attempts to enable High Power If High Power cannot be switched on the test fails and an error message is displayed If High Power is switched on the High Power button is tested Press ENTER then press and release the HIGH POWER button on the CIP Release the MCP Enable Hold to run switch and press ENTER to continue Press ENTER to begin the test and the system will attempt to turn on High Power If High Power cannot be switched on the test fails and an error message is displayed If High Power is switched on the MCP Enabling test passes Press ENTER to continue with the test Keep the MCP Enable switch pressed AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 191 Chapter 8 Verifying the System Installation MCP E_STOP Button Test 1 Press the MCP E STOP button Is the red E STOP LED on the AWC module on Y N Attempting to enable HIGH POWER with the E STOP button pressed The external
256. own by the state of the DEV LED in the manual state LED group see Figure 9 3 on page 201 The table below describes the conditions Robot selected by DEV LED state pendant OFF 1 ON 2 FLASHING 3 and above AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 219 Chapter 9 Using the Manual Control Pendant MCP 220 The selected robot cycles from one robot to the next each time the DEV F3 key is pressed Be careful when recording positions with the MCP the position recorded by HERE or TEACH commands depends on the robot that is currently selected by the monitor or program and not on the robot selected by the MCP The following commands will allow you to teach the position of robot 2 regardless of which robot is selected by the MCP SELECT ROBOT 2 Choose robot to be accessed by Monitor EACH p 1 Record location s of robot 2 H Robots With Fewer Than Six Joints The MCP has six axis joint selection buttons In Cartesian modes WORLD TOOL these correspond to all six possible Cartesian values X Y Z RX RY RZ Not all mechanisms can move in all of these coordinates For example a 4 axis SCARA robot can move in only X Y Z and RZ Buttons that have no effect on your robot are ignored and in some cases cannot be selected Robots With More Than Six Joints In JOINT mode each of the six buttons is used to control a specific joint of the robot If the robot has more than six joints
257. p 271 switch 272 Vendor tooling mounting pattern dimensions 245 Verifying the system installation 179 Viewing angle 288 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Index LCD panel on MCP 203 Voltage changing setting on power chassis 89 90 99 102 maximum operating power chassis 49 minimum operating power chassis 49 overvoltage protection MV controllers 48 Voltage free contacts 115 for monitoring E Stop circuitry pas sive E Stop 115 W What to do in an emergency situation 41 Windows 95 program installation dialog box 130 Working areas 38 World location 206 World state 213 World state four axis SCARA 214 World Tool and Joint mode 212 Z Z stroke and payload 275 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 289 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 MAIL TO Adept Technology Inc Technical Publications Dept 150 Rose Orchard Way San Jose CA 95134 FAX 513 792 0274 adex adept technology inc 150 Rose Orchard Way
258. packing for relocation 52 Required clearance for robot cables 56 materials and tools for replacing Cleanroom bellows 236 robot arm and signal cable clearance 56 Requirements environmental 47 facility 44 MV controller power 48 PA 4 power chassis 49 power 48 robot system operating environment 47 tool and equipment for robot installation 53 Risk assessment 33 Category 1 34 Risks that cannot be avoided 40 Robot and control system cable installation 82 and controller ID labels 52 brakes 185 cleaning fan air filter 229 definition of industrial 27 dimension drawings 243 grounding 93 installation 53 installation dimension drawings 54 installation on base 60 intended uses 35 joint locations 26 location displaying 206 lubrication 222 228 modifications 37 operating modes 197 shipment specifications 49 speed limited in Manual mode 112 states 213 static forces 29 transport and storage 50 unpacking and inspection 51 working area 38 Robot mounting bolt tightness checking 228 Robot system operating environment requirements 47 Robot with eyebolts lifting 61 Robot mounted equipment grounding 94 Robots with fewer than six joints 220 with more than six joints 220 Robot to EJI cable installation 85 Rotary seal assemblies on Adept XL IP 54 robot 234 RS 232 JCOM 77 connector 158 RS 232 Term connector pinassignments 159 RS 422 485 connector 160 pin assignments 160 RUN HOLD on MCP 212 286 AdeptOne XL AdeptThree XL Robot Ins
259. pe of interface you are installing The type of interface that V expects when it initializes depends on the options ordered with your system If your system was ordered with the AdeptWindows PC option V will initialize and expect the operator interface to be made using a PC computer equipped with the Adept Windows PC software see section 6 3 If your system is not ordered with the AdeptWindows PC option V will initialize and expect the operator interface to be made using either A user supplied terminal connected to the RS 232 TERM connector on the AWC board see section 6 2 or The monitor keyboard and pointing device connected to the optional VGB board see section 6 1 Systems without the AdeptWindows PC option will automatically select the correct of these two options depending on what hardware you connect NOTE The system start up behavior is determined by the configuration DIP switch on the AWC board and the software DIP switch settings in the controller NVRAM The instructions in this section assume that both of these DIP switches have been left in their factory default settings If you have changed these settings or wish to change the start up behavior of the system see the Adept MV Controller User s Guide for details on the AWC DIP switch settings and the Instructions for Adept Utility Programs for details on the software DIP switch settings AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 125 C
260. pecs 261 specifications 260 top and side dimensions 243 working envelope 255 AdeptThree XL dimensions 244 external equipment mounting area 245 initial Payload and Gainset tuning val ues forJ4 155 Joint 1 motion 257 Joint 2 LEFTY RIGHTY configurations 258 Joint 3 and Joint 4 motions 259 performance specifications 262 softstop and hardstop specs 263 specifications 262 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 277 Index top and side dimensions 244 USR1 to USR5 lines max current 137 working envelope 256 AdeptWindows installation 130 AdeptWindows Controller AWC board connectors and indicators 66 serial I O ports 159 Adept XL camera bracket 150 kit 149 mounting pattern 246 Clean Room robot bellows replacement 236 connector locations 84 fan filter inspection and cleaning 229 ground point 94 impact and trapping point hazards 30 initial Payload and Gainset tuning val ues forJ4 154 IP 54 robot bolt resealing procedure 235 cleaning information 234 IP 54 robot bolt resealing detail 235 joint motions 26 quillbellows 237 robot base air filter and cable connector locations 139 assembly 224 solenoid kit 141 system grounding diagram 110 tool flange dimensions 247 transportation pallet 51 upper and lower quill shafts 226 Adept XL Cleanroom features 270 Adept XL robot factory installed options 269 Adept XL robots 25 Amplifier module fuses 238 installing 239 interlock circuit 239 removing 239 App
261. pendix A Adept XL Robot Factory Installed Options 272 Vacuum Switch Maintaining adequate levels of vacuum is critical for cleanroom environments The robot gives no external indication whether the vacuum is present or not Adept suggests vacuum switches be used as a method of assuring proper vacuum is present Such a switch could provide contact closure while the vacuum is within the appropriate range The switch can be used in series with any other external E Stop devices This method will allow High Power to be turned on only if vacuum is present The user would see an External E Stop error message on the system monitor terminal if the vacuum fails NOTE To comply with the requirement for redundant E Stop loops use two independent switches if an E Stop is needed to sense the presence of proper vacuum Testing the Vacuum Setting the vacuum switch requires that all parts of the robot and vacuum systems be installed High Power need not be enabled but the sealed Arm Power and Arm Signal cables connecting the robot to the Adept MV controller and Adept PA 4 power chassis must be connected Connect a vacuum gauge to the pipe tee just outside the robot s vacuum supply fitting Turn the vacuum system on and wait a few moments for the system to stabilize Adjust the vacuum to within the limits mentioned in Vacuum Requirements on page 269 plus roughly 1 1 2 inches W C of vacuum Adjust the switch so that this is the vacuum fal
262. pported by the lift Slowly lower the robot while aligning the base and the tapped mounting holes in the plate or spool Do not remove the permanent eyebolts Insert a M12 x 60 mm or 1 2 13 UNC x 2 5 inch bolt fitted with both a lock washer and a flat washer through each of the three mounting holes in the robot base into the mounting plate or spool and torque to 90 Nem 65 ft lb Install the air filter provided in the installation kit and connect to a compressed air source the meets the requirements detailed in Compressed Air Requirements on page 44 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 61 Chapter 3 Robot Installation 3 2 Using the Brake Release Button Brakes The Adept XL robot has fail safe spring actuated air release brakes on joints 1 2 3 and 4 These brakes are engaged whenever High Power is off The brakes are intended primarily to restrict arm movement when high power is off but they also assist in stopping robot motion when the emergency stop circuitry is activated or when there is a robot motion error These brakes are not designed to routinely stop the robot Brake Release Button 3 3 To manually position the arm without turning on High Power a brake release button is located on the joint 1 inner link The brake release button releases all four joints of the Adept XL robot see Figure 2 2 on page 51 The brake release function works only if a compressed air supply
263. pt XL IP 54 Robot Bolt Resealing Detail 1 Apply a thin coat of Loctite 242 to the bolt threads 2 Tighten and torque the M5 bolt to 3 4 Nem 30 in Ib AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 235 Chapter 10 Maintenance 10 8 Adept XL Clean Room Robot Bellows Replacement 236 The quill Nitrile bellows should be visually inspected for wear every month If any signs of wear are visible the bellows should be replaced The procedure below outlines the replacement of the bellows Required Materials and Tools To perform this procedure you will need the following tools parts and materials 1 Bellows used for both 8 inch and 14 inch Adept XL robots P N 40861 42010 2 Medium size flat bladed screw driver Removing the Bellows Position the robot in an area that allows access to the outer link area Move joint 3 midway between the hard stops Disable High Power to the robot Switch off the On Off power switch on the Adept MV controller and the Adept PA 4 power chassis Refer to Figure 10 8 on page 237 while performing this procedure Loosen the top bellows clamp and slide it out of the way Pull the top of the bellows down and away from the outer link housing Remove the lower bellows clamp Carefully pull the bellows off the bearing Installing the New Bellows Place the top bellows clamp around the top cuff of the bellows Carefully slide the bellows up and over the exposed quill Place the smal
264. r put the robot in a safe area and carefully move the robot using the different joint numbers to verify how the MCP moves the robot See the documentation for the motion devices you are using for details on their joint assignments 216 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Moving a Robot or Motion Device With the MCP Joint 1 Joint 2 Joint 1 gt Joint 2 Joint 3 4 PE E Joint 3 Joint E 2 Joint 4 Figure 9 16 JOINT State Four Axis SCARA Figure 9 17 shows the joint assignments for a typical six axis robot as always the first time you move a robot carefully verify the joint assignments AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 217 Chapter 9 Using the Manual Control Pendant MCP 218 Joint 4 Joint 4 Joint 5 Joint 5 Joint 6 Gripper Joint 6 Figure 9 17 JOINT State Six Axis Robot Free State When free state is selected individual joints are freed from servo control and the robot brakes if any are released Unlike the other states you can make multiple selections from the manual control buttons to free as many joints as required In some cases such as joints 1 and 2 on an AdeptOne AdeptThree robot multiple joints are freed by selecting a single button On some robots Free mode may have been disabled by the manufacturer on some or all joints As soon as the COMP PWR button is pres
265. r Chassis Specifications The following power consumption information is provided to allow customers to install adequate electrical wiring and power sources for worst case short duration demands of the Adept PA 4 power chassis The typical values are for calculating air conditioning requirements Table 11 5 Power Consumption for PA 4 Power Chassis Line Voltage Typical Worst Case 380 415 VAC 50 60Hz 3 phase Current RMS 8 5 amps phase 20 amps phase Watts 1 65 kW 3 kW 200 240 VAC 50 60Hz 3 phase Current RMS 7 2 amps phase 17 amps phase Watts 1 65 kW 3 kW In the 380 415 VAC configuration EMC Test Information the Adept system draws current for a short duration during the positive peak voltage only Information on EMC testing of the Adept control system can be obtained from the FAXBack numbers listed in How Can I Get Help on page 41 264 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Harting Connectors 11 6 Harting Connectors The following figure and tables provide the pin descriptions for the Harting connectors on the Arm Power cable Pin 24 Pin 1 Pin 1 Pin 24 Pin 32 Pin 9 Pin 9 Pin 32 Harting Female Connector Harting Male Connector Arm Power Cable Robot Base Figure 11 22 Harting Connect
266. r the feet of the units as shown in Figure 4 5 4 Install the four M4 x 8 mm flat head screws in the holes indicated in Figure 4 5 to secure the brackets CAUTION Do not use screws longer than 8 mm to install the bracket Doing so could cause damage to your equipment M4 x 8mm four each Cutout Bracket flat head Phillips screws Adept MV Adept PA 4 Controller Power Chassis sil Figure 4 5 Joining the Power Chassis and Controller Bottom View Space Around the Chassis When the controller and power chassis are installed you must allow 50 mm 2 in at the front of the power chassis and 25 mm 1 in at the top and bottom of the Adept MV controller for proper air cooling CAUTION It is important to keep the air filters clean so the forced air cooling system can work efficiently See section 10 4 on page 228 for details on cleaning the filters Rack or Panel Mounting The power chassis and controller can be rack or panel mounted using the mounting brackets that are shipped in the accessories kit The brackets can be attached at the rear of the controller power chassis for panel mounting or they can be attached to the front of the controller power chassis for rack mounting AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 71 Chapter 4 Adept MV Controller Installation 72 Panel Mounting To panel mount the controller or power chassis install one bracket on e
267. rchased from Adept If you are using a serial connection Connect the Adept controller to the PC using a standard serial cable Use the RS232 TERM serial port on the AWC board Installing the AdeptWindows Software The AdeptWindows software for the PC is distributed on one diskette The disk contains an installation program to properly install the software on the PC The following programs will be installed AdeptWindows PC AdeptWindows Off line Editor AdeptWindows DDE Server AdeptWindows TFIP Server After installation each of these programs can be started from the Windows Start menu bar NOTE All the above applications are installed However only AdeptWindows PC is required for the operator interface To install the software 1 Make a note of the keyword on the AdeptWindows Installation Disk and insert the disk in the 3 5 floppy drive typically drive A of your PC 2 From the Start menu bar in Windows Start Run AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 129 Chapter 6 User Interface Installation The following dialog box is displayed Run 71x Type the name of a program folder or document and Windows will open it for you Bun In Seperate Memon Space Cancel Browse Figure 6 2 AdeptWindows Installation 3 Type A SETUP in the text box 4 Choose OK to start the installation process By default the software is installed into the subdirec
268. re normally closed N C The switches must comply with the safety requirements of all European and national standards If the switches do not comply the whole installation will not provide sufficient safety for Category 3 WARNING Do not use switches in the E Stop circuit that do not comply with Category 3 requirements AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 113 Chapter 5 MMSP Installation and Configuration The specifications for user supplied E Stop and safety barrier switches are Two pole redundant contacts positive drive per EN 60204 1992 Section 10 7 3 Minimum switching power 24 VA volt amps Minimum switching voltage 24 VDC Minimum switching current 1 0 A DC The terminals for the user supplied E Stop safety barrier switches and the names of the connectors and signals are given in Table 5 5 Terminal Assignments for Customer E Stops The table below gives the terminal assignments of the terminal block TB4 on the Control Rail of the Security Panel All contacts must be closed to enable High Power Make sure that sufficient E Stop switches are provided in the workcell so they can be easily reached in an emergency Install a removable terminal block connector supplied in the accessory kit on TB4 Then connect to appropriate customer E Stops and other safeguards as described in this section WARNING Adept highly recommends using all of the provided additional customer E Stop contac
269. ree contacts 115 Customer external equipment mounting area 245 Customer requirements 274 Customer Safety Barrier designof 115 mute function 111 switch specifications 114 Customer Service assistance phonenumbers 41 Customer supplied AC power cord speci fications for security panel 109 Cycle setting on MCP 209 D Data Entry buttons 202 Definition of a Manipulating Industrial Robot 27 DEL button 202 Description of mute capability 111 Description of numbers in the MMSP 3 E Stop drawing 120 DeviceNet JDVC 77 DeviceNet communication link 156 Dialog box Windows 95 program installation 130 Digital I O connections 78 connectors on the CIP 173 displaying on MCP 207 from CIP input specifications 121 from CIP JSIO output specifications 123 input signals on TB1 TB2 122 output signals on TB3 123 Digital input signal assignments on termi nal blocks TB1 and TB2 122 Digital input wiring examples JSIO connector 175 Digital output signal assignments on ter minal block TB3 123 Digital output wiring for JSIO connector 176 Digital signals on the Category 3 E Stop board 121 Dimensions 243 254 Adept MV 10 and MV 5 controllers 248 Adept PA 4 power chassis 249 AdeptOne XL robot 243 AdeptThree XL robot 244 camera bracket mounting pattern 246 Controller and PA 4 mounting 280 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Index brackets 252 Controller Interface Panel CIP 250 Manual Control
270. resistors and inductive protection diodes CAUTION Applying an external voltage to the customer E Stop circuit on an MMSP equipped system can permanently damage the E Stop components AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 117 Chapter 5 MMSP Installation and Configuration ESTOPZAV e RF3 Interface From MA CIP N x ESTOP Est Es2 and FESTOP24V MCP ESTOP V ESTOPINP Note Interface from a See Figure 5 17 on b EN MCP ENABLE SR4 page 119 for x No SWITCH DEADMAN 1 amp 2 ED Dm2 j s Wiring Diagram 11 24 DEADMAN1 DEADMAN2 SR5 IB414 1847 ba E V ESTOPINP po POM i Oo TB5 1 TB4 2 e 1B4 8 m 1B4 34 TB4 9 sra D Li eet 33 cc T PC 0g TB5 2 TB4 4 4 1B4 10 TB5 3 r 34 24 12 24 12 SR5 y SP6 spe SR7 sn TB54 TB4 5 dl ETRE WU 54 Mm _ z Hog TB5 7 cepe ip D 8 gt TB4 6 oH 34 3 IB4 126 24 SR6 e 12 12 sre SR8 SR9 SR9 Q pum 7 nm las 11 23 15 9 L KEYSWO 34 n i SR7 o RL1 p o s O TB5 10 m MANUAL 1 X A RF2 Y AUTO qUANUAL te MANUAL 2 A ES oan TIN MANUAL 1 1 SR6 V PASESTOP 43 R15 R16 220 1W 220 1W e 7 44 1 1 1 1 m o SR7 E R13 z R5 z R4 y Lo 43 220 1W CR8 2 2 2 2 j es e ui ei o LA
271. rify that the robot is mounted level and that all fasteners are properly installed and tightened Verify that any end of arm tooling is properly installed Verify that all other peripheral equipment is properly installed and in a state where itis safe to turn on power to the robot system AC Power to the Adept Components Checks Verify that the Adept MV controller and the Adept PA 4 power chassis are correctly connected to their AC power supplies 1 Make sure that AC power is shut off to both the Adept MV controller and the PA 4 power chassis 2 Verify that the three phase AC power 180 264 VAC for 4 wire 380 VAC for 5 wire is connected to the Adept PA 4 power chassis or the optional MMSP security panel if it is installed 3 Verify that the single phase AC power 180 264 VAC is connected to the Adept MV controller AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 179 Chapter 8 Verifying the System Installation 4 If the System Power On Off switch on the CIP is used check the connections to this switch 5 Verify that all voltages and voltage frequencies are within range see section 2 4 on page 48 Board and Cable Installation Checks Make sure that all the boards in the Adept PA 4 power chassis and Adept MV controller are secured and the connection cables are correctly installed 1 Secure all boards and blank front panels to the Adept MV controller chassis Tighten both the top and bottom mounting
272. rkcell Table 5 3 Customer Supplied AC Power Cord Specifications for Security Panel Cord rating 25 amps Number and size of 380 415 VAC 25 x 2 5 mm duct TUNE 200 240 VAC 4 x 2 5 mm Table 5 4 Connection of Main AC Power Cord to the Circuit Breaker on the Power Rail X2 Wire Description Wire Color Terminal Number Color code 30 380 415VAC line 1 black X2 F1 L1 line 2 black X2 F1 L2 line 3 brown X2 F1 L3 neutral blue X2 N X2 PE ground green yellow Color code 309 200 240VAC line 1 black X2 F1 L1 line 2 black X2 F1 L2 line 3 brown X2 F1 L3 ground green yellow X2 PE AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 109 Chapter 5 MMSP Installation and Configuration Grounding an MMSP Equipped System The Security Panel must be grounded using the M5 lug on the right side of the panel see Figure 5 1 and Figure 5 2 The ground wire should be as short as possible Typically it would be grounded to the frame of the equipment cabinet User Supplied Ground Wire Typical User Supplied Equipment Cabinet for End of Arm Tooling Power Chassis Controller Equipment Cabinet Ground Point
273. robot is intended for use in small parts assembly and material handling for payloads typically less than 12 kg 26 5 lb A HyperDrive option is available for this robot that delivers higher power to the joint 1 and 2 motors This option is used for applications that require faster throughput The AdeptThree XL robot is intended for use in parts assembly and material handling for payloads less than 25 kg 55 Ib and for those applications that require a longer reach than the AdeptOne XL robot WARNING For safety reasons it is prohibited to make certain modifications to Adept robots see section 1 6 The Adept MV controller and the Adept PA 4 power chassis are component subassemblies of a complete industrial automation system The controller and power chassis subassemblies must be installed inside a suitable enclosure The controller and power chassis subassemblies must not come into contact with liquids Additionally a standard Adept XL robot must not come into contact with liquids An Adept XL robot equipped with the IP 54 option can withstand some moisture contact The Adept equipment is not intended for use in any of the following situations e In hazardous explosive atmospheres In mobile portable marine or aircraft systems In life support systems In residential installations In situations where the Adept equipment will be subject to extremes of heat or humidity See Table 2 2 on page 47 for allowable temperature and hu
274. rogram from another master robot 4 Off line or CAD programming AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 33 Chapter 1 Safety 1 4 Risk Assessment Category 1 34 Installations Not Requiring Programmer to Enter Workcell WARNING The Adept supplied system components provide a Category 1 control system as defined by EN 954 The robot system must be installed with user supplied interlock barriers The interlocked barrier should interrupt the AC supply to the PA 4 power chassis in the event of personnel attempting to enter the workcell when High Power is enabled even for teaching in Manual mode The user designed interlocks themselves should be designed to provide a Category 3 level of control per EN 954 Failure to install suitable guarding could result in death or injury WARNING If the programmer needs to enter the workcell when High Power is ON Adept s risk assessment indicates that a Category 3 control system is required Some teaching methods do not require the programmer to enter the workcell If these methods are used exclusively the robot should be installed with interlocked guarding to ensure AC power is removed from the PA 4 power chassis whenever a person enters the workcell In situations with low exposure consideration factors EN 1050 specifies use of a Category 1 Control System per EN 954 EN 954 defines a Category 1 Control System as one that employs Category B components designed
275. rsts per EN61000 4 4 Exposing the MCP to voltages higher than 500V may cause the robot to shut down In this event it may be necessary to unplug then reconnect the MCP to restart the robot CAUTION Damage may result if an MCP III is plugged into older Adept controller systems that contain a VME Front Panel VFP Damage may also result if older MCPs part numbers other than 10332 11000 are plugged into a CIP Plug the MCP into the connector marked MCP on the CIP The jack and plug are keyed to ensure proper connection The CIP connector is an AMP 16 pin circular plastic male connector A female connector is used on MCP cable MCP Cradle The MCP is stored in the MCP cradle when it is not being held by an operator The cradle has a retaining clip that keeps the enabling switch closed The MCP cradle must be installed outside of the robot workcell See Figure 11 13 on page 254 for the dimensions of the cradle Controller Interface Panel CIP __ MCP Bypass Plug install if no MCP Manual Control Pendant Figure 4 12 MCP Connection MCP Bypass Plug The MCP Bypass plug is optional and must be installed when not using the MCP The Adept part number for this bypass plug is P N 10335 01060 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 81 Chapter 4 Adept MV Controller Install
276. s 48 Adept MV Controller Power Requirements Table 2 3 Adept MV Controller Power Requirements Auto Ranging Minimum Maximum Recommended Frequency External Circuit Nominal Operating Operating 3 Voltage Ranges Voltage Voltage Phasing Breaker kings user supplied 100V to 120V 90V 132V 50 60Hz 10 amps and 1 phase 200V to 240V 180V 264V Power to the Adept MV controller and all amplifiers and motion devices must come from a single source The maximum interruption time operating voltage below specification tolerated by the controller is 16 milliseconds Facility Overvoltage Protection The user must protect the controller from excessive overvoltages and voltage spikes If the country of installation requires a CE certified installation or compliance with IEC 1131 2 the following information may be helpful IEC 1131 2 requires that the installation must ensure that Category II overvoltages i e line spikes not directly due to lightning strikes are not exceeded Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltage Category II i e not higher than the impulse voltage corresponding to the rated voltage for the basic insulation The user supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient In the industrial environment nonperiodic overvoltage peaks may appear on mains
277. s Damage to your equipment can result from improper use of this wiring Adept XL Robot Solenoid Kit This section describes mounting the 24V solenoid option kit on an Adept XL Robot The solenoid kit Adept P N 90862 00100 is available through Adept NOTE The valves are mounted inside the outer link cover The robot has been prewired for a bank of four 24 VDC solenoid valves Power and signal lines for the solenoids are terminated at a 9 pin D sub connector mounted inside the outer link cover see Figure 7 4 on page 144 The signals actuating the valves are directly switchable from Vt using software signals 3001 and 3002 Refer to the SIGNAL OPEN OPENI CLOSE and CLOSEI commands in the V Language Reference Guide for additional information Each driver is designed to handle 24 VDC solenoids at a nominal 0 075 mA per valve The solenoid valve assembly Adept P N 30862 00100 consists of four independent valves valve 1 through valve 4 on a common manifold see Figure 7 3 The manifold supplies air at the user s line pressure 70 psi minimum to 110 psi maximum Each valve has two output ports A and B The output ports are arranged so that when port A is pressurized port B is not pressurized Conversely when port B is pressurized port A is not In the Adept XL robot the air lines from port A on each valve are plugged at the factory at the solenoid assembly Tools Required e M2 5 Allen driver e M4 Allen driver e Eight
278. s Equipment RS 232 JCOM Connector There is one RS 232 serial port JCOM for general purpose serial I O functions on the CIP see Figure 4 10 on page 78 for the location of the JCOM connector This serial port is referred to as device LOCAL SERIAL 4 This serial port can be accessed by any AWC board configured to run V The connector is a 9 pin DB 9 male receptacle The signal and pin information are shown in Table 7 7 See the V Language User s Guide for information on serial I O See the Instructions for Adept Utility Programs for setting the default serial port configuration using the CONFIG _C program The serial port on the CIP can be configured for use at up to 38 400 bps Table 7 7 JCOM Connector Pin Assignments Pin Signal Pin Signal 1 Not used 6 Not used 2 RXD 7 Not used 3 TXD 8 Not used 4 Not Used 9 Not used 5 SG Signal Ground Figure 7 12 JCOM Pin Locations NOTE The serial port on the CIP does not provide hardware handshaking signals 158 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting User Supplied Serial Communications Equipment AdeptWindows Controller AWC Board Serial I O Ports The AdeptWindows Controller AWC board has three serial I O connectors two RS 232 and one RS 422 485 port see Figure 7 13 Systems using a programmer s terminal ASCII connect through the RS 232 Term port on the AWC board HD LAN RS 422 485 RS
279. s Circuit Breaker The power chassis circuit breaker is rated at 15A and is located on the lower left front of the chassis on the power entry module It also functions as an on off switch to isolate the chassis CAUTION If the circuit breaker trips due to current overload it indicates an internal fault Do not reset the circuit breaker yourself Contact Adept Customer Service see section 1 18 on page 41 for details on contacting Adept Chassis and Amplifier Module Fuses Six chassis fuses are located inside the base of the power chassis on the power control board These fuses are not user replaceable If you suspect that a chassis fuse may have blown contact Customer Service In addition to the fuses in the power chassis there are additional fuses located inside the power amplifier modules The amplifier fuses are not user replaceable If you suspect that an amplifier fuse may have blown contact Customer Service CAUTION Failure of a chassis or an amplifier fuse indicates an internal circuit fault which must be corrected before the fuse is replaced Do not attempt to replace the fuse yourself Contact Adept Customer Service see section 1 18 on page 41 for details on contacting Adept Removing and Installing Amplifier Modules The Adept PA 4 power chassis is shipped from the factory with the amplifier modules installed in the chassis Any unused slots are filled with blank covers Normally you will not need to remove the amplif
280. s failed and a message will be displayed on the monitor and MCP indicating why 2 Verify that all E Stop devices are functional MCP CIP and user supplied Test each mushroom button safety gate light curtain etc by enabling High Power and opening the safety device The High Power push button light on the CIP should go out and the red ES LED on the AWC should be lit AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 183 Chapter 8 Verifying the System Installation 8 4 Using the SAFE_UTL Program MMSP Only Before an MMSP equipped system can be used the Adept utility program SAFE_UTL must be run to very that the MMSP safety equipment in running properly Category 3 systems contain several components to ensure safety when the robot is operating in Manual mode Some components should be tested at the time of commissioning These components should also be tested every six months Adept provides the SAFE_UTL Utility Program to test these components This section gives instructions for using SAFE_UTL and describes the tests required to commission the robot Additional tests should be performed periodically These tests are also described in this section Category 3 Robot Components Accelerometer An accelerometer is located in the outer link of the robot to prevent excessive acceleration of joints 1 and 2 while operating in Manual mode If the accelerometer is tripped the emergency stop circuit is opened causi
281. scription Beschreibung Name Namen Part Number Teilenummer Revision R vision Nom R f rence Ethernet kit Ethernet Ausr stung AdeptNet 90332 02020 gt P1 Ethernet kit VME Analog I O Module Analog AIO 10330 00970 gt B Ein Ausgabemodul Carte d entr es sorties analogiques VME Force sensing kit VFI Ausr stung VFI 90211 00000 08464 00550 gt B Capteur d efforts MP6 Kit MP6 Ausriistung MP6 90332 12400 gt A Kit MP6 NOTE Products listed in Table 2 must be tested by the user in the final system configuration to assure full compliance with the European EMC Directive NOTE Les produits list s dans le tableau 2 doivent tres test s par l utilisateur apr s l assemblage et la configuration finale des quipements afin de s assurer que l ensemble r ponde aux directives Europ ennes EMC AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Table of Contents A A E 25 Definition of a Manipulating Industrial Robot oauan aaa aa 27 Adept Equipment Compatibility asasan aaaea 27 1 1 Notes Cautions and Warnings 00 cece ees 28 1 2 Precautions and Required Safeguards cc eee arannana 28 Maximum Robot Forces and Torques aasan aaraa 29 Seife tViBGlttie s ta eta soe ota roa ote sti hoa pe ica e de is 29 Impact and Trapping Points iiie ens 30 Hazards From Expelling a Part or Attached Tooling 30 Additional Safety Information
282. sed or another selection is made from the manual control buttons all joints are placed back under servo control and will not move freely Figure 9 18 shows the free state for a four axis SCARA robot The joint assignments in the free state are the same as the joint assignments in joint state WARNING As soon as a joint is selected from the manual control buttons the related joint is free to move in some cases multiple joints may be freed up In many cases the weight on the joint will be sufficient to move the joint and cause damage or harm For example when joint 3 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Moving a Robot or Motion Device With the MCP ona SCARA or Cartesian robot is freed the joint is free to fall to the end of its travel In articulated robots multiple links of the robot may be free to fall when a single joint is freed up Be extremely careful when selecting a joint in Free mode Joint 2 Joint 1 C 3 C 2 3 Joint 3 Joint 4 Joint 1 Free Joint 2 Free Joint 3 Free Joint 4 Free Gripper Figure 9 18 FREE State Four Axis SCARA Controlling More Than One Robot Like the monitor and each program task the MCP also can have a robot attached When moving a robot from the MCP or displaying joint values or world locations by pressing the DISP key only the currently selected robot is affected The robot currently selected by the MCP is sh
283. sed interface using a 128 Testing Dual Brake Valves With MMSP 194 gripper valves 147 MMSP hardware 222 vacuum 272 Text based interface using a terminal 128 Thermal hazard 38 Tool and equipment requirements 53 Tool flange dimensions of the Adept XL robots 247 Tool state and TOOL transformation 215 four axis SCARA 215 onMCP 214 six axis robot 216 TOOL transformation 215 Tower bracket tubing cable tie installation 146 Transport 37 and storage 50 Travel limiting joint 62 Tube and cable routing for solenoid installation 145 Typical 380 415 VAC connection for MMSP system 106 3 phase 200 240 VAC connection for MMSP system 106 AC power installation diagrams 106 U Unacceptable modifications 37 Unpacking 51 and inspecting the Adept equipment 51 information 50 the Adept equipment 49 User quill flange dimensions of the Adept XLrobot 247 air line command summary 147 brake release jumper 98 connections in the Adept XL robot 148 connector JUSER 76 connector locations on the tower assembly 138 hardware to be provided by 43 interface installation 125 signal and solenoid driver lines 137 USER1 1 through USER 2 4 137 USER1 1 through USER1 6 USER2 1 Through USER 2 4 Without MMSP Option 137 User supplied safety equipment on JUSER 181 Using Brake Release button 62 Manual Control Pendant MCP 197 SAFE_UTL program MMSP Only 184 Safety Utility MMSP Option 222 V Vacuum installation 271 requirements 269 supplypum
284. source Connect the monitor AC power cord to the monitor then plug it into an appropriate voltage source AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Graphical User Interface Using the VGB Board 3 Connect the double ended keyboard cable to the KEYBOARD connector and the POINTER connector on the VGB board A standard PC style 101 key keyboard can be used instead of the Adept supplied keyboard A pointing device that is compatible with Microsoft serial mouse protocols can be used instead of the Adept supplied integrated trackball For systems with the optional AdeptVision system camera output will be displayed at full frame rates in the vision window on the monitor If you have purchased the AdeptVision option the system is installed If you are adding the AdeptVision option to an existing system see the Adept MV Controller User s Guide for installation details AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 127 Chapter 6 User Interface Installation 6 2 Text Based Interface Using a Terminal With an Adept MV controller system that does not have one of the graphical user interface options the customer must supply the terminal and cable to interface to the controller The terminal must be a Wyse Model 60 or 75 with an ANSI keyboard or a compatible terminal You may also be able to use a computer with suitable terminal emulation software For DOS or Windows compatible computers the programs
285. t MV Adept MV4 AdeptVision AIM VisionWare AdeptMotion MotionWare PalletWare FlexFeedWare AdeptNet AdeptFTP AdeptNES AdeptTCP IP AdeptForce AdeptModules AdeptWindows AdeptWindows PC AdeptWindows DDE AdeptWindows Offline Editor 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 Manufacturer s Declaration We Wir Nous Adept Technology Inc 150 Rose Orchard Way San Jose California 95134 USA in accordance with EU Directive 89 392 EEC Annex II B declare under our sole responsibility that the product erkl ren in alleiniger Verantwortung daf das Produkt d clarons sous notre seule responsabilit que le produit EN 954 Category Klasse Cat gorie 1 Category Klasse Cat gorie 3 Robot Roboter AdeptThree XL 30862 10300 30862 10300 AdeptOne XL 30862 10301 10304 30862 10301 10304 Pendant Handbedienger t MCP III 90332 48050 90332 48050 Unita portatile Control system Adept MV 10 30340 20000 40000 30340 20000 40000 Steuerung Syst me de commande Adept PA 4 30336 31000 30336 31000 Sistema di comando A Amp 10337 15200 10337 15200 Dual B Amp 10338 51000 90338 51010 CIP 30350 10350 30350 10350 MMSP 90862 00700 to which this declaration relates is in conformity with the following standards auf das sich dies
286. t PA 4 Adept MV 10 340 200 240V 1G 200 240V Figure 5 11 Typical 3 Phase 200 240 VAC Connection for MMSP System 106 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option Connecting Power Cord of Power Chassis to Security Panel WARNING Electrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord An incorrect installation can injure or kill anybody who touches the equipment in the robot workcell WARNING The 3 phase AC power cord of the PA 4 power chassis must be installed at the contacts on the Power Rail X2 This ensures that the MMSP can remove power from the power chassis when rewired Failure to do this prevents safe operation and could permit injury or death The user end of the cord is unterminated Connect each conductor of the power cord securely to the contacts of the contactor AP2 and terminals for protective ground and the neutral See Table 2 4 on page 49 for the information on terminal numbers and color code for the connections The installation must meet all applicable local and national standards and regulations NOTE In 380 415V installations a 5 wire installation 3 line neutral PE is required In 200 240V installation a 4 wire installation no neutral is required The blue wire from the PA 4 power chassis must be insulated see Figure
287. t installation 0 2 c cece ccc eee eee eee eee eens 53 3 1 Mounting the Robot a a e a eee 53 Tool and Equipment Requirements 0 000 ee 53 Installing a Base for the Robot ecserin niar nn 54 Robot Installation Dimension Drawings isses 54 Required Robot Arm and Signal Cable Clearance o o oo ooo mmm 56 Installing a Mounting Plate sas erea o a en 58 Installing a Mounting SOOO n 59 Mounting a Robot ona Base ow enn 60 3 2 Using the Brake Release Button 0000 e eee eee eee 62 A ideale ee rea se eeee hada RAMUS heeded ees 62 Brake Release BUTTON epp rosoe eens 62 3 3 Limiting Joint Travel a i csaa rense ra Peer eee 62 OOED gesa iaa lo CIPUE 62 10 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Table of Contents m efejeje sta LEE 62 Caresian Limit 919p s s xiii ev EUR e Y xo e HORSE ES Phe ecd 63 4 Adept MV Controller Installation 65 AdeptWindows Controller AWC Board Connectors and Indicators 66 A Amplifier Module Overview iiis ees 67 Connectors and Indicators iiie 67 Dual B Amplifier Module Overview sns 68 Connectors and Indicators iiie 68 4 1 Mounting the Adept MV Controller and Power Chassis 69 Joining an Adept PA 4 Power Chassis to an Adept MV Controller 69 Joinirig ARMS TOP etus sa uen Sata dete bene e 70 Jolning datr The BOTIOM wens sd cet A eR ike Ee 7
288. t pipe distances Estimates of pipe fitting flows converted to straight pipe equivalents for three common pipe diameters are shown in Table A 1 These distances are then added to the nominal amount of straight pipe to create a total pipe length There are practical limits to the length of pipe of a certain diameter The Adept XL Cleanroom Robot Option provides a 1 1 4 inch male thread pipe fitting for the vacuum connection on the outside of the base of the robot see Figure A 1 on page 270 This can be adapted to any vacuum supply pipe being used Adept recommends the connection include the following features e A union at the robot that allows the robot to be removed from the workcell e A tee with a threaded plug machined to accept a vacuum sensing switch This allows the vacuum to be tested A gate valve in line with the vacuum piping and located near the robot This will allow regulation of the vacuum at the robot Keep in mind that gate valves have flow losses 10 to 12 percent higher than that of globe or ball valves A union at the wall separating the vacuum pump and robot e A union at the vacuum pump that allows the pump to be replaced Table A 1 Pipe Fitting Flow Equivalents in Feet of Straight Pipe Pipe Size Fitting 1 1 4 inches 1 1 2 inches 2 inches 90 degree 7 feet 8 feet 10 feet 45 degree 1 5 feet 1 8 feet 2 3 feet AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 271 Ap
289. t should be able to move 10 degrees beyond the defined locations in both directions After the new test locations are defined the following message is displayed resting Joint 1 on the monitor Release then press th Enable Hold to run The test prompts will be displayed on the MCP as well as here button on the MCP Press the High Power button when the button blinks AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Tests Performed at Time of Commissioning Press the CMP PWR button Hold the SPEED BAR then press and release the STEP button While continuing to STEP button hold the SPEED BAR press and release the Accelerometer has tripped as expected The MCP controlled move is repeated If the test passes the following is displayed Accelerometer test passes Press ENTER to continue Pressing ENTER will either begin the next test to be performed or display the main menu If the test fails the main menu is displayed B Amp Voltage Restrict Test WARNING The user must remain outside the robot workcell with all safety barriers closed while conducting these tests Failure to observe this warning could cause serious injury As this test is started High Power must be enabled as described in the previous test The voltage restrict circuitry is tested to ensure that it is operational The following messages are displayed as the pr
290. t the base of the robot see Figure A 1 on page 270 The fitting provides for attachment of a 3 inch diameter hose secured with a 1 2 inch wide hose clamp Blower requirements should be based on Z stroke and payload of the user s application In general long Z strokes with small payloads require more pressurization while short Z strokes with large payloads require less pressurization because the bellows acts as a pump actuated by joint 3 motion A graph of pressure and flow requirements based on Z stroke and payload is shown in Figure A 2 on page 275 These pressure and flow requirements are at the blower attachment fitting The blower must supply clean dry air Blowing moist dirty air into the robot may reduce the life of the robot or cause internal damage 274 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Head vs Flow Adept XL zi D 2 2 0 o te e x 2 A TE SS AN 5 0c o E H H H H H H 10 O i0 O 110 O 10 O 10 oO io e o O O Wo sf x O c A QN W49 mola 5 5 Head Inches H 20 Stroke and Payload Figure A 2 Z 275 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C A A Amplifier module connections indicators 67 overview 67 AC power connecting power cord to security panel 109 connecting to power chassis 92 105 connecting MV controllers 87 MMSP system installation diagram for 200 240VAC 106 MMSP system installation diagram for 380 415
291. tOne XL Robot Specifications Table 11 1 AdeptOne XL Robot Performance Specifications Continued Joint Speed maximum Joint 1 650 sec Joint 2 920 sec Joint 3 1000 mm sec 39 4 in sec Joint 4 3300 sec Weight Robot without options 265 kg 583 Ib Power chassis with 3 amplifier modules approximately 16 4 kg 36 lb Adept MV controller with AWC 040 060 VGB approximately 14 5 kg 32 lb Design Life 120 million production cycles a Maximum possible running at reduced speed b The robot tool performs a continuous path motion consisting of all straight line segments 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and returning along the same path The endpoints of the cycle are approached in COARSE mode with a brake at end point Table 11 2 AdeptOne XL Robot Softstop and Hardstop Specs Joint Default Softstop Hardstop approximate Joint 1 X150 152 Braketrack 300 Hardstop Joint 2 140 142 Joint 3 0 to 356 mm 6 6mm to 371 mm 356 mm Configuration 0 to 14 in 0 26 to 14 6 in Joint 3 0 to 203 mm 6 6mm to 218 mm 203 mm Configuration 0 to 8 in 0 26 to 8 6 in Joint 4 270 None n between the softstop and hardstop Joint 1 has a braketrack An internal proximity sensor will cause a V error condition and shut down High Power to the robot if the braketrack area is entered Ad
292. tThree XL Robot Instruction Handbook Rev C Installation of the MMSP Option Connect Blue Wire Here for 380 415 VAC Power Rail X2 O00 O00 ojojo E AP1 AP2 I Y ololo 000 000 Blue Wire Labeled Neutral From 24 VDC Supply Figure 5 8 Moving Blue Wire From AP1 L2 to Neutral 380 415 VAC Part 2 1 a D TA Part 3 1 2 3 Rotating Voltage Selector in Power Chassis Open the front air intake grill on the power chassis by loosening two screws and swinging the grill out Inspect the voltage setting it is marked on the front of the voltage selector plug To change the voltage setting remove the selector rotate it 180 degrees so the required setting is shown and replace it see Figure 5 6 on page 101 Close the grill and secure the two screws Clearly mark or alter the ID label on the side of the PA 4 power chassis to show the new voltage configuration see Figure 5 7 on page 102 Clearly mark or alter the ID label on the side of the Security Panel to show the new voltage configuration Clearly mark or paste an alternative label over the existing label below the circuit breaker on the front of the chassis to show the new voltage configuration Reconnect the controller and Security Panel to the AC power source Insulating Power Chassis Power Cord All Systems WARNING High AC voltage is couple
293. tal I O channel usage accordingly Inputs on the optional DIO board or CIP JDIOx connectors cannot be used by the REACT and REACTI instructions Fast Input Signals 1001 to 1004 In addition to functioning as normal input signals signals 1001 to 1004 can have the following special uses e Fast DIO V interrupt events INT EVENT Robot and encoder position latch Vision trigger NOTE When the program task priorities are properly set there is a 2 ms maximum latency for fast inputs 1001 to 1004 when used with vt INT EVENT instruction requires the optional V Extensions License See the V Language Reference Guide for a description of the INT EVENT instruction 174 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Connecting User Supplied Digital O Equipment Adept Supplied Equipment User Supplied Equipment Typical Examples equivalent circuit 1 OG 41 1 ee Signal 1001 P E irm Example 1 i a 2 i 3 CR 43 ee 2 i 5 seats ds h Cer Power Ms acu E A Y Supply a Signal 1003 1 A x le O E E a o 1 ACD e E Signal 1004 DEN 8 4 i Nex t Example 2 Signal 1005 Pe E fo A p o ee dec o 4 E Signal 1006 i ey Ei scum 2S T 4 User Power o Seis apo 4 Os o Signal 1007 i DNE Blu 4 Supply 8 A eo pa D Signal 1008 me A lis ow a me s o e E A eee ans 6 Signal 1009 Ps E s O Example 3 en adig TER Sourcing e j
294. ted with a lock washer and a flat washer through the holes in the plate into each of the four plate to floor anchor holes Tighten the bolts to 55 Nem 40 ft lb of torque 10 Recheck the robot mounting surface of the plate and reinsert shims as required to bring the mounting surface horizontal within 0 25 degrees MMSP or 0 3 degrees no MMSP Installing a Mounting Spool The following sequence details the installation of the robot mounting spool to the floor see Figure 3 5 NOTE You can substitute M12 bolts of correct length in place of 1 2 13 UNC bolts to install mounting spool and robot 1 Drill and tap three M12 or 1 2 13 UNC 2B mounting holes through in the top of the spool as shown in Figure 3 2 for robot to spool attachment 2 Prepare the bottom of the mounting spool by drilling four 16 mm 5 8 inch diameter through holes as shown in Figure 3 1 for spool to floor anchoring 3 Place the spool exactly where the robot is to be installed Ensure that the spool is positioned so that the footprint for the robot is properly oriented to the workcell Transfer the locations of the four spool to floor mounting holes directly to the floor 4 Set the spool aside and drill four holes 22 mm 7 8 inch in diameter by 90 mm 3 5 inch deep in the floor at the locations identified in step 3 5 Using a vacuum cleaner remove all chips and debris from the holes drilled in step 4 and surrounding area 6 Insert an expa
295. tems 27 Maximum Torques and Forces AdeptOne XL ROBOT ke 29 Maximum Torques and Forces AdeptThree XL ROBOT eee 29 Maximum Adept XL Robot Joint Velocities in Runaway Situations 30 Sources for International Standards and Directives 0 0 0 cee 31 Other Standards Related Organizations 0 32 Partial List of Worldwide Robot and Machinery Safety Standards 33 Related Manuals eee A Gea a ead ad 42 Mounting Plate SpecificOatiONS 0 ooo ooooommnron E a aa 45 Robot System Operating Environment Requirements 0 o o ommo ooo 47 Adept MV Controller Power Requirements oauan aaa a 48 Adept PA 4 Power Chassis Power Requirements esses 49 Adept Shipping Crate Specifications 0 6 a 49 System CADIS LOMOTAS s we seed cod arate too sane Rea Da E RO RUE aes 83 Adept MV Controller Power Cord Specifications isses 88 AC Power Cord Specifications for Power Chassis ies 93 AC Power Cord Specifications for Power Chassis liis 107 Connecting Power Cord of the Power Chassis to the Terminals on the Power RAMO 9 air Labb aah has ctl Aree o s hA S od io Asal tas cp ep a 108 Customer Supplied AC Power Cord Specifications for Security Panel 109 Connection of Main AC Power Cord to the Circuit Breaker on the POwWer dil X2 4 ore table E eo deo de A uoi aid eise ol A UNDE 109 Terminal Assignments on TBA for Customer Supplied E Stop Switches 114 Terminal Assignment on
296. the workcell Using the plate as a template transfer the locations of the four plate to floor mounting holes directly to the floor AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Mounting the Robot 4 Set the plate aside and drill four holes 22 mm 7 8 inch in diameter by 90 mm 3 5 inches deep in the floor at the locations identified in step 3 5 Using a vacuum cleaner remove all chips and debris from the holes drilled in step 4 and surrounding area 6 Insert an expansion bolt anchor into each of the four holes in the floor Ensure that the threaded end of each bolt anchor is toward the bottom of each hole as shown in Figure 3 4 7 Reposition the plate over the anchor holes in the floor using care to align the four plate to floor holes with the anchor holes Ensure that the plate is positioned so that the footprint for the robot is properly oriented to the workcell 8 Verify that the top mounting surface of the plate is level ensure that the accuracy of the device used to level the plate exceeds the required leveling tolerances The surface must be horizontal within 0 25 degrees MMSP or 0 3 degrees no MMSP If the plate is not level insert shims between the plate and the floor to bring the plate within specifications The shims should be at least 75 mm 3 inches in diameter and have cutouts provided to fit around the anchor bolts 9 Insert aM12 x 100 mm or 1 2 13 UNC x 4 inch bolt fit
297. the tower assembly of the Adept XL robot These are referred to as User Signal Lines and may be used as signal lines for equipment mounted on the outer link or the tool flange The tower assembly is located under the quill cover see Figure 7 1 The pinouts for the User lines are shown in Table 7 1 on page 140 USER1 1 Through USER 2 4 USER1 1 through USER2 4 line pairs run from the robot tower see Figure 7 1 on page 138 to the User connectors on the Arm Signal cable see Table 7 1 on page 140 These lines can be used to connect limit switches or similar digital devices to the digital I O of the controller See the MV Controller User s Guide for further information on digital I O NOTE The MMSP option see Chapter 5 uses the signal lines on the User2 connectors these lines are not available for customer use CAUTION User lines are routed through the robot harness in close proximity to robot control signals To ensure long life these lines are constructed from 28 AWG high strand count wires and are not designed to carry high current or high voltage These lines should be limited to a maximum of 24 VDC at 2 Amps To minimize coupling with robot control signals in adjacent harnesses you should minimize voltage transients and maintain a current balance in each pair Exceeding these recommendations could couple noise onto the robot control lines and cause robot motion errors AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C
298. to the CIP 6 aaa 97 Connecting the Security Panel to the Adept Robot 0 2 eee 98 Connecting the Security Panel to the Adept PA 4 Power Chassis 98 Changing the Voltage Setting for the Power Chassis From 380 415 VAC to 200 240 VAC cee ete es 99 Changing the Voltage Setting for the Power Chassis From 200 240VAC to 380 A15VAC aaa tes 102 Connecting AC Power to the Adept PA 4 Power Chassis 105 Typical AC Power Installation Diagrams 6 0 0 0 ees 106 Connecting Power Cord of Power Chassis to Security Panel 107 AC Power Requirements for MMSP Option 00 0 eee 108 Connecting AC Power to the Security Panel 0 cc es 109 Grounding an MMSP Equipped System i sees 110 5 2 Security Panel Functions llle 111 Description of Mute Capability seen 111 Operating in Manual Mode sss en 112 5 3 Category 3 Emergency Stop and Teach Restrict Equipment 113 Terminal Assignments for Customer E SfOpS ees 114 Voltage Free Contacts for Monitoring E Stop Circuitry Passive E Stop 115 5 4 Category 3 Emergency Stop Circuitry 0 0 0 ee 117 5 5 Digital Signals on the Category 3 E Stop Board o oooocooo ooo 121 PRUPONE s ace tein aie ttt el e ede tid RUP e fn eod 121 12 AdeptOne XL AdeptThree XL Robot Instruction Handbook Hev C Table of Contents QUTBUTSIONGISs erica laico 122 6 user Interface Installation
299. to the digital outputs on the JSIO connector The examples are negative common and positive common Example 1 outputs 0001 to 0004 are shown with positive common Example 2 outputs 0005 to 0008 are shown with negative common NOTE These are examples Either method can be used in any combination on any channel Adept Supplied Equipment User Supplied Equipment Typical Examples equivalent circuit 25 D fH A s 5 Signal 0001 yx Hg Example 1 e a T3 Sourcing 3 wie aio l Oo T s Signal 0002 y 1 los 1 Q 4 a uuu T S E Css Power ms 4 4 S yal i Supply 2 Signal 0003 SG Bu a S suave alsin 2 o 7 i 4 1 S Signal 000 Mae oc z O Joo Moa 433 2 Signal 0005 y i laa si Example 2 5 Cee 7 Sinking 3 bs sae d AHY 2 SONA 0908 LIE a o OO C User Power S c ET 487 Load T Supply o Signal 0007 NEC lss s a L T o le eT 489 Load o Signal 0008 Suc peo i Ru See Emergency Stop GP Circuit on page 165 for Connections EE i details Figure 7 20 Digital Output Wiring for JSIO Connector AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Extended Digital I O Signals Table 7 14 JSIO Digital I O Connector Pin Assignments Signal a Pin Name Pin S
300. to withstand environmental influences such as voltage current temperature and EMI and that employs well tried safety principles The standard Adept XL control system system without MMSP Control System described in this handbook employs hardware components in its safety system that meet or exceed the requirements of the EU Machinery Directive and Low Voltage Directives Furthermore the standard control system is fully hardened to all EMI influences per the EU EMC Directive and meets all functional requirements of ISO 10218 EN 775 Manipulating Robots Safely In addition a software based reduced speed and soft servo mode has been incorporated to limit speed and impact forces on the Operator and production tooling when the robot is operated in Manual Mode In consideration of the above the standard AdeptOne XL AdeptThree XL control system meets or exceeds the requirements imposed by the EN 954 specified Category 1 level of safety as evidenced by the Manufacturer s Declaration of Conformity at the front of this handbook Adept has performed a risk assessment based on intended applications of this product Our assessment indicates that a Category 3 safety system as defined in EN 954 is required to protect the operator and programmer This protection may take two forms 1 Ifa programmer may need to enter the cell with High Power on then Adept s optional MMSP should be installed The system must be installed so that no one can
301. tomer Service for further information see How Can I Get Help on page 41 Cleaning Information The Adept XL IP 54 robot meets IP 54 requirements for dust and low pressure water splashing High pressure water nozzles should not be used on the Adept XL IP 54 robot If high pressure water nozzles are used near the Adept XL IP 54 robot install a protective cover to protect the robot against direct high pressure spraying To maintain the robot warranty follow the procedures listed below and pay close attention to the caution messages Removing the End Effector for Cleaning The end effector can be removed for a separate cleaning procedure refer to the instructions that come from the manufacturer of the end effector When the end effector is removed you must either plug the end of the quill so that no moisture can enter the robot or positively pressurize the robot Cleaning Procedure CAUTION Applying strong alkaline acidic or high chlorine cleaning chemicals may degrade the Adept XL IP 54 robot s surface finish Cleaning with high pressure sprays abrasive cleaning agents or scouring pads is not recommended on the Adept XL IP 54 robot The Adept warranty does not cover damage to seals the surface finish or consequential damage caused by failure to observe recommended cleaning procedures and cautions WARNING Personnel working in the robot workcell must always wear safety equipment see section 1 13 on page 40 1 With High
302. tomer supplied safety and power control equipment to the CIP 161 MCP 200 tothe CIP 80 one PC and one controller 134 power chassis cord to AC supply non MMSP system 92 to power rail terminals 108 to the security panel MMSP option 107 robot to the MV controller 85 robot to the power chassis 83 security panel MMSP option 93 to the Adept PA 4 power chassis 98 to the Adept robot 98 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 279 Index tothe CIP 97 system power switch to the CIP 169 user supplied digital I O equipment 173 serial communications equipment 158 Connectors on Control Rail 98 on Power Rail 108 Connectors and Indicators onA Amp 68 on B Amp 67 Contacts provided by the JUSER connector 161 Control Rail location of connectors 113 Controller and PA 4 dimensions with mounting brackets installed 252 connecting to power chassis 86 connecting to robot 85 dimensions MV 10 248 fuse information 233 IP address 133 joining to power chassis 69 panel mounting 72 power requirements Adept MV 48 rack mounting 72 spare parts list from Adept 240 spare parts list from third parties 240 Controller Interface Panel CIP back panel view 78 description 75 side view 77 Controlling more than one robot 219 Cradling the MCP 200 Crate specifications shipping 49 Current voltage ratings power chassis 49 Customer E Stops schematic 117 terminal assignments for TB4 114 terminal assignments for TB5 116 voltage f
303. tory C Adept AdeptWindows on the hard drive of your PC You can specify a different directory if desired Additionally during installation the software automatically creates the sub directory C Adept Disks Disk_C which can be mounted as an NFS directory by the Adept controller See the AdeptWindows User s Guide for details 5 When the installation program prompts you for the keyword enter the characters noted in Step 1 from the label on your AdeptWindows disk NOTE Do not confuse the keyword for the AdeptWindows software on the PC with the password for the AdeptWindows license on the Adept controller Setting Up the TCP IP Interface Ethernet Connection The IP address is the logical means by which the higher level Ethernet software identifies a specific node The IP address must be unique for each node within a LAN The network address and sub net mask of the PC must be set to IP Address 172 16 200 xx Subnet Mask 255 255 0 0 Where xx can be any number from 1 to 255 To setup the TCP IP interface on your computer 1 Make sure the network interface card on your computer is properly installed and then start your PC 2 Open the Network parameters window Start Settings Control Panel Network 130 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Graphical Interface Using AdeptWindows PC The following window is displayed or Microsoft Networks ss E 3Com Fast EtherL
304. truction Handbook Rev C Index S Safety 25 33 41 during maintenance 40 equipment for operators 40 expelling a part 30 impact and trapping points 30 required safeguards 28 sources for information 31 Safety aspects while performing maintenance 40 Safety barriers 29 requirements 29 Safety equipment for operators 40 Safety information 31 Safety requirements for additional equipment 38 Safety risks for systems with MMSP option 40 for systems without MMSP option 41 Safety utility how to use 184 193 using during maintenance Sealing the tool flange 274 Security panel 97 components 95 connecting to CIP 97 connecting to power chassis 98 connecting to robot 98 dimensions 251 functions 111 list of functions 111 Selecting a new program onMCP 209 Serial Port 2 RS 232 159 Setting up the TCP IP interface Ethernet connection 130 Shipment specifications 49 Shipping and storage 50 Shipping crate specifications 49 Shipping information 50 Side connectors on CIP 76 Signal interconnection installation 82 SIO board serial ports 160 Slow button on MCP 213 Soft buttons on MCP 201 Softstops 62 AdeptOne XL specifications 62 AdeptThree XL specifications 62 263 Solenoid valve assembly 144 193 222 Sound emissions 38 Sources for international standards and directives 31 Space around the chassis 71 Spare parts list Adept XL robot 241 MV 5 MV 10 240 PA 4 Amplifier Chassis 241 SPEC utility program to set softstops 62 Special
305. ts to develop and operate a safe robot workcell that complies with the European safety standards The robot system must comply with Category 3 per EN 954 which according to our risk assessment is the required category of safety for these Adept robot installations per EU Directives Table 5 5 Terminal Assignments on TB4 for Customer Supplied E Stop Switches Terminal on TB4 Signal Name TB4 1 Customer E Stop IN 1 TB4 2 Customer E Stop IN 1 TB4 3 Customer Safety Barrier 1 TB4 4 Customer Safety Barrier 1 TB4 5 Customer Safety Barrier Mute 1 TB4 6 Customer Safety Barrier Mute 1 TB4 7 Customer E Stop IN 2 TB4 8 Customer E Stop IN 2 TB4 9 Customer Safety Barrier 2 TB4 10 Customer Safety Barrier 2 TB4 11 Customer Safety Barrier Mute 2 TB4 12 Customer Safety Barrier Mute 2 114 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Category 3 Emergency Stop and Teach Restrict Equipment NOTE If any of the signal pairs in the table above are not connected to customer safety devices the contacts must be closed with a jumper otherwise the E Stop circuit is not closed and it is not possible to enable High Power C shaped metal jumpers are supplied in the accessory kit The Category 3 safety system provides two independent E Stop loops 1 and 2 The signals designated 1 and 2 represent pairs of signals from a two pole switch The 1 switches are in s
306. uipements Substitution ou ajout de composants non list s dans cette d claration Ajout de composants ou accessoires par le client 6 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Plug in Modules and Accessories Einschubmodule und Zubeh r Modules enfichables et accessoires Table 1 Table Tabelle Tableau 1 Table Tabelle Tableau 1 Description Beschreibung Name Namen Part Number Teilenummer Revision R vision Nom R f rence VME Digital I O Board DIO 10332 00800 gt P2 Digitales Ein Ausgabemodul Carte d entr es sorties VME VME Graphics Board Graphik VGB 10332 10250 gt P3 Modul Carte graphique VME VME Joint Interface Board EJI 10332 00505 gt A Achssteuerkarte Carte d axe VME Motion Interface Board MI3 10332 11400 gt P4 Achssteuerkarte Carte MI6 10332 12400 gt P2 d interface Mouvement VME AWC Processor Board AWC 040 10332 00714 gt P1 AWC Prozessormodul AWC 060 10332 00716 gt P1 Carte processeur AWC VME Vision Board Vision modul VIS 10332 00600 gt P2 Module d interface vision VME EVI 10332 00655 gt P1 Camera Kamera Cam ra 15600 00090 gt A Optional AUX SIO Board SIO 30332 12350 gt P2 AUX SIO Modul SIO 30332 12351 gt P2 Module AUX SIO SIO IDE 30332 22350 gt A SIO IDE 30332 22351 gt A Table 2 Table Tabelle Tableau 2 Table Tabelle Tableau 2 De
307. ure or flow will cause the brakes to engage which will disable High Power CAUTION Failure to supply clean dry oil free air may result in damage to mechanical electrical or pneumatic components inside the robot The user must supply all tubing and fittings to plumb the facility air supply to the robot The robot is supplied with an air filter with a standard 1 4 inch Industrial Interchange nipple 1 4 NPT type thread The compressed air to the robot must meet the specifications listed above Also see Figure 7 7 on page 148 WARNING The compressed air supply must be fed from a source that normally remains ON during an emergency stop Disconnecting the air supply will prevent the brake release from operating In an emergency the brake release may be required to release or gain access to a person trapped in the workcell Any manually operated isolation valves that could be used to interrupt the compressed air supply to the robot should be clearly labeled to indicate that the supply should be left ON in an emergency NOTE An air filter is supplied in the robot accessory kit and should be installed on the robot prior to connecting the compressed air supply 44 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Facility Requirements Mounting Surface Specifications The floor at the installation site must be concrete with a minimum thickness of 100 mm 4 in and must comply with all national and local codes The floor shou
308. utput Specifications JSIO CONNECTION 6 ees 175 JSIO Digital I O Connector Pin Assignments 0 00 00 00 cee 177 LED Status INGICOTONS sx a he Dot beca bf t nt 183 Robots With More Than 6 AXES 2 eee ees 220 Recommended Preventive Maintenance Schedule oo o o o 221 Adept MV Controller Fuse Ratings iiie een 233 Controller Spare Parts List From Adept ens 240 Controller Spare Parts List From Third Parties lise 240 PASA Spare ROMs lists 5o emassa tet pet Rope hob T RDUM xen freut 241 IP 54 and Adept XL Clean Room Robot Spare Parts LiSt 241 AdeptOne XL Robot Performance Specifications 0 0 0 0 oo 260 AdeptOne XL Robot Softstop and Hardstop SPECS 06 isses 261 AdeptThree XL Robot Performance Specifications s issus 262 AdepltThree XL Robot Softstop and Hardstop SPECS saaa esses 263 Power Consumption for PA 4 Power Chassis 0000 cece ees 264 Arm Power Harting Connector Pin Identification ooooo o o 266 Motor Winding Resistance Check suasana 267 Pipe Fitting Flow Equivalents in Feet of Straight Pipe 271 IP 54 Hardware Upgrade Kit 274 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Safety The Adept XL robots are four axis SCARA robots see Figure 1 1 Joints 1 2 and 4 are rotational joint 3 is translational See Figure 1 2 for a description of the robot joint locations The Adept XL robots requir
309. w to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance with your Adept software or hardware You can obtain this document through Adept On Demand The phone numbers are 800 474 8889 toll free 503 207 4023 toll call Please request document number 1020 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 41 Chapter 1 Safety 1 19 Related Manuals This manual covers the installation and maintenance of an Adept XL robot system There are additional manuals that cover programming the system reconfiguring installed components and adding additional optional components The following manuals available on the documentation CD ROM provided with each system provide information on advanced configurations and system specifications Table 1 8 Related Manuals Manual Title Description Adept MV Controller User s Guide 00330 01040 Describes the configuration and interface options for all Adept supplied processor boards and components that can be installed in an Adept control system AdeptWindows User s Guide 00963 07300 Describes complex network installations installation and use of NFS server software the Adept Windows Offline Editor and the AdeptWindows DDE software Instructions for Adept Utility Programs 00963 00000 Describes the utility programs used for advanced system configurations system upgrades file copying and other system configuratio
310. y be configured so they operate differently or they may not be configured at all Place your robot in a safe location and cycle the gripper to verify which side of the speed bar opens the gripper Tool State When tool state is selected movement in the X Y or Z direction is along an axis of the tool coordinate system The tool coordinate system is centered at the robot tool flange with the Z axis pointing away from the flange On most robots the positive X axis is aligned with the center of the tool flange keyway Before the speed bars will move the robot an axis of motion must be selected from the manual control buttons If X1 is selected pressing the speed bar will move the robot tool flange in the positive X direction Pressing the speed bar will move the flange in the negative X direction In a four axis robot positive rotation of the gripper RZ is clockwise as viewed from above Figure 9 14 shows the tool coordinate system for a four axis SCARA robot The SPEC utility is used to configure gripper activity See the Instructions for Adept Utility Programs 214 AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C Moving a Robot or Motion Device With the MCP Figure 9 15 shows the tool coordinate system on a six axis robot NOTE Figure 9 14 and Figure 9 15 are drawn with the assumption that the TOOL transformation is set to NULL all values are 0 If a TOOL transformation is in effect the tool c
311. y depending upon the program being run See the documentation for your application programs for details on these buttons Figure 9 3 shows the function buttons Data Entry Buttons The data entry buttons shown in Figure 9 4 are used to input data normally in response to prompts that appear on the pendant display The data entry buttons include YES NO DEL the numeric buttons 0 9 the decimal point and the REC DONE button These buttons are similar to the numeric keypad on a standard keyboard REC DONE Button Behaves like the Return or Enter key on a standard keyboard When data entry is complete pressing REC DONE sends the entry to the controller In many cases application programs have users press the REC DONE button to signal that they have completed a task DEL Button Behaves like the backspace key on a standard keyboard When data is being entered it will appear on the pendant display DEL will delete any characters that appear on the pendant display but have not been entered using the REC DONE button Application programs may also assign special functions to the DEL button Figure 9 4 Data Entry Keys Mode Control and Joint Axis Control Buttons The mode control and joint axis control buttons are used to control the robot from the pendant The use of these buttons is covered in Moving a Robot or Motion Device With the MCP on page 210 Speed Bars and Slow Button The speed bars an
312. you do not have the MMSP option on your robot you can skip the rest of this chapter and go to Chapter 9 WARNING These tests must be performed only by skilled or instructed persons Commissioned vs Not Commissioned As shipped from Adept the system is marked as not commissioned meaning the Category 3 components must be tested prior to system operation The brake solenoids and dump valves have been tested at the factory Prior to operating the robot in the Manual mode the system must be marked as commissioned The system is marked as commissioned only after the SAFE_UTL utility is executed and all tests pass If any of the tests fail carefully note any messages and then repeat the test If the failure persists contact Adept Customer Service NOTE Testing all Category 3 components requires approximately 40 minutes Attempting to enable High Power on a system marked as not commissioned while the MANUAL AUTO key switch is in the manual position will produce the following error message User has not tested Cat 3 system Switch can t be enabled AdeptOne XL AdeptThree XL Robot Instruction Handbook Rev C 185 Chapter 8 Verifying the System Installation Starting the SAFE_UTL Utility To perform the necessary tests the SAFE_UTL utility must be run Follow the steps below to load and execute the program 1 Remove all end effectors from the quill flange 2 Load the utility program into system m

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