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Adept Cobra s800 Inverted Robot User`s Guide

1. 123 5 338 0 mm 13 31 in 387 6 mm 15 26 in Minimum Radial PEL S Reach Cartesian R 167 0 mm Limits 6 58 in 314 0 mm 12 36 in Figure 7 7 Standard Robot Working Envelope Max Radial Reach Functional Area R 800 mm 31 50 in Max Instrusion Contact Radius R 852 12 mm 33 548 in Minimum Radial reach R 179 90 mm 7 083 in Ars Uu is ie s E d R 375 NT R 375 Cartesian Limits 324 mm 12 76 in Figure 7 8 IP 65 Robot Working Envelope Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 111 of 142 Chapter 7 Technical Specifications 7 2 Cobra s800 Inverted Robot Internal E STOP Connections SmartController Connections Cobra s800 Inverted Internal Connections XSLV 2 XSYSTEM 8 XSLV 6 XSYSTEM 14 29 XSLV 7 XSYSTEM 30 44 Force Guided Relay Cyclic Check Control Circuit To XSYS on SmartController ESTOPSRC ESTOPGND XSLV 1 XSYSTEM 17 HPWRREQ XSLV 5 XSYSTEM 34 Single Phase AC Input High Power to 200 240 VAC Amplifiers Force Guided Force Guided Figure 7 9 Internal E STOP Connections Diagram 7 3 XSYS XSYSTEM Connector Table 7 1 XSYS to XSYSTEM Connector Pinout eAIB only xsys XSYSTEM T l E SIS na comment lere ESTOP GND E Sto
2. 4X Q 14 Thru 2XR4 0o v6 160 80 i 10 L 5 i 7 a L 189 160 50 L o i Oe L 0 015 90 107 28 0 000 TR L 205 Figure 2 2 Robot Mounting Dimensions NOTE On the robot mounting surface there is a hole and a slot that can be used as locating points for user installed dowel pins in the mounting surface Using locating pins can improve the ability to remove and reinstall the robot in the same position Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 21 of 142 Chapter 2 Robot Installation Mounting Procedure e Always use at least two people and preferably three to mount the robot e The robot should be in the folded position when lifting See the following figure 183 2 500 778 Figure 2 3 Robot in Folded Position WARNING Do not attempt to extend the inner or outer links of the robot until the robot has been secured in position Failure to comply could result in the robot falling and causing either personnel injury or equipment damage Table 2 2 Mounting Bolt Torque Specifications Metric M12 x P1 75 ISO Property Class 8 8 S5Nm Nm EN 14 UNC SAE J429 Grade 5 or 65 ft Ibf ASTM A449 1 Using the dimensions shown in Figure 2 2 drill and tap the mounting surface for four M12 175 x 36 mm or 7 16 14 UNC x 1 50 in machine bolts bolts not provided See the previous table for bolt and torque specifications 2 Remove th
3. CAMERA RS 232 TERM RS 422 485 Eth 10 100 ooo coo E DER RS 232 1 RS 232 2 e la l Ne vs xFP XMcP Xpci xoc2 7 Y 7 d P xs SmartController CX ELT ENCOI Figure 1 4 Adept SmartController EX CX sDIO Module The optional sDIO module provides 32 optical isolated digital inputs and 32 optical isolated outputs and also includes an IEEE 1394 interface 1 2 Dangers Warnings Cautions and Notes in Manual There are six levels of special alert notation used in Adept manuals In descending order of importance they are DANGER This indicates an imminently hazardous electrical situation which if not avoided will result in death or serious injury DANGER This indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING This indicates a potentially hazardous electrical situation which if not avoided could result in injury or major damage to the equipment Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 14 of 142 Chapter 1 Introduction WARNING This indicates a potentially hazardous situation which if not avoided could result in injury or major damage to the equipment CAUTION This indicates a situation which if not avoided could result in damage to the equipment NOTE Notes provide supplementary information emphasize a point or procedu
4. 3 z 4 Wrist Motors 44tem collection Default Hand Open Signal 3001 Default Hand Close Signal 3002 Enable Brake Release Input False Controller Controller 106 Controller 106 Motion Specifications Timing Specifications E End Effector Selected End Effector Controller 106 Gripper R1 Cobra600 E Location OffsetFromParent 0 000 0 000 0 000 0 000 0 000 0 000 Motors List of robot motors Note that Motor 1 of the robot is element 0 Figure 6 27 Robot Editor with Joint 2 Expanded 5 Highlight the current values for joint 2 and replace them with the new values See the following table for recommended softstop values Table 6 8 Joint 2 Ranges for Adjustable Hardstops lay Hardstop Value Joint Limit Softstop J2 Hardstop Position 1 J2 Hardstop Position 2 J2 Hardstop Position 3 6 Once you have modified the upper and lower joint limit softstops you must reboot the system by cycling 24 VDC power to the SmartController The new joint limits will be in affect when the system reboot is done Recommended 81 Lower limit 80 Upper limit 80 51 Lower limit 50 Upper limit 50 4 21 Lower limit 20 Upper limit 20 NOTE J2 Hardstops can be installed in a number of positions depending on how the robot workcell needs to be configured The positions are spaced 30 apart Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 104 of 142 Chapter 7 Technical Specifications 7
5. p equivalent GND Pin 2 Signal 3004 GND Figure 6 7 OP3 4 and SOLND Circuits EOAPWR Connector This 4 pin connector see the following table provides 24 VDC power and ground for user applications See the following table for the pinouts and Table 6 4 for the output specifications Table 6 3 EOAPWR Connector Pinout mma peserotion pin toeten 1 24 VDC see Table 6 4 for current specs 2 3 24 VDC see Table 6 4 for current specs 4 pu pU as viewed on robot Mating Connector AMP Tyco 172167 1 4 pin Mini Universal Mate N Lok AMP Tyco 770985 1 Pin Contact Mini Univ Mate N Lok Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 81 of 142 Chapter 6 Optional Equipment Installation Internal User Connector Output Specifications The output specifications in the following table apply to the EOAPWR OP3 4 and SOLND internal user connectors Table 6 4 Internal User Connector Output Circuit Specifications mar ewe Power supply voltage range See Table 3 2 Operational current range per L E 700 mA channel i Total Current Limitation all los 1 0 A 50 C ambient channels on Lu Fs lt 1 5 A 25 C ambient On state resistance I 0 5 A R x03209 e 859 C out on Output leakage current Iu 25 uA Turn on response time 125 usec max 80 usec typical hardware only Turn off response time 60 usec max 28 usec typical hardware only Output Ww at inductive load V 65
6. 6 Use Add or Edit to set the values for DeviceNet 7 The fields that need to be entered are e Index a unique number for this mapping e Byte usually starts at 1 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 92 of 142 Chapter 6 Optional Equipment Installation e This is the input or output block where mapping starts A byte refers to 8 inputs or outputs so if you are using two 8 channel input blocks byte 1 would be the first input block and byte 2 the second e Bit usually starts at 1 e This is the bit within the byte where mapping starts To map the first input of an 8 channel input block this would be 1 e Signal the input or output signal number e g 1013 or 013 where mapping starts e Bit_length the number of input or output signals to map e MACID the MACID returned by the Scan 8 When you are finished click Done 9 Check that the assignments worked correctly by opening the Digital I O tab The new signals should show up as being mapped now 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 that have screw terminals in the plug to allow the user to make custom cables VIEWED FROM CONTACT END 4 3 5 1 2 B Male C
7. Chapter 5 Maintenance WARNING Lockout and tagout power before servicing WARNING The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons as defined in the Adept Robot Safety Guide The access covers on the robot and the AIB and eAIB are not interlocked turn off and disconnect power if these have to be removed 5 3 Checking Safety Systems These tests should be done every six months 1 Test operation of e E Stop button on Front Panel e E Stop button on the optional pendant e Enabling switch on the optional pendant e Auto Manual switch on Front Panel NOTE Operating any of the above switches should disable high power 2 Test operation of any external user supplied E Stop buttons 3 Test operation of barrier interlocks etc 5 4 Checking Robot Mounting Bolts Check the tightness of the base mounting bolts after one week and then every 6 months Tighten to 85 N m 65 ft lbf Also check the tightness of all cover plate screws Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 56 of 142 Chapter 5 Maintenance 5 5 Checking for Oil Around Harmonic Drives The Cobra s800 Inverted robot uses oil in its harmonic drive components for lubrication It is a good idea to periodically inspect the robot for any signs of oil in areas around the harmonic drive Check these locations e the area around Joint 1 e the area around Joint 2 e insi
8. The connection panel for Cleanroom robots is modified to accommodate the vacuum lines needed Users will still have use of the two 6 mm and three 4 mm air lines as well as the I O connections and DeviceNet port The 3 4 in vacuum fitting is a high flow low vacuum port The 3 8 in vacuum fitting is used to evacuate the bellows area of the robot 8 3 Requirements Table 8 1 Cleanroom Robot Requirements Recommended Volumetric Flow Rate P ER 3 4 inch NPT female fitting 0 20 m min 7 ft min aem e at the back of the robot 0 3 inHg 1 0 kpa pressure in 3 8 inch NPT female fitting 0 05 m min 1 6 ft min 18 at the back of the robot inHg 61 0 kpa pressure Quill inside diameter The inside diameter of the quill must be plugged by the user s end effector in order for sufficient vacuum to develop in the outer link The vacuum lines provided must maintain the listed vacuums as measured at the robot when the robot and vacuum lines are connected Adept recommends that you install in line vacuum gauges at the robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 118 of 142 Chapter 8 Cleanroom Robots 8 4 Exclusions and Incompatibilities Table 8 2 Internally Mounted Hand Valves Installation considerations The internal air line normally used to supply the internally mounted hand valves Adept Option Kit P N 02853 000 is instead used to provide vacuum to the bellows outer link One of the exte
9. V de V 45 turnoff U 0 5 A Load 1 mH DC short circuit current limit 07A lt ia lt 25A d NOTE Total current is the sum of the output current used by output signals 3001 3004 SOLND and OP3 4 and any user current drawn from EOAPWR ESTOP Connector The Break away E Stop function is provided to enable a high power shutdown from the outer link area For example it would be used if you want a break away gripper to shut down robot high power It lets you disable high power through a user relay circuit inside the robot The 2 pin ESTOP connector provides a pair of contacts that can be used for a Break away E Stop function at the end of the arm See the following table The function is disabled by default when the system is shipped The user must enable this function using the Adept ACE software see below and connect a normally closed circuit to Pins 1 and 2 When the circuit is opened the system will stop in an E Stop condition See the following table and figure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 82 of 142 Chapter 6 Optional Equipment Installation Table 6 5 ESTOP Connector Pine H eminem ESTOP Connector as viewed on robot Mating Connector AMP Tyco 172165 1 2 pin Mini Universal Mate N Lock AMP Tyco 770985 1 Pin Contact Mini Univ Mate N Lok Typical ESTOP Connector Circuit User supplied normally closed contact A LU an be connected to a break a
10. inputs See Using Digital I O on Robot XIO Connector on page 45 for connector pin allocations for inputs and outputs That section also contains details on how to access these I O signals via V eV DB26 high density female The following connections are different on the AIB and the eAIB XSYSTEM eAIB only includes the functions of the XPANEL and XSLV on the AIB This requires either an adapter cable to connect to the XSYS cable or an eAIB XSYS cable which replaces the XSYS cable For details see Cable Connections from Robot to SmartController on page 30 XPANEL DB26 high density male AIB only used only with Cobra i series robots for connecting the front panel and MCP circuit XSLV DB 9 female AIB only for connecting the supplied XSYS cable from the controller XSYS connector XBELTIO eAIB only adds two belt encoders EXPIO at the back of the robot which is not available on an AIB and an RS 232 interface RS 232 DB 9 male AIB only used only with Cobra i series robots for connecting a system terminal Ethernet x2 eAIB only these are not used with the SmartController CX and are not currently used with the SmartController EX Adept Cobra s800 Inverted Robot User s Guide Reo H1 Page 25 of 142 Chapter 3 System Installation 3 1 System Cable Diagram li IEEE 1394 Cable G MIR Controller SmartServo Port 1 1 to AIB eAIB SmartServo Adept Cobra s800 Inverted Robot Adept SmartControll
11. 1 Dimension Drawings IS Ka amp imm Cu a 425 1715 a La 800 0 e 278 5 Figure 7 1 Top and Side Dimensions Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 105 of 142 Chapter 7 Technical Specifications 509 5 l 231 7 do o MEA 7 e 0 E Required clearance to open AIB eAIB with the IP 65 connector Cable sealing box on IP 65 version only 375 4 Figure 7 2 IP 65 Top and Side Dimensions NOTE Other dimensions for the IP 65 version are the same as shown in Figure 7 1 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 106 of 142 Chapter 7 Technical Specifications 4X M4x0 7 6H V 10 Figure 7 3 Dimensions of the Camera Bracket Mounting Pattern Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 107 of 142 Chapter 7 Technical Specifications 12 0 mm 0 47 in See Detail A 3 0 mm 0 12 in
12. 9 How Can I Get Help RM 17 Related Mamuals 22 020 sosteenin tia R neve place Bons aR aT a rar a 18 Adept Document Library 2 2 2 20 2222220 ce cece eee eee eee cece eee s I eeee sees riran rninn 18 Chapter 2 Robot Installation 19 21 Transport and Storage aeaa aR cacti eta eh eile dation an sedate deasa aa 19 22 Unpacking and Inspecting the Adept Equipment ee 20 Before Unpacking 22 sra R NSZ 9 22 0 R 260 bie RE S dade trated eee ed dete etek dle edd eae 20 Upon Unpacking ox ccsice settee pedeadeccniaes tulad sdadevedads ck vk dur ba zc Ordre lee eededes i EO dnd 20 2 3 Repacking for Relocation oci oesoaue edenda Anna ool duane dyed cea Pest ican Atak edonlals 20 24 Environmental and Facility Requirements eee eee 20 25 Mo ting the BODOE 22 ac aes ai ee cte persise aes ikea aan ide Ipae keels 21 Mounting Surfaces E at eG Daeg ek ee eee ee ee ee Sees a 21 Mounting Procedure E 22 2 6 Connectors on Robot Interface Panel 24 Chapter 3 System Installation 27 3 1 System Cable Wisi rats i201 secon As See cates ietev Ip east i orra rrara 27 32 Cable arid Parts List E 28 3 3 Installing the SmartController iiec eode ee oma eere o3 epe echte pisani Ris co sa dec ePi ped ede ts 28 3 4 Connecting User Supplied PC to Robot 29 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 5 of 142 Table of Contents PC Requirements 222 2225 sceeete 29 3 5 Installing Adept ACE Software eee 29 3
13. Hardware Delay then click Next 3 Enable high power if not already enabled then click Next 4 Press an E Stop button on the Front Panel then click Next The utility will confirm that the hardware delay has been verified for this robot and display the delay times for channels A and B 5 Reboot the SmartController On some systems the SmartController will reboot automatically Teach Restrict Configuration Utility This utility sets the hardware Teach Restrict maximum speed parameter to factory specifications NOTE Ensure that the commissioning jumper is plugged into the XBELTIO jack on the eAIB before you start this procedure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 68 of 142 Chapter 5 Maintenance Procedure NOTE This procedure takes 2 or 3 minutes to complete From within the Adept ACE software 1 Open the robot object editor 2 Select Configure gt Safety Settings gt Configure Teach Restrict then click Next 3 From the Prerequisite screen click Next The wizard will go through all of the robot s motors and display messages that it is configuring Channel A and B for each It will then record the configuration and display the target times that it set 4 Click Finish 5 Reboot the SmartController On some systems the SmartController will reboot automatically Teach Restrict Verification Utility This utility verifies that the Teach Restrict parameters are set correctly and th
14. Joint 3 to the top of its travel Remove any existing Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 57 of 142 10 Chapter 5 Maintenance grease with a clean lint free soft cloth Using a syringe apply a small bead of grease to the Joint 3 ball screw grooves see Figure 5 1 Press the brake button and move Joint 3 to the bottom of its travel Remove any existing grease with a clean lint free soft cloth Apply a thin film of grease to any grooves of the ball screw that you did not reach in step 4 Move Joint 3 up and down several times to spread the grease evenly Remove 24 VDC power from the robot Reinstall the outer link cover For the Cleanroom and IP 65 versions replace the bellows Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 58 of 142 Chapter 5 Maintenance Joint 3 Ball Screw Lubrication Points Joint 3 Ball Screw Lubrication Points Upper Quill Grease Locations Lower Quill Grease Locations Quill Shaft Vertical Groove Lube Point A Pm cud Vertical Groove p Lube Point B NOTE Apply grease to the three vertical grooves Vertical Groove and the spiral groove Lube Point C Section A A Figure 5 1 Lubrication of Joint 3 Quill Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 59 of 142 Chapter 5 Maintenance 5 7 Replacin
15. Power Supply 24 VDC 204V 8A User Supplied Shielded Attach shield from user Power Cable supplied cable to ground screw on Cobra s800 24V 5A Inverted robot interface panel m Frame Ground Attach shield from user supplied cables to frame Adept SmartController Attach shield from user supplied ground on power supply cable to side of controller using star washer and M3 x 6 screw User Supplied Shielded Power Cable Figure 3 2 User Supplied 24 VDC Cable NOTE In order to maintain compliance with EN standards Adept recommends that DC power be delivered over a shielded cable with the shield connected to the return conductors at both ends of the cable 3 8 Connecting 200 240 VAC Power to Robot WARNING Appropriately sized branch circuit protection and Lockout Tagout capability must be provided in accordance with the National Electrical Code and any local codes Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 33 of 142 Chapter 3 System Installation Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system Specifications for AC Power Table 3 5 Specifications for 200 240 VAC User Supplied Power Supply Recommended Frequency External Circuit Phasing Breaker User Supplied Auto Ranging Minimum Maximum Nominal Voltage Operating Operating Ranges 200 V to 240 V 180 V 264 V 50 60 Hz 1 phase 10
16. Robot User s Guide Rev H1 Page 47 of 142 Chapter 4 System Operation Typical Input Wiring Example Adept Supplied Equipment equivalent circuit ww Signal 1097 PA Signal 1098 User Supplied Equipment Note all Input signals Signal 1099 2 Signal 1100 L co Signal 1101 e e Signal 1102 e Bank 1 Common 24 V BER GND Signal 1103 e Wiring Terminal Typical User can be used for either Input Signals sinking or sourcing ER configurations rm Part Present Sensor Feeder Empty Sensor S e D pty e Part Jammed Sensor S ow S e e Sealant Ready Sensor S 3 i cx lt S amp 5 kd 5 cu S os o 5 S S cx S hi E d S Signal 1104 e XIO Connector 26 Pin Female D Sub Signal 1105 Signal 1106 Signal 1107 Signal 1108 Bank2 12 o Common GND e e e sindu dNd Bunos JO peunBijuoo Z yueg MEM Input Bank2 24 V 6 0 0 0 Figure 4 5 Typical User Wiring for XIO Input Signals NOTE The OFF state current range exceeds the leakage current of XIO outputs This guarantees that the inputs will not be turned on by the leakage current from the outputs This is useful in situations where the outputs are looped back to the inputs for monitoring purposes XIO Output Signals The eigh
17. Table 3 1 Creating 24 VDC Cable 1 Locate the connector and pins from Table 3 4 2 Use 14 16 AWG wire to create the 24 VDC cable Select the wire length to safely reach from the user supplied 24 VDC power supply to the robot base NOTE You also must create a separate 24 VDC cable for the SmartController That cable uses a different style of connector For details see the Adept SmartController User s Guide 3 Crimp the pins onto the wires using the crimping tool recommended in Table 3 4 4 Insert the pins into the connector Confirm that the 24 V and ground wires are in the correct terminals in the plug 5 Prepare the opposite end of the cable for connection to your user supplied 24 VDC power supply Installing 24 VDC Robot Cable 1 Connect one end of the shielded 24 VDC cable to your user supplied 24 VDC power supply See the following figure The cable shield should be connected to frame ground on the power supply Do not turn on the 24 VDC power until instructed to do so in Turning on Power and Starting Adept ACE on page 53 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 32 of 142 Chapter 3 System Installation 2 Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the back of the robot The cable shield should be connected to the ground point on the interface panel For details see the following figure Adept Cobra s800 Inverted Robot User Supplied
18. clears the robot base see the following figure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 60 of 142 Chapter 5 Maintenance Figure 5 3 Opening and Removing Chassis 12 A support bolt for hanging the chassis p n 07116 000 is provided in the Accessory Kit e Unscrew the plug from the hole in the side of the robot body left side as viewed from the AIB eAIB see the following figure e Screw the support bolt into the side of the robot body Support Bolt Hole Figure 5 4 Support Bolt Hole 13 Carefully move the AIB eAIB chassis to the side of the robot base and hang it from the support bolt as shown in the following figure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 61 of 142 Chapter 5 Maintenance Figure 5 5 Chassis Hanging from Support Bolt AIB Shown 14 Disconnect the white amplifier cable from the amplifier connector located on the chassis bracket see the following figure Amplifier Connector PMA Board Figure 5 6 Connectors on Chassis Frame and PMAI ePMAI Board AIB shown NOTE Use care when disconnecting the AIB eAIB cables from the PMAI ePMAI board in the following steps Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 62 of 142 Chapter 5 Maintenance 15 Carefully disconnect the following cables from their connectors on the PMAI ePMAI board by disengaging the securing latches e INTI e INT2 e ENC1 e ENC2 16 Disconnect and
19. connection to the facility AC power source Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 36 of 142 Chapter 3 System Installation Removable Bushing Cable Clamp Line Neutral Figure 3 5 AC Power Mating Connector Installing AC Power Cable to Robot 1 Connect the unterminated end of the AC power cable to your facility AC power source For details see Figure 3 3 and Figure 3 4 Do not turn on AC power at this time 2 Plug the AC connector into the AC power connector on the interface panel on the robot 3 Secure the AC connector with the locking latch 3 9 Grounding the Adept Robot System Proper grounding is essential for safe and reliable robot operation Follow these recommendations to properly ground your robot system Ground the Robot Base The user can install a ground wire at the robot base to ground the robot See Figure 3 6 for the ground point The robot ships with an M8 x 12 stainless steel hex head screw and M8 split and flat washers installed in the grounding hole The user is responsible for supplying the ground wire to connect to earth ground Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 37 of 142 Chapter 3 System Installation Ground Point on Robot Base with M8 x12 screw and washers installed Figure 3 6 Ground Point on Robot Base standard robot shown See Installing 24 VDC Robot Cable on page 32 for additional system grounding informat
20. details see the next section The braking system will not prevent you from moving the robot manually once the robot has stopped and high power has been removed In addition Joint 3 has an electromechanical brake The brake is released when high power is enabled When high power is turned off the brake engages and holds the position of Joint 3 Programmable E Stop Delay To set the programmable E Stop delay from the ACE software go to the object editor for the robot and enable Expert Access Object Expert Access NOTE This requires a password to enable Once enabled you will be able to see and modify the following three parameters among others e Auto Mode E Stop Shutdown Timeout e Hold to Run E Stop Shutdown Timeout e Manual Mode E Stop Shutdown Timeout Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 41 of 142 Chapter 4 System Operation Each of these is the time in seconds after that mode E Stop is asserted in which V eV is allowed to decelerate the robot engage the brakes and shut down power before the servo nodes automatically shut down power The value can be set from 0 immediate power off to 0 512 seconds If the deceleration is too slow or the brake on delay too long the servo will automatically cut power Brake Release Button Under some circumstances you may want to manually position Joint 3 on the Z Axis without turning on high power For such instances a Z Brake Release button
21. does not have to be symmetrical Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 99 of 142 Chapter 6 Optional Equipment Installation Joint 2 Adjustable Hardstop Plates Installed in Position 1 Figure 6 22 Joint 2 Adjustable Hardstop Locations Joint 2 Left Hardstop Plate installed in 81 degree position Joint 2 Fixed Hardstop Device Joint 2 Positive direction Joint 2 Negative direction 12 thru holes for M5 x 10 screws for installing Joint 2 hardstops located 30 degrees apart Joint 2 Right Hardstop Plate installed in 81 degree position View of under side of Inner Link looking up Figure 6 23 Screw Locations for Joint 2 Adjustable Hardstops 5 Usea 4 mm hex wrench to install four M5 x 10 screws with lock washers to secure each plate Tighten the screws to 4 5 N m 40 in Ib Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 100 of 142 Chapter 6 Optional Equipment Installation 6 Repeat the process for the second plate Note that the plates can be installed in multiple different positions depending on how much you need to limit the range of Joint 2 7 For IP 65 version installations e There will now be one or two gaps between the ends of the adjustable hardstop plates e Cut one of the IP 65 arcs
22. is located on the robot status panel see Figure 4 2 When system power is on pressing this button releases the brake which allows movement of Joint 3 NOTE 24 Volt robot power must be ON to release the brakes If this button is pressed while high power is on high power will automatically shut off WARNING When the Brake Release button is pressed Joint 3 may drop to the bottom of its travel To prevent possible damage to the equipment make sure that Joint 3 is supported while releasing the brake and verify that the end effector or other installed tooling is clear of all obstructions 4 4 Front Panel Manual Auto 4 Mode Mode STOP Figure 4 3 Front Panel 1 XFP connector Connects to the XFP connector on the SmartController 2 System 5 V Power On LED Indicates whether or not power is connected to the robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 42 of 142 Chapter 4 System Operation 3 Manual Automatic Mode Switch Switches between Manual and Automatic mode In Automatic mode executing programs control the robot and the robot can run at full speed In Manual mode the system limits robot speed and torque so that an operator can safely work in the cell Manual mode initiates software restrictions on robot speed commanding no
23. joint motion in mm or deg Figure 6 19 Robot Editor with Joint 1 Expanded 5 Highlight the current values for joint 1 and replace them with the new values See the following table for recommended softstop values for Position 1 or Position 2 Table 6 7 Joint 1 Ranges for Adjustable Hardstops 93 5 Lower limit 92 5 Upper limit 92 5 114 Lower limit 113 Upper limit 113 6 Once you have modified the upper and lower joint limit softstops you must reboot the system by cycling 24 VDC power to the SmartController The new joint limits will be in affect when the system reboot is done Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 97 of 142 Chapter 6 Optional Equipment Installation Joint 2 Adjustable Hardstops The Joint 2 Adjustable Hardstop see the following figure consists of two curved plates that are the adjustable hardstops a small black rectangular block that is the fixed hardstop and the screws required to install them The adjustable hardstop plates can be installed in different locations depending on how much you need to limit the Joint 2 range of motion L A E Figure 6 20 Joint 2 Hardstops NOTE The Joint 2 Adjustable Hardstop requires extra steps to be installed on the IP 65 version of the Cobra s800 Inverted IP 65 Installation The adjustable hardstop plates cover 8 of the 12 holes in the inner link at Joint 2 The other 4 holes must be covered with pieces fr
24. rleiPerR Nexed eo ee ATEO NEEE RERS TES 81 Internal User Connector Output Specifications e e e III 82 ESTOP ConnmectOM 22 3 m lpinccleeiiiitcll Aalen le e toed es pated eth ated hee te aoe se cete Les rre Lt 82 65 Mounting Locations for External Equipment e 84 6 6 Installing Robot Solenoid Kit 85 Introduction zio ea dri Dee ee ee a Ei a SEE eee 85 Tools Reg ired aaae R aa aa aod A RRR aR pee pa 2 tae 86 EGG ce T fees EO ER R 86 6 7 Installing Camera Bracket Kt 90 Mitro ductio T 90 Tools Reguit d 505 ceo cen cts aie e eE Eene sde ee Ardea Eae Macias Saeed seek Iraide TRIES 90 Procedure Em 90 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 7 of 142 Table of Contents 6 8 DeviceNet Communication Link 1 oy cece ececdh ee cacetddpeee II kseub ee eben RU plese eden kei 91 Recommended Vendors for Mating Cables and Connectors see 93 69 Installing Adjustable EIsrdstops u seni obs is suse qoe Ee Eae nonna epe eame Oran 94 Joint 1 Adjustable Hardstops ssssssssssssssssssllllllllllls sss sess sess ll rtl tel 94 Joint 2 Adjustable Hardstops o cecece 22 le eee cee e epo eee d cocaine eas 98 Chapter 7 Technical Specifications 2 ooo ce eee eee 105 71 Dimension Drawings sese eee eee 105 7 2 Cobra s800 Inverted Robot Internal E STOP Connections 0 2 20 20 2222220 112 7 3 XSYSINSYSEBM Connector c2cec ioe cobtcnc ots a idedncs wicket s icsa denis tdacelaeaelcespeseeie 112 74 XSLV Conne
25. safe to turn on power to the robot system System Cable Checks Verify the following connections e Front Panel to the SmartController e Pendant to the SmartController via the pendant adapter cable e User supplied 24 VDC power to the controller e User supplied ground wire between the SmartController and ground e One end of the IEEE 1394 cable into the SmartServo port 1 1 connector on the SmartController and the other end into the SmartServo connector on the robot interface panel e XSYS cable between the XSYS connector on the SmartController and the robot interface panel XSLV connector AIB or eAIB XSLV adapter and XSYSTEM connector eAIB with the latching screws tightened or Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 52 of 142 Chapter 4 System Operation eAIB XSYS eAIB cable between the robot interface panel XSYSTEM connector and XSYS connector on the SmartController and the latching screws tightened See Cable Connections from Robot to SmartController on page 30 e User supplied 24 VDC power to the robot 24 VDC connector e User supplied 200 240 VAC power to the robot 200 240 V AC connector User Supplied Safety Equipment Checks Verify that all user supplied safety equipment and E Stop circuits are installed correctly Turning on Power and Starting Adept ACE After the system installation has been verified you are ready to turn on AC and DC power to the system and start up Adept ACE 1 Manually
26. the other could use Position 2 or none Modifying Joint Limit Softstop Locations for Joint 1 After installing the adjustable hardstops you must modify the softstop locations using the Adept ACE software Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 94 of 142 Chapter 6 Optional Equipment Installation 1 From Adept ACE select the robot in the tree structure pane 2 Open the robot editor Figure 6 17 Robot Editor with Joints Closed 3 Click the in front of Joints to display all of the joints Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 95 of 142 Chapter 6 Optional Equipment Installation 0 000 0 000 0 000 0 000 0 000 0 000 Figure 6 18 Robot Editor with Joints Expanded 4 Click the in front of 1 to open the values for joint 1 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 96 of 142 Chapter 6 Optional Equipment Installation f Controller 106 R1 Cobra600 True True 1 4 item collection Shoulder 105 105 2 Elbow 3 Z EJ 4 Wrist Motors 4 item collection Default Hand Open Signal 3001 Default Hand Close Signal 3002 Enable Brake Release Input False Controller Controller 106 Controller 106 Motion Specifications Timing Specifications Controller 106 Gripper R1 Cobra600 0 000 0 000 0 000 0 000 0 000 0 000 User minimum and maximum limits for
27. through hole in the tool flange and can be used as a keying or anti rotation device in a user designed end effector If hazardous voltages are present at the end effector you must install a ground connection from the base of the robot or the outer link to the end effector For details see Grounding Robot Mounted Equipment on page 38 NOTE A threaded hole is provided on the tool flange see Figure 7 4 The user may attach a ground wire through the quill connecting the outer link and the tool flange 6 2 Removing and Installing the Tool Flange The tool flange can be removed and reinstalled If the flange is removed it must be reinstalled in exactly the same position to avoid losing the calibration for the system There is a setscrew on the flange that holds the rotational position of the flange on the quill shaft A ball bearing behind the setscrew contacts the shaft in one of the vertical spline grooves in the shaft Follow the procedures that follow to remove and reinstall the flange assembly Removing the Flange 1 Turn off high power and system power to the robot 2 Remove any attached end effectors or other tooling from the flange 3 Use a 2 5 mm hex driver to loosen the setscrew see Figure 6 1 4 Note the vertical spline groove that is in line with the setscrew You must replace the flange in the same position 5 Use a socket driver to loosen the two M4 socket head screws 6 Slide the flange down slowly until it is off
28. void your warranty Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 132 of 142 Chapter 9 IP 65 Option 9 7 User Connectors User Electrical and DeviceNet On the back of the robot base above the AIB eAIB the user electrical IO Blox and DeviceNet connectors are fitted with removable plugs at the factory see the following figure If you use any of these connectors you must provide a seal see following note at the connection to prevent moisture from entering the robot NOTE The user electrical connector DB 25 and the IO Blox connector DB 9 above the AIB eAIB require a gel seal gasket to maintain an adequate seal The gaskets are supplied in the Accessory Kit p n 04860 000 User Electric DeviceNet IO Blox IP 65 Compressed Air Fitting 4 mm Air Lines 6 mm Air 3x Lines 2x Figure 9 9 User Connectors on Robot Base capped covered The user electrical and DeviceNet connectors on the outer link are accessible with the cover removed The following figure shows the locations of the internal connectors See Removing Installing Outer Link Cover on page 128 for instructions on removing and re installing the outer link cover 4 mm Air Line 6 mm Air Line DeviceNet User Electric 4 mm Air Line 2 Spare Air Lines Figure 9 10 IP 65 Internal Connectors with Outer Link Cover Removed Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 133 of 142 Chapter 9 IP 65 Option User
29. 1 Page 38 of 142 Chapter 4 System Operation 4 1 Robot Status LED Description The robot Status LED indicator is located at the top of the status panel as shown in the following figure The blinking pattern indicates the status of the robot The current robot model supports the UL standard The LED on this robot is amber For details see the following figure and table Robot Status LED Indicator Figure 4 1 Robot Status LED Indicator Location Table 4 1 Status LED Definitions on UL Certified Robots ot No display 24 VDC not present See Status Panel Fault Codes on page 40 for information on Fault Codes Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 39 of 142 Chapter 4 System Operation 4 2 Status Panel Fault Codes The status panel shown in the following figure displays alpha numeric codes that indicate the operating status of the robot including detailed fault codes Table 4 2 gives meanings of the fault codes These codes provide details for quickly isolating problems during troubleshooting The displayed fault code will continue to be displayed even after the fault is corrected or additional faults are recorded All displayed faults will be cleared from the display and reset to a no fault condition upon successfully enabling high power to the robot or power cycling the 24 V supply to the robot Z Brake Release Status Panel Button for Displaying Fault Codes Figure 4 2 Status Panel T
30. 43 mm 1 69 in JE a 4 03 mm r7a 41 15 mm 50 mm A y 001 in 1 620 in 569i Dowel Pin Hole 01 mm 63 0 mm 2 48 in mm 6 0 mm V 4 0005 in 0 2362 in 0 in C BC 50 0 mm 1 9685 in 4X M6 x 1 6 H Thru User Ground E 004 in AMI B omm Lodin H T E JC M R 3 56 mm R 0 140 in Y 5 08 mm 0 20 in M3 X 0 5 6 H Thru 4 14 mm 0 163 in N ae 1 5mm 0 059 in 6 80 mm tT 0 268 in ERN i i N c 25 Detail A Figure 7 4 Tool Flange Dimensions See Figure 9 7 for a diagram of the IP 65 version tool flange Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 108 of 142 Chapter 7 Technical Specifications 278 5 Figure 7 5 External Tooling on Top of Robot Arm Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 109 of 142 Chapter 7 Technical Specifications 34 Outer Link Bottom View 4X M4x0 7 6H v 8 Figure 7 6 External Tooling on Underside of Outer Link Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 110 of 142 Chapter 7 Technical Specifications Max Radial Reach Functional Area R 800 0 mm 31 50 in Max Intrusion Contact Radius R 847 3 mm 33 36 in
31. 6 Cable Connections from Robot to SmartController 000000000000000000000000000000001 30 3 7 Connecting 24 VDC Power to Robot 31 Specifications for 24 VDC Power see ee e K 31 Details for 24 VDC Mating Connector e 515000511501 n rrn 31 Creating 24 VDC A T 32 Installing 24 VDC Robot Cable LL desde see cR bide ddeeaceseentdtess sigedseactdacstenearete 32 3 8 Connecting 200 240 VAC Power to Robot 33 Specifications for AC PoWer i col descccloleseducseclocbeuecPeN i pP eases dea she RA e t PERDE 34 Details for AC Mating Connector ee ss n nm IIeIr3i3f3l22222 36 Creating the 200 240 VAC Cable see 36 Installing AC Power Cable to Robot s 37 39 Grounding the Adept Robot System e 37 Ground the Robot Base cheno ac cpece ego ea d ie ac e RET E eaae e E epe e ln ME onu Odds sane 37 Grounding Robot Mounted Equipment ee e e sss e ettet 38 3 10 Installing User Supplied Safety Equipment 2 2 2020e0e0eeceeee cece eeeeeeeees 38 Chapter 4 System Operation 39 4 1 Robot Status LED Description e 39 4 2 Status Panel ino x 40 ce MM POE 41 Programmable E Stop Delay 222222 2220 22 eee eee eee cece eee eee 115051 roire irienn 41 Brake Release Button 2 3 2 5 eese lam ences dese eid oad cea e apes awed buds tiene een saa da ade 42 AA Front Panel ese ER sec ease cs colt ee ERE PRENNE 42 45 Connecting Digital I O to the System lt 1 2 ati cease ees reo aer dap ees ee Sacked 43 Us
32. 9 2 Modifications to Meet IP 65 Classification Outer link The Cobra s800 Inverted robot has different seals for the IP 65 version The outer link cover has been widened slightly to accommodate a larger seal The user connections are not available from the outside of the outer link on the IP 65 version Rather the outer link cover must be removed to access these connections and the connections continue through the quill rather than outside of the outer link Refer to Removing Installing Outer Link Cover on page 128 AIB eAIB Cable Seal The cables entering the AIB eAIB have a special seal assembly to achieve IP 65 classification This is covered in Removing Installing the Cable Entry Housing on page 124 and Installing the Roxtec Cable Seal Assembly on page 135 Controller This chapter applies to the Adept Cobra s800 Inverted robot not to the Adept SmartController NOTE The Adept SmartController must be installed inside a NEMA 1 rated enclosure Hard Stop Rotation Range Because the outer link cover has been widened it cannot rotate as far as the standard inverted Cobra The hard stop has been enlarged to limit the outer link s rotation at J2 to prevent the outer link from hitting the robot body Refer to Table 7 4 for specifications for both Cobra versions 9 3 AIB eAIB Cable Seal Overview There are two sealing assemblies for the AIB eAIB cables One is a Roxtec Cable Seal Assembly It consists of dense foam with adju
33. Adept Cobra s800 Inverted Robot User s Guide Adept Cobra s800 Inverted Robot User s Guide P N 06937 000 Rev H1 May 2013 5960 Inglewood Drive Pleasanton CA 94588 USA Phone 925 245 3400 Fax 925 960 0452 adept Otto Hahn Strasse 23 44227 Dortmund Germany Phone 49 231 75 89 40 Fax 49 231 75 89 450 Block 5000 Ang Mo Kio Avenue 5 05 12 Techplace Il Singapore 569870 Phone 65 6755 2258 Fax 65 6755 0598 Copyright Notice The information contained herein is the property of Adept Technology Inc and shall not be reproduced in whole or in part without prior written approval of Adept Technology Inc The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology Inc The documentation is periodically reviewed and revised Adept Technology Inc assumes no responsibility for any errors or omissions in the documentation Critical evaluation of the documentation by the user is welcomed Your comments assist us in preparation of future documentation Please submit your comments to techpubs adept com Copyright 2007 2013 by Adept Technology Inc All rights reserved Adept the Adept logo the Adept Technology logo AdeptVision AIM Blox Bloxview FireBlox Fireview Meta Controls MetaControls Metawire Soft Machines and Visual Machines are registered trademarks of Adept Technology Inc Brain on Board is a registered trademark of Adept Te
34. Air Lines On the back of the robot base the user air line connectors are fitted with removable plugs at the factory see Figure 9 9 The user air line connectors on the outer link are accessible with the cover removed See Figure 9 10 for locations of the internal connectors See Removing Installing Outer Link Cover on page 128 for instructions on removing and re installing the outer link cover CAUTION Failure to prevent water intrusion through improperly sealed external fittings will void your warranty Robot Solenoid Option In an IP 65 robot if you are installing the internally mounted solenoid valves Adept Option Kit p n 02853 000 you must use a different air line than described in Installing Robot Solenoid Kit on page 85 The internal air line normally used to supply the solenoid manifold is instead used to provide positive airflow pressure to the bellows and outer link You can use one of the passive 6 mm user air lines shown in Figure 9 9 and Figure 9 10 for the solenoid connection 9 8 Maintenance Replacing IP 65 Bellows Check the bellows Adept p n 04625 000 periodically for cracks wear or damage Replace bellows if necessary using the following procedure 1 Remove the lower bellows clamp by removing two M3 screws and pulling the clamp apart See Figure 9 11 2 Remove the tool flange Refer to Removing and Installing the Tool Flange on page 75 for the tool flange removal procedure 3 Remove the upper b
35. Amps Specifications are established at nominal line voltage Low line voltage can affect robot performance Table 3 6 Typical Robot Power Consumption Average RMS Current Peak Power Power W A W 8 5 77 For short durations 100 ms NOTE The Adept robot system is intended to be installed as a piece of equipment in a permanently installed system Many parts of Europe use an impedant neutral DANGER AC power installation must be performed by a skilled and instructed person refer to the Adept Robot Safety Guide During installation unauthorized third parties must be prevented from turning on power through the use of fail safe lockout measures WARNING Adept systems require an isolating transformer for connection to mains systems that are asymmetrical or use an isolated impedant neutral Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 34 of 142 Chapter 3 System Installation Facility Overvoltage Protection The user must protect the robot from excessive overvoltages and voltage spikes If the country of installation requires a CE certified installation or compliance with IEC 1131 2 the following information may be helpful IEC 1131 2 requires that the installation must ensure that Category II overvoltages i e line spikes not directly due to lightning strikes are not exceeded Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overv
36. CE software onto the PC and connects it to the robot via an Ethernet cable PC Requirements To run and use Adept ACE software the following hardware and software are required NOTE The specifications are also listed in the ACE PackXpert Datasheet available on the Adept corporate website Hardware e Processor Core2Duo 2 0 GHz or better e Disk Space 500 MB recommended minimum e RAM 2 GB or more e Monitor SVGA minimum resolution 800 x 600 e Ethernet IEEE 1394 or Gigabit Ethernet support Software e Operating System Microsoft Vista 32 bit Microsoft Windows XP with Service Pack 2 Microsoft Windows Server 2003 with Service Pack 1 or Microsoft Windows 2000 with Service Pack 4 e Microsoft NET Framework 2 0 or later included in the installation of the Adept ACE installer Microsoft Internet Explorer version 5 01 or later necessary for viewing Online help 3 5 Installing Adept ACE Software You install Adept ACE from the Adept Software CD ROM Adept ACE needs Microsoft NET Framework The Adept ACE Setup Wizard scans your PC for NET and installs it automatically if it is not already installed 1 Insert the CD ROM into the CD ROM drive of your PC If Autoplay is enabled the Adept Software CD ROM menu is displayed If Autoplay is disabled you will need to manually start the CD ROM 2 Especially if you are upgrading your Adept ACE software installation from the Adept Adept Cobra s800 Inverted Robot
37. Cable Seal Assembly Figure 9 2 IP 65 Cable Entry Housing Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 125 of 142 Chapter 9 IP 65 Option Cable Entry Inner Housing Gasket Cable Body Entry Housing Center Gasket Figure 9 3 Exploded View of Cable Entry Housing Seal Assembly Gaskets are shaded Removing the Cable Entry Housing Cover The cable entry housing cover is attached to the cable entry housing body with four screws The Roxtec cable seal assembly is attached to the cable entry housing cover See Figure 9 3 and Figure 9 4 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 126 of 142 Chapter 9 IP 65 Option Cable Entry Housing Body Center Gasket Cable Entry Housing Cover Roxtec Cable Seal Figure 9 4 Cable Entry Housing with Cover Removed CAUTION Do not remove the Roxtec cable seal assembly To remove the cable entry housing cover remove the four M6 screws holding the cover to the body and carefully lift the cover e The gasket between the cover and body is attached to the body with adhesive Leave the gasket in place It will be reused for reassembly e The cables will still be attached to the AIB eAIB The connections to the AIB eAIB are now accessible under the cover Disconnect the AIB eAIB connections and remove the cable entry housing cover and cable assembly Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 127 of 142
38. Chapter 9 IP 65 Option Installing the Cable Entry Housing Cover NOTE The cable entry housing body must have been installed before installing the cable entry housing cover 1 Ensure that the gasket is between the cable entry housing cover and body attached to the body with adhesive Refer to the Center Gasket Figure 9 3 Check for any signs of damage to the gasket If damaged it must be replaced The gasket is p n 04821 001 2 Make all connections to the AIB eAIB before attaching the cover 3 Attach the cable entry housing cover to the body with four M6 screws Removing the Cable Entry Housing Body The cable entry housing cover must be removed before removing the cable entry housing body 1 Remove the four M4 x 50 screws holding the cable entry housing body to the AIB eAIB 2 Remove the cable entry housing from the AIB eAIB The gasket between the AIB eAIB and body is attached to the body with adhesive Leave the gasket in place It will be reused for reassembly Installing the Cable Entry Housing Body 1 Ensure that the gasket is between the AIB eAIB and the cable entry housing body attached to the body with adhesive Refer to the Inner Gasket Figure 9 3 Check for any signs of damage to the gasket If damaged it must be replaced The gasket is p n 04820 000 2 Attach the cable entry housing body to the AIB eAIB with four M4 x 50 screws 9 5 Removing Installing Outer Link Cover The IP 65 robot outer link cover
39. IO Termination Block Installation Guide for details XIO Input Signals The 12 input channels are arranged in two banks of six Each bank is electrically isolated from the other bank and is optically isolated from the robot s ground The six inputs within each bank share a common source sink line The inputs are accessed through direct connection to the XIO connector see Table 4 5 or through the optional XIO Termination Block See the documentation supplied with the Termination Block for details The XIO inputs cannot be used for REACTI programming high speed interrupts or vision triggers See the V Language User s Guide for information on digital I O programming Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 46 of 142 Chapter 4 System Operation XIO Input Specifications Table 4 6 XIO Input Specifications Operational voltage range OFF state voltage range ON state voltage range Typical threshold voltage Operational current range OFF state current range ON state current range Impedance V 3 9 KO minimum Turn on response time hardware 5 psec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time Turn off response time hardware 5 usec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time NOTE The input current specifications are provided for reference Voltage sources are typically used to drive the inputs Adept Cobra s800 Inverted
40. If a three phase power source is used it must be symmetrically earthed with grounded neutral Connections called out as single phase can be wired Line to Neutral or Line to Line Details for AC Mating Connector The AC mating connector is supplied with each system It is shipped in the cable accessories box The supplied plug is internally labeled for the AC power connections L E N Table 3 7 AC Mating Connector Details AC Connector details AC in line power plug straight female screw terminal 10 A 250 VAC Qualtek p n 709 00 00 TH Digi Key p n Q217 ND NOTE The AC power cable is not supplied with the system but is available in the optional Power Cable kit listed in Table 3 1 Creating the 200 240 VAC Cable 1 Locate the AC mating connector shown in Table 3 7 2 Open the connector by unscrewing the screw on the shell and removing the cover 3 Loosen the two screws on the cable clamp see Figure 3 5 4 Use 18 AWG wire to create the AC power cable Select the wire length to safely reach from the user supplied AC power source to the robot base 5 Strip 18 to 24 mm insulation from each of the three wires 6 Insert the wires into the connector through the removable bushing 7 Connect each wire to the correct terminal screw and tighten the screw firmly 8 Tighten the screws on the cable clamp 9 Replace the cover and tighten the screw to seal the connector 10 Prepare the opposite end of the cable for
41. MPa 28 114 0 19 0 786 Tools Required e Assorted hex drivers e Cable ties e Diagonal wire cutters e Solenoid Valve Upgrade Kit Adept p n 02853 000 Procedure 1 Turn off all power to the robot 2 Remove three screws on each side of the outer link cover Remove two screws on top and remove the cover For the IP 65 version refer to Removing Installing Outer Link Cover on page 128 3 Connect the Internal Solenoid Valve Cable assembly to the Solenoid Manifold assembly by plugging the SOL 1 connector into Valve 1 and SOL 2 into Valve 2 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 86 of 142 Chapter 6 Optional Equipment Installation Spare air line Connector for the solenoid valves Pem nuts to mount the solenoid manifold Figure 6 11 Solenoid Mounting Bracket with Connector and Spare Air Line 4 Cut and discard the cable ties holding the spare air line at the top of the mounting bracket Move the air line away to facilitate the mounting of the solenoid manifold see Figure 6 11 5 Mount the solenoid manifold onto the bracket using the supplied M3 x 25 mm screws and washers see Figure 6 12 6 Insert the spare air line into the air intake coupling of the solenoid manifold Make sure the air line is pushed in all the way and secured in place by the intake coupling Confirm by pulling the air line NOTE If you are installing on an IP 65 robot the spare air line is used for a diffe
42. Robot User s Guide Rev H1 Page 120 of 142 Chapter 8 Cleanroom Robots Lubrication The upper and lower sections of the quill require lubrication in the same manner as the standard Cobra s800 Inverted robot See Lubricating Joint 3 Ball Screw on page 57 Remove the bellows before lubrication Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 121 of 142 Chapter 9 IP 65 Option 9 1 IEC IP 65 Classification The factory installed IP 65 version provides an improved level of dust and water protection IP 65 means dust tight and protection against low pressure water jetting e Dust Resistance protection of the equipment inside the robot shell against ingress of solid foreign objects e Specifically for IP 65 Dust Protection No ingress of dust is allowed e Water Resistance protection of the equipment inside the robot shell against harmful effects due to the ingress of water e Specifically for IP 65 Water Protection Water projected in jets against the robot enclosure from any direction shall have no harmful effects Figure 9 1 Adept Cobra s800 Robot IP 65 Version NOTE If ordered the IP 65 option comes from the factory pre installed These instructions cover disassembly and reassembly for maintenance or for access to the user connections which are inside the outer link in the IP 65 version Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 123 of 142 Chapter 9 IP 65 Option
43. Signal 3002 Break away E stop Enable False Enable Brake Release Input False Calibration File scobra cal Controller SmartController 84 SmartController 84 21 Matinn Cnacific abiane Figure 6 9 Screen Shot with Break away E Stop Parameter Field NOTE When the Break away E Stop function has been enabled you must connect a normally closed circuit to pins 1 and 2 of the ESTOP connector as described above If this is not done the system will be in an E Stop condition and you will not be able to enable power 6 5 Mounting Locations for External Equipment Two locations are provided for mounting the user s external equipment on the robot arm The first location is on the top side of the outer link and the second is on the bottom side of the outer link Each location has four tapped holes See Figure 7 5 and Figure 7 6 for the dimensions NOTE The cover on the outer link must be removed for maintenance lubrication so keep this in mind when mounting any external equipment to the outer link cover Also see Installing Camera Bracket Kit on page 90 for information on mounting cameras on the robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 84 of 142 Chapter 6 Optional Equipment Installation 6 6 Installing Robot Solenoid Kit Introduction This procedure describes how to mount the 24 V solenoid option kit on an Adept Cobra s800 Inverted robot The solenoid kit is available as Adept p n 02853 000 The robot
44. User s Guide Rev H1 Page 29 of 142 Chapter 3 System Installation ACE software CD ROM menu click Read Important Information 3 From the Adept Software CD ROM menu click Install the Adept ACE Software 4 The Adept ACE Setup wizard opens Follow the instructions as you step through the installation process 5 When the install is complete click Finish 6 After closing the Adept ACE Setup wizard click Exit on the CD ROM menu and proceed to the Start up Procedure NOTE You will have to restart the PC after installing Adept ACE 3 6 Cable Connections from Robot to SmartController The following cables are shipped in the cable accessories box e Locate the IEEE 1394 cable length 4 5 M e For an AIB system locate the XSYS cable e For an eAIB system locate the eAIB XSYS cable or eAIB XSLV adapter cable which can be used with an existing XSYS cable Install one end of the IEEE 1394 cable into the SmartServo port 1 1 connector on the SmartController and the other end into a SmartServo connector on the AJB or eAIB interface panel as shown in Figure 3 1 AIB only e Install the XSYS cable between the robot interface panel XSLV safety interlock connector and XSYS connector on the SmartController and tighten the latching screws eAIB only e For a new SmartController system with an eAIB the system will be supplied with a 15 ft 4 5 m cable with connectors for XSYS DB9 on one end and XSYSTEM DB44 on the other Connec
45. able 4 2 Status Panel Code IO Blox Fault Address AC Power Fault Duty Cycle Exceeded Joint Power System Fault Code Processor Overloaded RSC Fault Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 40 of 142 Chapter 4 System Operation Status Code Encoder Fault Joint Status Code E Stop Delay Fault External Sensor Stop Firmware Mismatch Code 10 For more information on status codes go to the Adept Document Library on the Adept website and in the Procedures FAQs and Troubleshooting section look for the Adept Status Code Summary document Dus Dus 4 3 Brakes The robot has a braking system that decelerates the robot in an emergency condition such as when the emergency stop circuit is open or a robot joint passes its softstop 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 customizable feature allows the motors to decelerate under servo control to a stop This can aid in eliminating coasting or overshooting on low friction mechanisms It can also aid in the reduction of wear on highly geared high inertia mechanisms while maintaining safety compliance per all standards The Programmable E Stop delay can be set up in Adept ACE in the robot editor The default setting is correct for most applications For
46. al Equipment Installation 12 Disconnect the tubing from the 6 mm User Air fitting shown in Figure 6 13 Fold the tubing out of the way 13 Insert the spare air line into the back of the empty 6 mm User Air fitting Figure 6 13 NOTE This 6 mm User Air connector and the 6 mm User Air connector in Figure 6 3 are not functional for other uses after this modification 14 Replace the User Connector Panel cover taking care to ensure that all tubing is inside the cover and nothing gets crimped or pinched while pushing the cover into position Replace four screws to secure the cover Tighten the screws to 1 6 N m 14 in Ib 15 Replace the outer link cover and tighten the screws to 1 6 N m 14 in lb Refer to Removing Installing Outer Link Cover on page 128 for IP 65 version torque values 16 Connect the factory air supply to the 6 mm User Air connector For the non IP 65 robot this is the air connector just modified 17 From the Adept ACE software a Click the Digital I O button in the controller toolbar gt SmartControler Smartc Z amp xal The Digital I O window will open 0 Digital 1 0 SmartController SmartController x gt 1 Show M Outputs M Inputs M Robot I Soft Custom 3001 3016 9449 4444 b Check Robot c Select Signal 3001 and Signal 3002 the first two blocks to activate the solenoids one at a time d The selected blocks will turn green to indicate they are active Adep
47. amera mount to the camera channel using M5 x 12 mm screws Camera Plate Camera Brackets optional Camera Channel Figure 6 14 Mounting a Camera on the Robot 6 8 DeviceNet Communication Link DeviceNet is a communications link that connects industrial I O devices to a message packeting network All nodes 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 Cobra s series robot e Male micro style 12 mm thread DIN connector at the robot base see Figure 6 2 e Female micro style 12 mm thread DIN connector for joint 2 of the robot see Figure 6 5 and Figure 6 15 e A non standard DeviceNet cable consisting of two shielded twisted pairs that connect the base and joint 2 connectors Adept considers this cabling to be a drop line with a maximum total length of 6 meters 20 feet and therefore uses the following wire sizes Adept DeviceNet thin cable amo prave Signal pairs 28 AWG 24 AWG This means that total current on the power pairs must be limited to 2 A instead Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 91 of 142 Chapter 6 Optional Equipment Installation of the standard 3 A 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 achi
48. anel on the back of Joint 1 for user electrical lines see Figure 6 3 This connector is wired directly to a 25 pin female connector on the top of the outer link see Figure 6 4 These connectors can be used to run user electrical signals from the user panel through the robot and up to the outer link NOTE The connectors shown in Figure 6 4 are not available on the outside of this link for the IP 65 version of the Cobra s800 Inverted Refer to User Connectors on page 133 Wire Specifications Wire size 0 1 mm 27 AWG Pin Numbers 1 24 12 pairs twisted in pairs as 1 amp 2 3 amp 4 5 amp 6 23 amp 24 Maximum current per line 1 Amp 6 4 Internal User Connectors The internal user connectors OP3 4 EOAPWR and ESTOP can be accessed with the outer link cover removed see Figure 6 5 The SOLND connector is located on the opposite of the bulkhead area see Figure 6 6 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 78 of 142 Chapter 6 Optional Equipment Installation OP3 4 EOAPWR J3 BRK ESTOP Figure 6 5 Internal User Connectors OP3 4 EOAPWR ESTOP WARNING When the outer link cover is removed you see the label shown above Do not remove the J3 ENC or J4 ENC encoder cable connectors from their sockets If they are removed the calibration data will be lost and the robot must be run through a factory recalibration process which requires special software and tools SOLND Connector Figur
49. at the hardware Teach Restrict maximum speed control is working This is a two part wizard The first is run in Auto mode The second is run in Manual mode Before running this verification utility the Teach Restrict must be configured NOTE If the commissioning jumper is plugged into the XBELTIO jack on the eAIB remove it before you start this procedure Automatic Mode Procedure WARNING The robot will move during this wizard Ensure that personnel stay clear of the robot work area From within the Adept ACE software 1 Open the robot object editor 2 Select Configure Safety Settings Verify Teach Restrict then click Next 3 Teach a Start Position This can be any position that does not conflict with obstacles or the limits of joint movements e If the robot is already in such a position you can just click Next e Otherwise move the robot to such a position then click Next Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 69 of 142 Chapter 5 Maintenance e The screen will display the number of degrees that each joint is expected to move during the verification process e You can click Preview Motions on this screen to view the motions at slow speed The default speed is 10 but you can change that speed with this screen s speed control e You can click Move to Ready to move the robot to the Ready position The robot will move each joint in succession It will generate an over speed condition f
50. ations Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 19 of 142 Chapter 2 Robot Installation 2 2 Unpacking and Inspecting the Adept Equipment Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit If any damage is indicated request that the carrier s agent be present at the time the container is unpacked Upon Unpacking Before signing the carrier s delivery sheet please compare the actual items received not just the packing slip with your equipment purchase order and verify that all items are present and that the shipment is correct and free of visible damage If the items received do not match the packing slip or are damaged do not sign the receipt Contact 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 17 Retain all containers and packaging materials These items may be necessary to settle claims or at a later date to relocate equipment 2 3 Repacking for Relocation If the robot or other equipment needs to be relocated reverse the steps in the installation procedures that appear in this chapter Reuse all original packing containers and materials and follow all safety notes used for installation Improper packaging for shipment will void your warranty Sp
51. button on the Front Panel within 10 seconds The Front Panel is shown in Figure 4 3 If the button stops blinking you must Enable Power again NOTE The use of the blinking High Power button can be configured or eliminated in software Your system may not require this step This step turns on high power to the robot motors and calibrates the robot The Robot Status LED glows amber The code on the Robot Diagnostic Panel displays ON see Figure 4 2 Verifying E Stop Functions Verify that all E Stop devices are functional pendant Front Panel and user supplied Test each mushroom button safety gate light curtain etc by enabling high power and then opening the safety device The High Power push button light on the Front Panel should go out for each Verify Robot Motions Use the pendant if purchased to verify that the robot moves correctly Refer to your Adept pendant user s guide for complete instructions on using the pendant If the optional pendant is not installed in the system you can move the robot using the Robot Jog Control in the Adept ACE software For details see the Adept ACE User s Guide 4 7 Learning to Program the Robot To learn how to use and program the robot see the Adept ACE User s Guide which provides information on robot configuration control and programming through the Adept ACE software point and click user interface For V eV programming information refer to the V eV user and ref
52. chnology Inc in Germany Adept ACE Adept AIB Adept Cobra s800 Inverted Adept eAIB Adept SmartController CX Adept SmartController EX Adept T2 Adept T20 eV and V are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Created in the United States of America Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 4 of 142 Table of Contents Chapter 1 Introduction sse 11 14 Product Description IER raia eee need R pe eb H RSI d 9 tee 90 11 Adept Cobra s800 Inverted Robots 22 a cce RRR Se be cepe TecI IIl TRR RR ne se steed a KI NR RR eti 11 Adept AIB eAIBIM cieli eOe AAEE S e EEO eE OARE EE AA EREA 12 Adept SmartController cisco te duende eM etes det hee Ele etl bod LER ER 13 12 Dangers Warnings Cautions and Notes in Manual 14 1 3 Safety Pr cautionS c 15 1 4 What to Do in an Emergency Situation 20220200 cece nce e eee eee eee eeeeeeees 15 1 5 Additional Safety Information eee eee 15 Manufacturer s Declaration of Compliance MDOC 2 222222222 cece eee eee cece e eee 16 Adept Robot satety Guide reads icetonccacopbans ARA E A A a REE dR 16 1 6 Intended Use of th Robots goeccc0950 8 2c lei Erde eoa thes cece tees Cech engi nana 16 1 7 Installation Overview sooo 5 ts t ies ose eters ce casi set ec oat tated ap het gio eee ee 16 1 8 Manufacturer s Declaration 17 1
53. ctor eee eee 113 79 MM NODOE Specifications isrener o e Hag Taa ATN RAN Tahan 113 Chapter 8 Cleanroom Robots 117 8 1 Cobra s800 Inverted Cleanroom Option see 117 Intro duchOn sessen 2 sts cededlenacedsesedeeSensdeade ss mies camnaderd ose cee aa eaa 117 8 2 COMMECHONS sssr rios r ess oie 3 ear bison uU etd eee phen sere duke 118 8 3 Requirements 2 60 02 0ec edd detest obe eene eee ide dete ex See e eect eee 118 84 Exclusions and Incommpatibilities ee 119 8 5 Maintenance aaa 9229 3979 2992 e a a P RR ERRA H Raa AA NHAT 119 Bellows Replacement aa Zro T ar he sie et Ss eke E EaR degen E ed eet he ea 119 PEMD TICALION sarees EE ECOUTER IER LIH 121 Chapter 9 IP 65 Option 123 9 1 IEC IP 65 Classification 220 2020 0 002 o eee sess ese sn re e e eee 123 9 2 Modifications to Meet IP 65 Classification 124 Outer lnk 2 22 o2co di ees abode todd de ee Ube Lo iodels oth ee eld Rc ERIS DberiicilgEes 124 AIB eAIB Cable TT 124 Controller 124 Hard Stop Rotation Range e 124 9 3 AIB eAIB Cable Seal Overview onus colts de alerts nner Rb eres IE Hed pEE 124 94 Removing Installing the Cable Entry Housing 124 Removing the Cable Entry Housing Cover e llle esses sessi 126 Installing the Cable Entry Housing Cover e 222222222 cece cece cence cece cece eeeeeeeeeeeeee 128 Removing the Cable Entry Housing Body 128 Installing the Cable Entry Housing Body 128 95 Removing installing Outer Link Cov
54. ctric Air line pass through 6 mm diameter 2 quantity 4 mm diameter 3 Electrical pass through 24 conductors 12 twisted pairs Weight without options 51 kg 112 Ib gt The robot tool performs continuous path straight line motions 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and back along the same path COARSE is enabled and BREAKs are used at each end location Not achievable over all paths Table 7 4 Softstop and Hardstop Specifications Hardstop approximate Joint 2 IP 65 version 1585 0 a 210 mrm T 5 to 215 mm Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 115 of 142 Chapter 8 Cleanroom Robots 8 1 Cobra s800 Inverted Cleanroom Option Introduction The Adept Cobra s800 Inverted robot is available in a Class 10 Cleanroom model This option is a factory installed configuration Adept part number 09854 000 Changes to the robot include the addition of a bellows assembly mounted at the Joint 3 quill fully sealed access covers and a vacuum system to evacuate the volume within the robot Figure 8 1 Adept Cobra s800 Cleanroom Robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 117 of 142 Chapter 8 Cleanroom Robots 8 2 Connections 4 gt User Electrical port ee DeviceNet port 3 8 in FPT 4 amp Airlines 2 x 6 mm O f b 7 mne E D 3 4 in FPT I O Blox port 3x4mm Figure 8 2 Cleanroom Connections
55. d the Adept ACE commissioning For a new system with an eAJB the robot and the eAIB will have been commissioned at the factory and should not need commissioning If you are replacing an AIB with an eAIB you will need to commission the system In rare cases with a new robot with an eAIB you may need to commission the system e If the system will not power up and the robot status display shows SE you need to commission the system e If the system will not power up in Manual mode and the robot status display shows TR you need to commission the system Safety Commissioning Utilities The Adept eAIB adds two functions that implement safety in hardware e E Stop This serves as a backup to the standard software E Stop process The system will always try to stop the robot using the software E Stop first The hardware E Stop will take over in the event of a failure of the software E Stop e Teach Restrict Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 65 of 142 Chapter 5 Maintenance This limits the maximum speed of the robot when it is operated in Manual mode As with the E Stop this is a hardware backup to software limits on robot speed If the software fails to limit the robot speed during manual operation the hardware Teach Restrict will disable power to the system These two functions are only in the eAIB amplifiers They were not implemented in hardware in the AIB amplifiers so these utilities do not a
56. de the base of the robot by opening the AIB eAIB chassis and inspecting internally Be sure to remove all power to the robot before opening the AIB eAIB chassis Contact Adept if you find any signs of oil in these areas 5 6 Lubricating Joint 3 Ball Screw Use LG 2 Lubricating Grease Lithium Soap Synthetic Hydrocarbon Adept part number 90401 04029 CAUTION Using improper lubrication products on the Adept Cobra s800 Inverted robot may cause damage to the robot Lubrication Procedure 1 Turn off main power to the controller and robot Lock out and tag out power 2 Remove the outer link cover by removing six screws located on the sides and top of the cover Carefully remove the cover WARNING When the Outer link cover is removed you see the label shown in Figure 2 3 Do not remove the J3 ENC or J4 ENC encoder cable connectors from their sockets If they are removed the calibration data will be lost and the robot must be run through a factory recalibration process which requires special software and tools For the IP 65 version refer to Removing Installing Outer Link Cover on page 128 for instructions on removing the link cover and Replacing IP 65 Bellows on page 134 for instructions on removing the bellows For the Cleanroom version refer to Maintenance on page 119 for instructions on removing the bellows The outer link cover is standard 3 Switch on 24 VDC power to the robot 4 Press the brake button and move
57. dept home page To go directly to the Adept Document Library type the following URL into your browser http www adept com Main KE DATA adept search htm To locate information on a specific topic use the Document Library search engine on the ADL main page To view a list of available product documentation use the menu links located above the search field Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 18 of 142 Chapter 2 Robot Installation 2 1 Transport and Storage This equipment must be shipped and stored in a temperature controlled environment within the range 25 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 the following figure The robot must always be stored and shipped in an upright position in a clean dry area that is free from condensation Do not lay the crate on its side or any other position this could damage the robot The robot weighs 51 kg 112 Ib with no options installed Place forklift here ice Figure 2 1 Robot on a Transportation Pallet WARNING Use a forklift or pallet jack to lift the robot on its transportation pallet Do not lift the robot from other loc
58. dure have not changed If you need to disconnect the inner link from the robot base for service for example you can preserve the Joint 2 motor encoder information by installing a backup battery in the inner link see Installing an Encoder Battery in the Inner Link on page 73 Battery Replacement Time Periods If the robot is kept in storage and not in production or the robot is turned off no 24 VDC supply most of the time then the battery should be replaced every 5 years If the robot is turned on with 24 VDC supplied to the robot more than half the time then you can increase the replacement interval to a maximum of 10 years NOTE Dispose of the battery according to all local and national environmental regulations regarding electronic components Battery Replacement Procedure 1 Obtain the replacement battery pack 2 Switch off the SmartController Switch off the 24 VDC input supply to the robot Pe M Switch off the 200 240 VAC input supply to the robot 5 Disconnect the 24 VDC supply cable from the robot 24 VDC input connector see Figure 2 5 for locations of the connectors 6 Disconnect the 200 240 VAC supply cable from the robot AC input connector 7 Using a 5 mm hex key carefully unscrew the AIB or eAIB chassis securing screw see Figure 5 2 Note that the screw does not need to be completely removed in order to remove the chassis as this screw is captured on the chassis heat sink 8 While holding the c
59. e 6 6 SOLND Connector Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 79 of 142 Chapter 6 Optional Equipment Installation SOLND Connector This 4 pin connector provides the output signals for the optional Robot Solenoid Kit See Installing Robot Solenoid Kit on page 85 for installation details Table 6 1 SOLND Connector Pinout CO NANNNNLT 3 as viewed on robot Mating Connector AMP Tyco 172167 1 4 pin Mini Universal Mate N Lok AMP Tyco 770985 1 Pin Contact Mini Univ Mate N Lok OP3 4 Connector This 4 pin connector see Figure 6 5 provides the output signals for a second set of optional robot valve solenoids or other user supplied devices For details see the following table and Figure 6 7 Table 6 2 OP3 4 Connector Pinout mma Deserndon L OP3 4 Connector Mating Connector AMP Tyco 172167 1 4 pin Mini Universal Mate N Lok AMP Tyco 770985 1 Pin Contact Mini Univ Mate N Lok Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 80 of 142 Chapter 6 Optional Equipment Installation SOLND Connector Circuit D For optional Robot Solenoid Kit installation or 24VDC other user supplied devices West Signal 3001 equivalent circuit GND Signal 3002 GND OP3 4 Connector Circuit For optional second set of solenoids or 24VDC other user supplied devices circuit
60. e four screws on top of the wooden robot base protection box see Figure 2 4 e Remove the robot base protection box Retain the four screws and box for possible later relocation of the equipment Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 22 of 142 Chapter 2 Robot Installation Robot base protection box Place forklift here Place pallet jack underneath the pallet Figure 2 4 Robot on a Transportation Pallet 3 While the robot is still bolted to the transportation pallet use a forklift or other mechanical lifting device to lift the robot and position it directly under the mounting surface Make sure that one person watches the robot carefully as it is lifted and transported to ensure it does slip or become unbalanced WARNING The center of mass of the robot may cause the robot to fall over if the robot is not secured to the pallet 4 Slowly lift the robot while aligning the base and the tapped mounting holes in the mounting surface 5 Install but do not tighten the user supplied mounting bolts and washers CAUTION The base casting of the robot is aluminum and can easily be dented if bumped against a harder surface NOTE Verify that the robot is mounted squarely will not rock back and forth before tightening the mounting bolts 6 Remove the bolts securing the robot to the pallet e Retain these bolts for possible later relocation of the equipment s Move the pallet out of the way 7 Tigh
61. ecify this to the carrier if the robot is to be shipped CAUTION Before unbolting the robot from the mounting surface 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 as shown in Figure 2 1 2 4 Environmental and Facility Requirements The Adept robot system installation must meet the operating environment requirements shown in the following table Table 2 1 Robot System Operating Environment Requirements Ambient temperature 5 to 40 C 41 to 104 F Pollution degree 2 EC 1131 2 EN 61131 2 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 20 of 142 Chapter 2 Robot Installation Robot protection class ISO Cleanroom rating cleanroom model only ISO 4 Fed Reg Class 10 NOTE See Dimension Drawings on page 105 for robot dimensions 2 5 Mounting the Robot Mounting Surface The Adept Cobra s800 Inverted robot is designed to be mounted in an inverted position When designing the mounting structure you must account for load and stiffness The mounting structure must be rigid enough to prevent vibration and flexing during robot operation Excessive vibration or mounting flexure will degrade robot performance Adept recommends the mounting structure be stiff enough so that the first vibration mode is greater than 70 Hz The following figure shows the mounting hole pattern
62. eees 60 Installing a New AIB or eAIB Chassis eee cece eee eee eee eee s s eeeeeeeeeeeeeeeeeeees 64 5 8 Commissioning a System with an eAIB 1o uccsecssor cadealevevesid osceuvinassardcenteenieceseoss 65 Safety Commissioning Utilities lt a a sn esee dc cabs np A RER ESPE iSe ae AAN R 65 E Stop Configuration Utility lt 9 9 a 2 Rea eC iar cde e ee eee D N eee ee eee ete ete 67 E Stop Verification Utility 2 22 22 Ea T deus Eee ee ok eee eee RN eA iell 68 Teach Restrict Configuration Un 68 Teach Restrict Verification Utility 2222222202 a Kd side EA a cdeceeeenedeeaceteeescdegentccacdeene tess 69 59 Replacing the Encoder Battery Pack 70 Battery Replacement Time Periods sse 71 Battery Replacement Procedure eisieiiue eeill e pe ge coi diessa aesti pS ena Sge iQ iiiii i ipie 71 Installing an Encoder Battery in the Inner Link ee 73 Chapter 6 Optional Equipment Installation 75 6 1 Installing End Effectors 25223258 ehid ew eau se OE Ere ied se Soo ees dees 75 6 2 Removing and Installing the Tool Flange 75 Removing the Flange esec sa a aaa 0 aa aR R RRR RRR vc dso ER a ces R RR RRR RRR R RA 75 Installing the Flange TTT 76 6 3 User Connections on Robot ee 76 User Airlines eeen a si bea i a e eae e n ESS 76 User Electrical ETT 78 64 Internal User Connectors e 78 empiece 80 OP3 4 Connector sssssssssssslllllllllllls sse e ll e cece cece eeeeeeeeeeeeeeeeeeeeeeees 80 BOAPWIR ConBectOE 2 cec nnerrecccRErDesRinetwce cos
63. ellows clamp by removing two M3 screws and pulling the clamp apart 4 Slide the old bellows down off of the quill 5 Install a new bellows by sliding it up onto the quill 6 Re install the upper bellows clamp e You must align mating surface of the clamp half rings with the bellows seam see Figure 9 12 e Tighten the screw to secure the bellows 7 Re install the tool flange 8 Place new gaskets in the bottom bellows clamp Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 134 of 142 Chapter 9 IP 65 Option e Extra gaskets are shipped in the Accessory Kit p n 04860 000 e Ensure that the mating surfaces are clean before assembly 9 Install the clamp over the bottom of the bellows on the bearing ring just above the tool flange s Align the mating surfaces of the clamp half rings with the bellows seam see Figure 9 12 e Tighten the screw to secure the clamp Bellows Seam Upper Bellows Clam E Bellows Clamp Bellows Bottom Bellows Clamps Lower Bellows Bottom View Clamp 4 R Bottom Clamp Gaskets Figure 9 11 Bellows Figure 9 12 Bellows Clamps Gaskets NOTE Align the bellows clamps with the bellows seam on both upper and lower clamps 9 9 Installing the Roxtec Cable Seal Assembly CAUTION Unless you need to replace a cable with a new cable the Roxtec cable seal assembly should not be opened NOTE If you only need to disconnect cables from the AIB eAIB refer to Removin
64. er XSYS eAIB XSYS Cable Controller XSYS to AIB eAIB XSLV XSYSTEM SS yj E Terminator Installed zit User Supplied Ground Wire Controller XFP to TT TTT Front Panel XFP 24 VDC Power to Controller XDC1 Ethernet to PC E A Front Panel 7 Controller XMCP to Pendant HH WW Ub U eres O CJ N Pendant 24 VDC Power I optional to Robot User Supplied i 24 VDC Input 200 240 VAC L ingle ph 5 User Supplied single phase User Supplied PC running 24 VDC Power Adept ACE software Supply Figure 3 1 System Cable Diagram AIB Shown NOTE See Installing 24 VDC Robot Cable on page 32 for additional system grounding information Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 27 of 142 Chapter 3 System Installation 3 2 Cable and Parts List Table 3 1 Cable and Parts List Part Description IEEE 1394 Cable 4 5 M Standard cable supplied with system XSYS Cable AIB only 4 5 M Standard cable supplied with AIB system eAIB XSYS Cable 4 5 M Standard cable supplied with eAIB system eAIB XSLV Adapter Cable Standard adapter cable 250 mm for AIB eAIB upgrade Front Panel Cable 3 M Supp
65. er v2 02 st ccc csesee ec detidesail escdepeeese i Ges pde rus 128 Removing Outer Link Cover ss io ZR RN KRE ih ede geese cies ARR el ede ee gs be 4b ee ee ee 128 Installing Outer Link Cover no da R pee eee Sa eee ceed et pine See eg a 130 9 6 Customer Requirements c ce22 22c2di2 sceeescsseeeedecedaee eo t eene soecebdcaceseseseeesitecested 131 Sealine the Tool Flang 44 cae tet St a te cae dI eds Joon Seen atisadeen aA 131 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 8 of 142 Table of Contents Pressarizing the Robot 2 s EDU EDAD ee ee 132 97 User Connectors esee eroe VEN EDAD ED Renee diei 133 User Bl ctrical and DeviceNet eiue obli Qo REDE c bled dI WR ie ecl V IIR 133 USTANE S 522 502 cocesotoceceoccoc une d dee cen e TO Eee ote A MP CE eco ee 134 Robot Solenoid Option e 134 9 8 Maintenance 2a codes Lec So AI PRI LLL SoS 8 he Mee eA M E t e A Ad sere edu 134 Replacing IP 65 Bello w8 245 dec osse M RID IS Gp RENE DEM n a a a 134 9 9 Installing the Roxtec Cable Seal Assembly 135 9 10 Removing the Roxtec Cable Seal Assembly 140 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 9 of 142 Chapter 1 Introduction 1 1 Product Description Adept Cobra s800 Inverted Robots Adept Cobra s800 Inverted robots are four axis SCARA robots Selective Compliance Assembly Robot Arm see the following figure Joints 1 2 and 4 are rotational Joint 3 is translational See Figure 1 2 for an illustra
66. erence guides in the Adept Document Library ADL on the Adept website For more details on the ADL see Adept Document Library on page 18 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 54 of 142 Chapter 5 Maintenance 5 1 Field replaceable Parts WARNING Only qualified service personnel may install or service the robot system The following parts are the only field replaceable parts Table 5 1 Field replaceable Parts Encoder battery pack 09977 000 3 6 V 6 8 Ah This has replaced part number 02704 000 AIB Amp In Base 04900 000 eAIB Amp In Base 19800 800 These parts must only be replaced with the Adept part numbers identified in the preceding table 5 2 Periodic Maintenance Schedule The following table gives a summary of the preventive maintenance procedures and guidelines on frequency Table 5 2 Inspection and Maintenance mm O o Op ee Check E Stop enable key switches and barrier interlocks See Section 5 3 Check robot mounting bolts See Section 5 4 Check for signs of oil around the harmonic drives See Section 5 5 Lubricate Joint 3 Z axis ball screw See Section 5 6 Replace Encoder battery 5 to 10 See Section 5 9 years NOTE The frequency of these procedures will depend on the particular system its operating environment and amount of usage The periods shown are approximate modify the schedule as needed Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 55 of 142
67. essurized The positive pressure reinforces the sealing properties of the gaskets and seals provided in the IP 65 robot The tool flange for the IP 65 robot has an additional protective shield on the outer edge that is not present on the standard robot tool flange The following figure shows the side view dimensions The bottom face of the flange mounting surface is the same as the standard flange see Figure 7 4 72 2 3 8 6 8 A 76 2 Units in mm Figure 9 7 IP 65 Tool Flange Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 131 of 142 Chapter 9 IP 65 Option Pressurizing the Robot The user must supply compressed air to maintain positive air pressure inside the robot 1 Remove the shipping plug from the compressed air fitting located just above the AIB eAIB See Figure 9 8 Compressed Air Fitting Figure 9 8 Compressed Air Fitting on Robot 2 Connect a compressed air source to the air fitting The specification for the regulated air supply is shown in the following table Table 9 1 Compressed Air Specifications 3 bar 10 57 liters per minute 44 PSI 10 2 cubic feet per minute CAUTION The compressed air supply must be clean and dry and it must be on continuously to maintain a positive air pressure inside the robot Failure to do this could result in moisture or particle buildup inside the robot and lead to reduced performance or damage to the robot This will also
68. evable However Adept has tested the internal cable only at 125k baud See the Adept SmartController User s Guide for physical installation Use Adept ACE controller configuration for software setup This assigns the controller signals to the physical ports of the DeviceNet nodes For details see the topic on V eV System Configuration in the Adept ACE User s Guide NOTE The local setting baud rate must match the DeviceNet node s setting From the Adept ACE software 1 Double click on the controller in the tree structure pane This opens the object editor for the controller Select Configure gt Configure V or e V Select DEVICENET If there is no LOCAL statement you are prompted to add one before scanning The LOCAL statement in the DeviceNet configuration specifies the MAC ID of the Adept controller on the DeviceNet bus The default setting is 0 Set the MAC ID so that all the nodes on the bus have different MAC IDs LOCAL MACID n BAUD n This statement also defines the baud rate of the DeviceNet scanner The baud rate depends on multiple factors such as the length of the DeviceNet cable the DeviceNet components on the bus etc Syntax of the LOCAL statement LOCAL MACID local id BAUD baud rate MACID for the Adept controller on the bus Baud rate to be used on the DeviceNet 125K 250K or 500K Click Scan This scans for your physical DeviceNet nodes and return the MACIDs for them
69. g Installing the Cable Entry Housing on page 124 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 135 of 142 Chapter 9 IP 65 Option CAUTION Roxtec cable seal modules will not seal if not reinstalled properly RG M63 1 RG M63 4 RG M63 9 pes Housing 1 Housing 1 pes Housing 1 pes Pressure screw Pressure screw 1 pes Pressure screw 1 pes Lock nut Lock nut 1 pes Lock nut 2 pes Washer Washer 2 pes Washer 1 pes Compression rubber Compression rubber 1 pes Compression rubber 1 pes Module 40 10 32 Module 20w40 3 pcs Module 13 3w40 1 pes Slip washer Slip washer 1 pes Slip washer 1 pes O ring O ring 1 pes O ring 1 pes Lubricant Lubricant Lubricant Slip Pressure TN screw Compression rubber washer 1 Remove the lock nut from the housing 2 Verify that the O ring is positioned correctly Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 136 of 142 Chapter 9 IP 65 Option 3 Insert the housing into the Cable Entry Housing Cover and fasten with the lock nut Tighten the lock nut securely 4 Pull all of the cables through the Roxtec Cable Seal Assembly Temporarily remove the pressure screw slip washer and the washer 5 Temporarily remove the pressure screw slip washer and washer Adapt modules which are to hold Achieve a 0 1 1 0 mm gap cables by peeling layers until you between the two halves when held reach the gap seen in pic 7 against the cable 6 Adapt the modules which a
70. g the AIB or eAIB Chassis CAUTION Follow appropriate ESD procedures during this procedure Removing the AIB or eAIB Chassis 1 2 3 11 Switch off the SmartController Switch off the 24 VDC input supply to the chassis Switch off the 200 240 VAC input supply to the chassis If the robot is the IP 65 version refer to Removing Installing the Cable Entry Housing on page 124 for instructions on removing the cable entry housing so that you will have access to the AIB eAIB connections Disconnect the 24 VDC supply cable from the chassis 24 VDC input connector See Figure 2 5 for locations of connectors Disconnect the 200 240 VAC supply cable from the chassis AC input connector Disconnect the XSYS cable from the chassis XSLV connector AIB or Disconnect the eAIB XSLV Adapter cable from the chassis XSYSTEM connector or the eAIB XSYS cable from the chassis XSYSTEM connector eAIB Disconnect the 1394 cable from the chassis SmartServo connector Disconnect any other cables which may be connected to the chassis such as XIO or any others Carefully unscrew the chassis securing screw see the following figure Use a 5 mm hex key Note that the screw does not need to be completely removed in order to remove the chassis as this screw is captured on the chassis heat sink Securing Screw 1 on AIB Figure 5 2 Securing Screw on Chassis Lift up the chassis and lift out the bottom of the chassis so the bottom shelf
71. has been pre wired to accommodate a bank of two 24 VDC solenoid valves Power for the internal mounting is accessible via a connector mounted inside the outer link cover see Figure 6 11 The signals actuating the valves are directly switchable from the Adept ACE software using software signals 3001 and 3002 1 Open the gripper object editor 2 Select the Open Close tab 3 Set the signal values for Open Close and Release View 1 View 2 u 4bx Figure 6 10 Setting Solenoid Signal Values The Adept supplied solenoids each draw a nominal 75 mA at 24 VDC Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 85 of 142 Chapter 6 Optional Equipment Installation The solenoid valve assembly consists of two independent valves Valve 1 and Valve 2 ona common manifold The manifold supplies air at the user s line pressure 28 psi minimum 0 19 MPa to 114 psi 0 786 MPa 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 Cobra s series robots the air lines from Port A on each valve are plugged at the factory at the solenoid assembly The Solenoid Kit for the Adept Cobra s series robot is available through Adept Contact your Adept Sales Representative for current price and availability Table 6 6 Air Pressure Air Pressure PSI Air Pressure
72. has special sealing hardware to ensure nothing can enter the inside of the robot If you need to remove the outer link cover from the robot for any reason follow the procedures that follow Removing Outer Link Cover 1 Turn off main power to the controller and power chassis 2 Turn off the air supply to the robot 3 Clean the exterior of the outer link thoroughly to remove any dust or particles that might fall inside the robot when the cover is removed Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 128 of 142 Chapter 9 IP 65 Option 4 Unscrew the collar nut on the top of the outer link see Figure 9 5 5 Remove the two screws and nylon washers on the top of the outer link 6 Remove the two screws one on each side at the front of the outer link Make sure the O ring on each screw stays in place and is not lost 7 For the 8 screws along the side of the cover 4 on each side see Figure 9 5 loosen only 1 to 2 turns just enough to loosen the inside clamp nuts Do not completely remove the screws See the label on the side of the outer link cover CAUTION Do not loosen these screws any more than 2 turns because the clamp nut on the inside of the cover might come loose and fall inside the robot Two screws nylon washers one on each side Collar Nut Four screws on each side Two screws o rings one on each side Figure 9 5 Cover Removal Instructions 8 Whe
73. hassis heat sink carefully hang the chassis on the support bolt on the side of the robot chassis see Figure 5 4 and Figure 5 5 so there is access to the battery See the following figure for the location of the battery pack Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 71 of 142 10 11 12 13 14 Chapter 5 Maintenance Encoder Battery Pack Figure 5 12 Location of Encoder Battery Pack The battery cable assembly has two sets of connectors Locate the secondary unused battery cable in the wire bundle inside the robot base Place the new battery pack next to the original one but do not disconnect the original one Connect the new battery pack to the connectors on the secondary unused battery cable Make sure that the positive and negative connections are correct Once the new battery pack is connected disconnect and remove the original battery pack Place the new battery pack in the original location on the fan bracket inside the base of the robot Close the robot and reconnect the cables by reversing the steps in the beginning of this procedure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 72 of 142 Chapter 5 Maintenance Installing an Encoder Battery in the Inner Link If you need to separate the inner and outer link assemblies from the robot base assembly for service for example you need to install a backup battery in the inner link to preserve the Joint 2 motor e
74. he only time that this jumper will be used It is part number 11901 000 and must be removed for Verification and normal operation Sy Figure 5 11 eAIB Commissioning Jumper e An Adept pendant is required for the Teach Restrict verification E Stop Configuration Utility This utility sets the E Stop hardware delay to factory specifications NOTE Ensure that the commissioning jumper is plugged into the XBELTIO jack on the eAIB before you start this procedure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 67 of 142 Chapter 5 Maintenance Procedure From within the Adept ACE software 1 Open the robot object editor 2 Select Configure gt Safety Settings gt Configure ESTOP Hardware Delay then click Next This procedure will configure Channel A and then Channel B It will then report the delay that it set for each 3 Reboot the SmartController On some systems the SmartController will reboot automatically 4 Reboot the eAIB E Stop Verification Utility This utility verifies that the hardware E Stop parameters are set correctly and that the hardware E Stop is working The hardware E Stop must have already been configured for this wizard to run NOTE If the commissioning jumper is plugged into the XBELTIO jack on the eAIB remove it before you start this procedure Procedure From within the Adept ACE software 1 Open the robot object editor 2 Select Configure Safety Settings Verify ESTOP
75. ing Digital I O on Robot XIO Connector ee 45 Optional I O Products loose Za ZEE Leads ERa LA eea aeaa Ee Rade 46 XIO Input Signals 2 023600 Zd Z 0 g a ee ed eke 46 AXIO Output Signals ooo T 48 XIO Breakout Cable 2 E R c ce R Raa cece eee eee ee eee eeee ARAR RR RR Eiris 50 4 6 Starting the System for the First Time 52 Verifying Installation 226 5252 ivequgdsstieenhinniocdacearensesmeubhacddidd adeemeseaSecsceblddiescmn desde ES 52 Turning on Power and Starting Adept ACE 53 Enabling High Power s 22 ii dente ecolussbthelqccc steemcneenceced Reactes Ronda be oniddp inet 54 Verifying E Stop Functions 22 222220202222 e cece eee cece eee eee eee e cess eeeeeeeeteeeeeeeeeeeees 54 Verify Robot Motions seisi Soh er N EN R aR RR ATE eee Sheek 54 4 7 Learning to Program the Robot 54 Chapter 5 Maintenance 55 5l Field replac able Parts osos iid ee a a dTa tinea es fet EARE EU i 55 5 2 Periodic Maintenance Schedule 55 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 6 of 142 Table of Contents 5 3 Checking Safety Systems MEE 56 5 4 Checking Robot Mounting Bolts 56 55 Checking for Oil Around Harmonic Drives 1 1 ccs sc etexseeeeiuteieecieteiee 57 5 6 Lubricating Joint 3 Ball Screw e 57 Lubrication Procedure 2 5 ds lle a Ea aa Diss enra 57 5 7 Replacing the AIB or eAIB Chassis 60 Removing the AIB or eAIB Chassis 00500051 eeeee tees eeeeeeeeee
76. ion Grounding Robot Mounted Equipment The following parts of an Adept Cobra s800 Inverted robot are not grounded to protective earth the Joint 3 quill and the tool flange If hazardous voltages are present at any user supplied robot mounted equipment or tooling you must install a ground connection from that equipment tooling to the ground point on the robot base Hazardous voltages can be considered anything in excess of 30 VAC 42 4 VAC peak or 60 VDC Also see Tool Flange Dimensions on page 108 for the grounding point on the tool flange DANGER Failing to ground robot mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end effector when an electrical fault condition exists 3 10 Installing User Supplied Safety Equipment The user is responsible for installing safety barriers to protect personnel from coming in contact with the robot unintentionally Depending on the design of the workcell safety gates light curtains and emergency stop devices can be used to create a safe environment Read the Adept Robot Safety Guide for a discussion of safety issues Refer to the Adept SmartController User s Guide for information on connecting safety equipment into the system through the XUSR connector on the SmartController There is a detailed section on Emergency Stop Circuits and diagrams on recommended E Stop configurations Adept Cobra s800 Inverted Robot User s Guide Rev H
77. is placement Figure 5 9 Installing Chassis in Robot Base 7 Once the chassis is in place before securing the screw push the chassis up to properly seat it and use a 5 mm hex key to tighten the chassis securing screw shown in Figure 5 2 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 64 of 142 10 11 12 13 14 15 16 17 Chapter 5 Maintenance Connect the 200 240 VAC supply cable to the chassis AC input connector Connect the XSYS cable to the chassis XSLV connector AIB Or Connect the eAIB XSYS cable or XSYS cable with eAIB XSLV Adapter to the chassis XSYSTEM connector eAIB Connect the 1394 cable to the chassis SmartServo connector Connect any other cables which may be connected to the chassis such as XIO or any others Connect the 24 VDC supply cable to the chassis 24 VDC input connector If the robot is the IP 65 version refer to Removing Installing the Cable Entry Housing on page 124 for instructions on installing the cable entry housing Switch on the 200 240 VAC input supply to the chassis Switch on the 24 VDC input supply to the chassis Switch on the SmartController Once the system has completed booting test the system for proper operation 5 8 Commissioning a System with an eAIB Commissioning a system involves synchronizing the robot with the eAIB NOTE This section only applies to robots that have an eAIB amplifier A robot with an AIB amplifier does not nee
78. lied with Front Panel T1 T2 Pendant Adapter Cable Supplied with Adept T2 pendant option Power Cable Kit contains Available as option 24 VDC and AC power cables XIO Breakout Cable 12 inputs Available as option see 8 outputs 5 M XIO Breakout Cable on page 50 Y Cable for XSYS cable Available as option see connections to dual robots Adept Dual Robot requires two eAIB XSLV cables Configuration Procedure for an eAIB 3 3 Installing the SmartController Refer to the Adept SmartController User s Guide for complete information on installing the Adept SmartController This list summarizes the main tasks 1 Mount the SmartController and Front Panel WARNING Ensure that the front panel is located 2 Connect the Front Panel to the SmartController 3 Connect the pendant if purchased to the SmartController Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 28 of 142 outside of the workcell and outside of the work envelope Chapter 3 System Installation 4 Connect user supplied 24 VDC power to the controller Instructions for creating the 24 VDC cable and power specification are covered in the Adept SmartController User s Guide 5 Install a user supplied ground wire between the SmartController and ground 3 4 Connecting User Supplied PC to Robot The Adept Cobra s800 Inverted robot must be connected to a user supplied PC for setup control and programming The user loads the Adept A
79. ls For improved safety relative to European standards implemented in 2012 The two amplifiers look very similar and both fit the Cobra s800 Inverted robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 12 of 142 Chapter 1 Introduction Adept AIB Figure 1 3 Adept Amplifier AIB Shown Adept SmartController The SmartController motion controller is the foundation of Adept s family of high performance distributed motion controllers The SmartController is designed for use with e Adept Cobra s Series robots e Adept Quattro robots e Adept Viper s Series robots e Adept Python linear modules e Adept MotionBlox 10 e Adept sMI6 SmartMotion The SmartController supports a conveyor tracking option as well as other options There are two models available the SmartController CX which uses the V Operating System and the SmartController EX which uses the eV Operating System Both models offer scalability and support for IEEE 1394 based digital I O and general motion expansion modules The IEEE 1394 interface is the backbone of Adept SmartServo Adept s distributed controls architecture supporting Adept products The SmartController also includes Fast Ethernet and DeviceNet Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 13 of 142 Chapter 1 Introduction SmartController EX
80. mmends a 24 V 6 A power supply to allow for startup current draw and load from connected user devices such as solenoids and digital I O loads If multiple robots are to be sourced from a common 24 V power supply increase the supply capacity by 3 A for each additional robot CAUTION Make sure you select a 24 VDC power supply that meets the specifications in Table 3 2 Using an underrated supply can cause system problems and prevent your equipment from operating correctly See the following table for recommended power supplies Table 3 3 Recommended 24 VDC Power Supplies JMP160PS24 24 VDC 6 7 A 160 W SP 150 24 24 VDC 63 A 150 W Mean Well SP 150 24 24 VDC 6 3 A 150 W Details for 24 VDC Mating Connector The 24 VDC mating connector and two pins are supplied with each system They are typically shipped in the cable accessories box Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 31 of 142 Chapter 3 System Installation Table 3 4 24 VDC Mating Connector Specs Connector Details Connector receptacle 2 position type Molex Saber 18 A 2 Pin Molex p on 44441 2002 Digi Key p n WM18463 ND Pin Details Molex connector crimp terminal female 14 18 AWG Molex p n 43375 0001 Digi Key p n WM18493 ND Recommended crimping tool Molex Hand Molex p n 63811 0400 Crimper E Digi Key p n WM9907 ND NOTE The 24 VDC cable is not supplied with the system but is available in the optional Power Cable kit see
81. more safety information Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 15 of 142 Chapter 1 Introduction Manufacturer s Declaration of Compliance MDOC This lists all standards with which each robot complies For details see Manufacturer s Declaration on page 17 Adept Robot Safety Guide The Adept Robot Safety Guide provides detailed information on safety for Adept robots It also gives resources for more information on relevant standards It ships with each robot manual and is also available from the Adept Document Library For details see Adept Document Library on page 18 1 6 Intended Use of the Robots The Adept Cobra s800 Inverted robot is intended for use in parts assembly and material handling for payloads less than 5 5 kg 12 1 Ib See Robot Specifications on page 113 for complete information on the robot specifications Refer to the Adept Robot Safety Guide for details on the intended use of Adept robots 1 7 Installation Overview The system installation process is summarized in the following table Refer also to the system cable diagram in Figure 3 1 For dual robot installations see the Adept Dual Robot Configuration Procedure which is available in the Adept Document Library Table 1 1 Installation Overview Task to be Performed Mount the robot to a flat secure mounting surface Install the SmartController Front Panel pendant optional and Adept ACE user interface I
82. more than 250 mm sec 4 High Power On Off Switch and Lamp Controls high power which is the flow of current to the robot motors Enabling high power is a two step process An Enable Power request must be sent from the user supplied PC an executing program or the pendant Once this request has been made and the High Power On Off lamp button is blinking the operator must press and release this button and high power will be enabled NOTE The use of the blinking High Power button can be configured or eliminated in software Your system may not require this step NOTE If enabled the Front Panel button must be pressed while blinking default time out is 10 seconds If the button stops blinking you must enable power again 5 Emergency Stop Switch The E Stop is a dual channel passive E Stop that supports Category 3 CE safety requirements Pressing this button turns off high power to the robot motors NOTE The Front Panel must be installed to be able to Enable Power to the robot To operate without a Front Panel you must supply the equivalent circuits 4 5 Connecting Digital I O to the System You can connect digital I O to the system in several different ways For details see the following table and Figure 4 4 Table 4 3 Digital I O Connection Options Product I O Capacity For more details XIO Connector on Robot i see Using Digital I O on Robot XIO Connector on page XDIO Connector on 12 inputs see Adept SmartCon
83. move the robot joints away from the folded shipping position which is shown in Figure 2 3 Turn on the 200 240 V AC power See Connecting 200 240 V AC Power to Robot on page 33 DANGER Make sure personnel are skilled and instructed refer to the Adept Robot Safety Guide Turn on the 24 VDC power to the robot see Connecting 24 VDC Power to Robot on page 31 The Status Panel displays OK The Robot Status LED will be off Verify the Auto Manual switch on the Front Panel is set to Auto Mode Turn on the user supplied PC and start Adept ACE e Double click the Adept ACE icon on your Windows desktop or e From the Windows Start menu bar select Start gt Programs gt Adept Technology gt Adept ACE gt Adept ACE On the Adept ACE Getting Started screen e Select New SmartController Workspace e Select Create Workspace for Selected Controller to make the connection to the controller e Select the IP address of the controller you wish to connect to or manually type in the IP address Click OK You will see the message Working please wait Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 53 of 142 Chapter 4 System Operation Enabling High Power After you have started Adept ACE and connected to the controller enable high power to the robot motors Using Adept ACE to Enable High Power 1 From the Adept ACE main menu click the Enable High Power icon 2 Press and release the blinking High Power
84. n all 8 screws are loose but not removed lift the cover up and slide it back along the cable track and out of the way WARNING When the Outer link cover is removed you see the label shown in Figure 2 3 Do not remove the J3 ENC or J4 ENC encoder cable connectors from their sockets If they are removed the calibration data will be lost and the robot must be run through a factory calibration process which requires special software and tools Protect the cover with a soft cloth or other padding material so the cover does not get scratched see the following figure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 129 of 142 Chapter 9 IP 65 Option Figure 9 6 IP 65 Robot with Outer Link Cover Removed Installing Outer Link Cover 1 Check the cover O ring around the inner groove of the cover to make sure it is in place and not crimped before installing the cover If the O ring is worn or damaged replace it The O ring is Adept p n 06356 000 2 Hold the cover over the outer link and check to see that the clamp nuts attached to the 8 side screws are positioned so they will slip into place when the cover is lowered onto the outer link 3 Slowly lower the cover onto the outer link making sure the O ring does not fall out or get pinched as the cover presses down to make the seal NOTE As you lower the cover onto the outer link make sure the 8 side screws are pushed all the way in so the clamp nuts will slide i
85. ncoder information NOTE Before you disconnect the Joint 2 motor cable from the AIB eAIB chassis you need to perform the procedure below If you do not the Joint 2 motor encoder information will be lost and you will need to re initialize the robot after you reconnect the Joint 2 motor cable to the AIB chassis 1 Obtain the replacement battery pack p n 09977 000 2 Turn off all power to the robot 3 Remove 10 screws on the bottom of the inner link cover and remove the inner link cover 4 Locate the battery cable in the wire bundle in the inner link Encoder Battery Encoder Battery Cable Figure 5 13 Location of Encoder Battery Cable in Inner Link 5 Connect the battery pack to the connectors on the battery cable Make sure that the positive and negative connections are correct NOTE After the inner link assembly has been reassembled with the robot base assembly and the wire harness has been securely connected to the AIB eAIB chassis you can remove the encoder battery in the inner link Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 73 of 142 Chapter 6 Optional Equipment Installation 6 1 Installing End Effectors The user is responsible for providing and installing any end effector or other end of arm tooling End effectors can be attached to the tool flange using four M6 screws See Figure 7 4 for a dimension drawing of the tool flange A 6 mm diameter x 12 mm dowel pin user supplied fits in the
86. nstall the IEEE 1394 and XSYS cables between the robot and SmartController Create a 24 VDC cable and connect it between the SmartController and the user supplied 24 VDC power supply Create a 24 VDC cable and connect it between the robot and the user supplied 24 VDC power supply Create a 200 240 VAC cable and connect it between the robot and the facility AC power source Reference Location Mounting the Robot on page 21 Installing the SmartController on page 28 Cable Connections from Robot to SmartController on page 30 Installing the SmartController on page 28 Connecting 24 VDC Power to Robot on page 31 Connecting 200 240 VAC Power to Robot on page 33 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 16 of 142 Chapter 1 Introduction Task to be Performed Reference Location Install user supplied safety barriers in the workcell Installing User Supplied Sa Equipment on page Read System Operation on page 39 to learn about connecting Connecting Digital I O to digital I O through the XIO connector on the robot the System on page 43 Read System Operation on page 39 to learn about starting the Starting the System for the system including system start up and testing First Time on page 52 Read Optional Equipment Installation on page 75 if you need Installing End Effectors on to install optional equipment including end effectors user air and electrical lines external equipment s
87. nto the correct position 4 Install the two screws and nylon washers at the top of the outer link and tighten to 5 in Ib 0 56 N m 5 Install the two screws check for O ring on screw near the front of the outer link and tighten to 10 in lb 1 1 N m 6 Tighten the 8 side screws to 10 in lb 1 1 N m Be careful to not over tighten Begin with the two screws one on each side at the back of the outer link then move forward to the next two and so on until all eight are tightened This pattern is recommended to achieve a secure fit around the cover 7 Install the collar nut and tighten until secure 8 Remember to turn on the compressed air supply to the system before restarting the robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 130 of 142 Chapter 9 IP 65 Option 9 6 Customer Requirements The IP 65 robot provides most of the hardware needed to achieve an IP 65 protection level but customers must provide a way of sealing the tool flange and pressurizing the robot through the compressed air fitting located just above the AIB eAIB These two requirements sealing the tool flange and pressurizing the robot are critical to achieving the IP 65 level of protection In addition the robot must be inspected periodically to make sure these requirements are being met as part of a periodic maintenance program Sealing the Tool Flange The tool flange must be sealed so that the robot shell can be positively pr
88. ntroller 106 65 Controller 106 R1 Cobra600 49x Object Configure Control True True 1 Sitem colecton Motors 4 tem collection Default Hand Open Signal 3001 Default Hand Close Signal 3002 Enable Brake Release Input False Controller Controller 106 Controller 106 Motion Specifications Timing Specifications E End Effector Selected End Effector Controller 106 Gripper R1 Cobra600 E Location OffsetFromParent 0 000 0 000 0 000 0 000 0 000 0 000 Parent Joints List of robot joints Note that Joint 1 of the robot is element 0 Figure 6 25 Robot Editor with Joints Closed 3 Click the in front of Joints to display all of the joints Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 102 of 142 Chapter 6 Optional Equipment Installation Controller 106 Controller 106 Controller 106 Gripper R1 Cobra600 E View 1 dx Figure 6 26 Robot Editor with Joints Expanded 4 Click the in front of 2 to open the values for joint 2 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 103 of 142 Chapter 6 Optional Equipment Installation amp Controller 106 Controller 106 Controller 106 R1 Cobra600 1 gt x Object Configure Control 3D Visualization Visible True Configuration Enabled True Robot Number 1 El Joints 4 item collection 1 Shoulder B 2 Elbow Motion Limits 150 150
89. olenoids etc 1 8 Manufacturer s Declaration The Manufacturer s Declaration of Incorporation and Conformity MDOC for Adept robot systems can be found on the Adept website in the Download Center of the Support section http www adept com support downloads file search NOTE The Download Center requires that you are logged in for access If you are not logged in you will be redirected to the Adept website Login page and then automatically returned to the Download Center when you have completed the login process 1 From the Download Types drop down list select Manufacturer Declarations 2 From the Product drop down list select your Adept robot product 3 Click Begin Search The list of available documents is shown in the Search Results area which opens at the bottom of the page You may need to scroll down to see it 4 Use the Description column to locate the document for your Adept robot and then click the corresponding Download ID number to access the Download Details page 5 On the Download Details page click Download to open or save the file 1 9 How Can I Get Help Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance with your Adept software and hardware Additionally you can access information sources on Adept s corporate website http www adept com e For Contact information http www adept com contact americas e For Product Support information http
90. oltage Category Il 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 power supply lines as a result of power interruptions to high energy equipment such as a blown fuse on one branch in a 3 phase system This will cause high current pulses at relatively low voltage levels The user shall take the necessary steps to prevent damage to the robot system such as by interposing a transformer See IEC 1131 4 for additional information AC Power Diagrams Note F1 is user supplied must be slow blow L d 10 200 240 VAC vn DF BA 20A User Supplied AC Power Cable L Line N Neutral E N L E Earth Ground Adept Cobra s800 Inverted Robots 19 200 240 VAC Figure 3 3 Typical AC Power Installation with Single Phase Supply Note F4 and F5 are user supplied must be slow blow d L1 F510A 200 240 VAC 30 L2 200 240 VAC 13 FA 10 A T E User Supplied AC Power Cable E N L Li Adept Cobra L Line 1 N a 2 s800 Inverted E Earth Ground Robots 10 200 240 VAC Figure 3 4 Single Phase Load across L1 and L2 of a Three Phase Supply Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 35 of 142 Chapter 3 System Installation NOTE
91. om one of the IP 65 arcs To accomplish this you will cut one of the IP 65 arcs to fill in the gaps between the two adjustable hardstop plates The IP 65 arcs are scribed to indicate where they may be cut see the following figure You will need to cut either one or two arc segments that cover a total of four holes The remainder of the IP 65 arcs will not be needed Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 98 of 142 Chapter 6 Optional Equipment Installation Figure 6 21 IP 65 Arcs Installation Procedure 1 Remove the bottom cover from the underside of the inner link 2 For the IP 65 version from the underside of the inner link looking up remove the 12 M5 x 10 screws and lock washers that hold the IP 65 arcs onto the IP 65 gaskets Both arcs lock washers and gaskets are half circles as shown in Figure 6 21 e Save the screws and IP 65 arcs for use later in this procedure e Leave the two gaskets in place at Joint 2 on the inner link 3 Slide the two adjustable hardstop plates around Joint 2 into the space between the inner and outer links see Figure 6 22 For the IP 65 version slide the adjustable hardstop plates over the existing gaskets taking care not to damage the gaskets 4 Looking up at the inner link from underneath align the holes in the plates with the holes in the inner link see Figure 6 23 NOTE The two sides do not have to have the hardstop in the same position so the workspace
92. onnector pins Micro Style Connector 4 LEGEND 5 1 Drain bare 2 V red 1 3 V black 4 CAN_H white 5 CAN_L blue Female Connector sockets Figure 6 15 Micro Style Connector Pinouts for DeviceNet Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 93 of 142 Chapter 6 Optional Equipment Installation 6 9 Installing Adjustable Hardstops Adept offers an adjustable hardstop kit for Joint 1 and Joint 2 on the Adept Cobra s800 Inverted robot This is a user installed option that can be used to limit the work envelope of the robot The Adept part number for the kit is p n 02592 000 Joint 1 Adjustable Hardstops The Joint 1 Adjustable Hardstop consists of two black rubber stop cylinders and the required screws to install them There are two locations for the hardstops on each side of the robot Position 1 and Position 2 see the following figure Joint 1 Adjustable Hardstop installed in Position 1 Figure 6 16 Joint 1 Adjustable Hardstops Installation Procedure 1 Remove the plug from the desired threaded hole Position 1 or 2 on each side of the robot Refer to Table 6 7 for the angle available for each position 2 Install the adjustable hardstop into the threaded hole using an 8 mm hex wrench Tighten to a torque of 5 1 Nem 45 in Ibf 3 Repeat the process on the other side of the robot NOTE The two sides do not have to have a hardstop in the same position One side could use Position 1 and
93. or each and verify that the hardware detected the over speed condition 4 Click Next to proceed to the Manual Mode Procedure If the Automatic Mode Procedure fails you will not be allowed to proceed with the Manual Mode Manual Mode Procedure The manual mode of this verification requires the use of an Adept pendant For this verification the Front Panel keyswitch must be in Manual mode 1 From the Introduction screen click Next e Set the pendant to Joint mode e Set the pendant manual control speed to 100 2 Click Next 3 Using the pendant jog any of the robot s joints until power is disabled This indicates that the Teach Restrict function is working 4 Click Next The results of the verification will be displayed 5 Click Finish 6 Reboot the SmartController On some systems the SmartController will reboot automatically 7 Reset the Front Panel keyswitch to Auto mode 5 9 Replacing the Encoder Battery Pack The data stored by the encoders is protected by a 3 6 V lithium backup battery located on the fan bracket inside the base of the robot CAUTION Replace the battery pack only with a 3 6 V 6 8 Ah lithium battery pack Adept P N 09977 000 Battery information is located in the base of the robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 70 of 142 Chapter 5 Maintenance NOTE The previous battery P N 02704 000 has been superseded by this battery pack The battery replacement interval and proce
94. p System Ground Eo emis 0 MEE Ps os pem T 4 HPWR_DIS High Power Disable Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 112 of 142 Chapter 7 Technical Specifications XSYS XSYSTEM 7 4 XSLV Connector Table 7 2 XSLV Connector Pinout AIB Only alpes comment Ies RC HS Ls estore TRT Mating Connector AMP Tyco 747904 2 9 pin D Sub AMP Tyco 748676 1 D Sub Cable Clamp 7 5 Robot Specifications Table 7 3 Robot Specifications Moment of Inertia Joint 4 450 kg cm 150 Ib in max Downward Push Force Burst 298 N 67 lb maximum no load Specifications subject to change without notice Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 113 of 142 Chapter 7 Technical Specifications Description s800 Inverted Robot Lateral Side Push Force 133 N 30 Ib maximum Burst 0 kg 0 48 sec at 20 C 0 51 sec at 40 C 0 54 sec at 20 C 0 54 sec at 40 C 55 kg 0 70 sec at 20 C 0 70 sec at 40 C Adept Cycle Sustained 180 J4 rotation 0 kg 0 48 sec at 20 C 0 48 sec at 40 C 0 54 sec at 20 C 0 61 sec at 40 C 5 5 kg 0 77 sec at 20 C 0 91 sec at 40 C Repeatability x y 0 017 mm 0 00067 in 0 003 mm 0 00012 in Theta 0 019 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 114 of 142 Chapter 7 Technical Specifications Joint Speed maximum Robot Brakes Joint 1 2 and 4 Dynamic Joint 3 Ele
95. pply to those amplifiers These two functions are supported by four wizards e E Stop Configuration This sets the E Stop hardware delay to factory specifications e E Stop Verification This verifies that the hardware E Stop is functioning correctly e Teach Restrict Configuration This sets the hardware Teach Restrict maximum speed to factory specifications e Teach Restrict Verification This verifies that the hardware Teach Restrict is functioning correctly The initial utility screen will tell you which functions are commissioned If a function is not commissioned its verification wizard will not be displayed Any displayed verification wizard can be run at any time to ensure that its function is working properly Prerequisites e The robot must be set up and functional e The robot must use eAIB amplifiers The AIB amplifiers do not support these hardware functions and these wizards will not run e Adept ACE software must be installed e The Front Panel keyswitch must be in Auto mode Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 66 of 142 Chapter 5 Maintenance ff 3 f STOP D v r CO amp A Keyswitch in Auto mode Figure 5 10 Adept Front Panel e No E Stops can be activated e For Configuration E Stop and Teach Restrict the eAIB Commissioning Jumper must be plugged into the XBELTIO jack on the eAIB NOTE This is t
96. re or give a tip for easier operation 1 3 Safety Precautions DANGER An Adept Cobra s800 Inverted robot can cause serious injury or death or damage to itself and other equipment if the following safety precautions are not observed e All personnel who install operate teach program or maintain the system must read this guide read the Adept Robot Safety Guide and complete a training course for their responsibilities in regard to the robot e All personnel who design the robot system must read this guide read the Adept Robot Safety Guide and must comply with all local and national safety regulations for the location in which the robot is installed e The robot system must not be used for purposes other than described in the Adept Robot Safety Guide Contact Adept if you are not sure of the suitability for your application e The user is responsible for providing safety barriers around the robot to prevent anyone from accidentally coming into contact with the robot when it is in motion e Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed 1 4 What to Do in an Emergency Situation 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 1 5 Additional Safety Information Adept provides other sources for
97. re to hold cables by peeling layers until you obtain the gap shown in 7 above 7 There must be a 0 1 1 0 mm gap between the two module halves when held against the cables Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 137 of 142 Chapter 9 IP 65 Option Application of the Roxtec lubricant is necessary for obtaining a water tight seal Use the lubricant liberally Wait at least 24 hours for the lubricant to set with the Roxtec modules before using the assembly 8 Thoroughly lubricate all modules both inside and outside with Roxtec Lubricant CAUTION The Roxtec cable assembly will not seal if adequate Roxtec lubricant is not used Start by placing a module half at Place the cables in the adapted the bottom modules 9 Place a module half at the bottom of the frame 10 Place the cables into the adapted module Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 138 of 142 Chapter 9 IP 65 Option S Add the second module half on Repeat step 10 11 until the top packing space is filled 11 Add the second adapted module half on top of the cables and module half 12 Repeat 10 and 11 until the Roxtec frame is filled Use non adapted modules where there are no cables Put the washer and slip washer Adjust the washer to match the back in place compression rubber 13 Install the washer and slip washer into the frame 14 Align the washer holes with the compression r
98. remove the ground wire from the chassis Keep the screw for reassembly later see the following figures Figure 5 7 Ground Screw on AIB Chassis J DER een PN 19800 000 HHEH Hp Figure 5 8 Ground Screw Hole on eAIB Chassis Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 63 of 142 Chapter 5 Maintenance 17 Tag the chassis with the appropriate fault diagnosis faults errors and robot serial number information Installing a New AIB or eAIB Chassis NOTE Use care when installing the AIB or eAIB chassis in the following steps 1 Remove the new chassis from its packaging check it for any signs of damage and remove any packing materials or debris from inside the chassis 2 Hang the chassis on the Supporting Bolt located on the side of the robot base Refer to Figure 5 4 3 Connect the ground wire to the chassis 4 Carefully reconnect the cables you removed from their connectors on the PMAI ePMAT board see Figure 5 5 Engage the securing latches on the connectors 5 Connect the white amplifier cable to the amplifier connector located on the chassis bracket 6 Insert the top of the chassis into the robot base in the groove at the top of the base see the following figure Tilt the bottom of the chassis down and into place against the robot making sure that none of the cables get trapped or pinched and that the chassis O ring is not damaged during installation Groove in robot base for chass
99. rent purpose in those robots You will have to provide a piece of 6 mm tubing to run from one of the 6 mm user air lines at the Joint 2 cover under the cover for the IP 65 version to the air intake coupling 7 Plug the connector plug into the female connector jack marked SOLND on the bracket 8 Use cable ties to secure the air line to the bracket as needed Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 87 of 142 Chapter 6 Optional Equipment Installation Air intake coupling with spare air line Tubing connected to output port Mounting screws for solenoid assembly Figure 6 12 Solenoid Placement Using Mounting Hardware 9 Install the appropriate lengths of 5 32 inch plastic tubing supplied into the two output ports on the manifold e Route the tubing up along the tower bracket next to the quill and down through the center of the quill e Use cable ties as needed to secure the tubing 10 For the IP 65 version robot skip to Step 15 11 Remove the four screws from the User Connector Panel see Figure 6 3 and remove the cover enough so you have access to the tubing under the cover See Figure 6 13 User Connector Panel cover lifted to access spare airline User Air fitting for connecting spare line Remove factory installed tubing first Figure 6 13 Connecting Spare Air Line to User Connector Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 88 of 142 Chapter 6 Option
100. rnal 6 mm user air lines would need to be used to supply the hand valves instead Performance considerations The air exhausting from the internally mounted hand valves may be of sufficient quantity quality to cause the robot to fail to meet Class 10 particulate limits Recommendation For these reasons Adept recommends mounting hand valves externally 8 5 Maintenance Bellows Replacement Check the bellows Adept p n 04625 000 periodically for cracks wear or damage Replace bellows if necessary using the following procedure Removing the Bellows 1 Loosen the lower bellows clamp by loosening the screw and pulling the clamp apart slightly See the following figure Figure 8 3 Lower Bellows Clamp 2 Remove the tool flange Refer to Removing and Installing the Tool Flange on page 75 for the tool flange removal procedure Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 119 of 142 Chapter 8 Cleanroom Robots 3 Loosen the upper bellows clamp by loosening the screw and pulling the clamp apart slightly See the following figure Figure 8 4 Upper Bellows Clamp 4 Slide the old bellows down off of the quill Installing the Bellows 1 Slide the new bellows up onto the quill 2 Reverse the steps listed in Removing the Bellows on page 119 Lm Upper Bellows Clamp Ring Bellows Lower Bellows Clamp Ring Tool Flange Figure 8 5 Cleanroom Bellows Replacement Adept Cobra s800 Inverted
101. ser s Guide Rev H1 Page 50 of 142 Chapter 4 System Operation Table 4 8 XIO Breakout Cable Wire Chart Signal Designation Pin Locations o T e a ao TS a eae S mR Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 51 of 142 Chapter 4 System Operation 4 6 Starting the System for the First Time Follow the steps in this section to safely bring up your robot system The steps include e Verifying installation to confirm all tasks have been performed correctly e Starting up the system by turning on power for the first time e Verifying all E Stops in the system function correctly e Moving each axis of the robot generally with the pendant to confirm that each one moves in the proper directions Verifying Installation Verifying that the system is correctly installed and that all safety equipment is working correctly is an important process Before using the robot make the following checks to ensure that the robot and controller have been properly installed DANGER 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 Mechanical Checks e Verify that the robot is mounted level and that all fasteners are properly installed and tightened e Verify that any end of arm tooling is properly installed e Verify that all other peripheral equipment is properly installed and in a state where it is
102. shown in Figure 6 21 so that you have the correct number and size arc segments to fill the gaps between the adjustable hardstop plates e Install the segments you just cut into the gaps between the plates Secure with M5 x 10 screws with lock washers e Tighten the screws to 4 5 N m 40 in lb e Note that there will be 8 M5 x 10 screws and lock washers from the adjustable hardstop kit left over after the IP 65 installation After this step all 12 holes around Joint 2 should be surrounded by gasket which is compressed by either an adjustable hardstop plate or an arc segment and an M5 x 10 screw 8 Slide the fixed hardstop block into the slot on the underside of the outer link see the following figure Joint 2 Fixed Hardstop Block installed on underside of Outer Link Figure 6 24 Fixed Hardstop Block for Joint 2 9 Use a 3 mm hex wrench to install two supplied M4 x 12 screws and lock washers to secure the hardstop block Tighten the screws to 2 5 N m 22 in lb 10 Reinstall the inner link bottom cover Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 101 of 142 Chapter 6 Optional Equipment Installation Modifying Joint Limit Softstop Locations for Joint 2 After installing the adjustable hardstops you must modify the softstop locations using the Adept ACE software 1 From the Adept ACE software select the robot in the tree structure pane 2 Open the robot editor Controller 106 Co
103. stable diameter holes for cables The foam and cables are mounted in a housing that compresses the foam thereby eliminating any gaps around the cables The other assembly is the cable entry housing which provides access to the AIB eAIB connections Instructions for removal and reinstallation of the cable entry housing are provided in the next section The Roxtec assembly is mounted through the cover of this assembly and should never need to be disassembled In the event that a cable needs to be replaced instructions are provided in Installing the Roxtec Cable Seal Assembly on page 135 for removing and reinstalling the Roxtec assembly 9 4 Removing Installing the Cable Entry Housing The Adept Cobra s800 Inverted robot IP 65 version has special sealing hardware at the AIB eAIB to ensure nothing can enter the inside of the robot or AIB eAIB If you need to remove Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 124 of 142 Chapter 9 IP 65 Option the cables from the AIB eAIB or remove the AIB eAIB from the robot for any reason please follow the procedures in this section CAUTION Unless you need to replace a cable with a new cable the Roxtec cable seal assembly should not be opened NOTE If you only need to disconnect cables from the AIB eAIB you can do so by just removing the cable entry housing cover covered in this section See Figure 9 4 Cable Entry Housing Body Cable Entry Housing Cover Roxtec
104. t Cobra s800 Inverted Robot User s Guide Rev H1 Page 89 of 142 Chapter 6 Optional Equipment Installation Digital 1 0 SmartController SmartController B K 1 Show Outputs T Inputs M Robot I Soft T Custom 3001 3016 BE eee WARNING Disconnect robot air pressure until this test is complete to prevent unsecured pneumatic lines from accidentally injuring personnel 6 7 Installing Camera Bracket Kit Introduction The Adept Cobra robot Camera Bracket Kit provides a convenient way of mounting cameras to the outer link of the robot The kit consists of the following e One camera plate e Two camera brackets e One camera mount slide bracket e One camera mount channel e M4 x 12 mm screws s M4 stainless steel flat washers e M5 x 12 mm screws Tools Required e M4 hex wrench e M3 hex wrench Procedure 1 Install the camera plate to the outer link with four M5 x 12 mm screws see Figure 6 14 as you perform this procedure 2 Install the two camera brackets to the camera plate with two stainless steel washers and two M4 x 12 mm screws for each bracket The camera brackets are not required unless you are mounting more than one camera 3 Mount the camera channel to the camera brackets or camera plate with M4 x 12 mm screws Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 90 of 142 Chapter 6 Optional Equipment Installation 4 Mount the camera to the camera mount 5 Mount the camera and c
105. t digital outputs share a common high side sourcing driver IC The driver is designed to supply any kind of load with one side connected to ground It is designed for a range of user provided voltages from 10 to 24 VDC and each channel is capable of up to Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 48 of 142 Chapter 4 System Operation 0 7 A of current This driver has overtemperature protection shorted load protection and is current limiting In the event of an output short or other overcurrent situation the affected output of the driver IC turns off and back on automatically to reduce the temperature of the IC The driver draws power from the primary 24 VDC input to the robot through a self resetting polyfuse The outputs are accessed through direct connection to the XIO connector see Table 4 5 or through the optional XIO Termination Block See the documentation supplied with the Termination Block for details XIO Output Specifications Table 4 7 XIO Output Circuit Specifications Power supply voltage range See Table 3 2 Operational current range per I 700 mA channel s Total Current Limitation all I 1 0 A 50 C ambient channels on M 1 5 A 25 C ambient On state resistance I 0 5 A R lt 0320 0 85 C out on Output leakage current LS 259 0 Turn on response time 125 usec max 80 usec typical hardware only Turn off response time 60 usec max 28 usec typical hardware onl
106. t the XSYSTEM end to the eAIB and the XSYS end to the SmartController Fora field upgrade from an old AIB if you already have the old DB9 DB9 cable routed and all you want to do is adapt your new eAIB to plug into the old cable use the eAIB XSLV Adapter cable This is a 1 ft 250 mm long adapter that essentially turns XSYSTEM into the old XSLV Connect the XSYSTEM end to the eAIB and the XSLV end to the old XSYS cable Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 30 of 142 Chapter 3 System Installation 3 7 Connecting 24 VDC Power to Robot Specifications for 24 VDC Power Table 3 2 Specifications for 24 VDC User Supplied Power Supply User Supplied Power Supply 24 VDC 10 150 W 6 A 21 6 V lt V 264 V Circuit Protection Output must be less than 300 W peak or 8 Amp in line fuse Power Cabling 1 5 1 85 mm 16 14 AWG Shield Termination Braided shield connected to terminal at both ends of cable see Figure 3 2 4 User supplied 24 V power supply must incorporate overload protection to limit peak power to less than 300 W or 8 A in line fuse protection must be added to the 24 V power source In case of multiple robots on a common 24 V supply each robot must be fused individually NOTE Fuse information is located on the AIB eAIB electronics The power requirements for the user supplied power supply will vary depending on the configuration of the robot and connected devices Adept reco
107. ten the user supplied mounting bolts to the torque specified in Table 2 2 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 23 of 142 Chapter 2 Robot Installation NOTE Check the tightness of the mounting bolts one week after installation and then recheck every 6 months See Maintenance on page 55 for periodic maintenance 2 6 Connectors on Robot Interface Panel 200 240 VAC XSLV Ground Point SmartServo Port 1 SmartServo Port 2 24 VDC Input 24 VDC Pin XIO XPANEL XSYSTEM Ethemet Ground Ports Point 24 V Pin Smart Servo Ports 24 VDC Input 200 240 VAC XBELTIO Figure 2 5 Robot Interface Panel AIB and eAIB The following connections are the same for both the AIB and the eAIB 24 VDC for connecting user supplied 24 VDC power to the robot The mating connector is provided Ground Point for connecting cable shield from user supplied 24 VDC cable Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 24 of 142 Chapter 2 Robot Installation 200 240 VAC for connecting 200 240 VAC single phase input power to the robot The mating connector is provided SmartServo x2 IEEE 1394 for connecting the IEEE 1394 cable from the controller SmartServo Port 1 1 to the robot amplifier The other SmartServo connector can be used to connect to a second robot or another 1394 based motion axis XIO for user I O signals for peripheral devices This connector provides 8 outputs and 12
108. the shaft Be careful not to lose the ball bearing 3 5 mm that is inside the flange behind the setscrew Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 75 of 142 Chapter 6 Optional Equipment Installation Quill shaft M4 Socket head cap screws Tool flange Setscrew Ra B pee Figure 6 1 Tool Flange Removal Details Installing the Flange 1 Make sure the ball bearing is in the setscrew hole inside the flange Hold it in place with your finger as you get ready to install the flange 2 Slide the flange up on the quill shaft as far as it will go and rotate until the setscrew is lined up with the original vertical groove 3 Support the flange while using a 2 5 mm hex driver to tighten the setscrew to finger tight Do not over tighten the setscrew because this will cause the flange to be off center from the quill shaft 4 Use a socket driver to tighten one of the socket head screws part of the way then tighten the other one the same amount Alternate between the two screws so there is even pressure on both once they are tight The torque specification for each screw is 8 N m 71 in lbf 6 3 User Connections on Robot User Air Lines There are five user air line connectors on the robot user panel on the back of Joint 1 see Figure 6 3 The five air lines run through the robot up to another set of five matching connectors on the top of the outer link see Fig
109. ting Digital I O to the System Table 4 4 Default Digital I O Signal Configuration Single Robot System en me sentes Controller XDIO connector Outputs 0001 0008 Robot 1 XIO connector 1097 1108 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 44 of 142 Chapter 4 System Operation ep neeaae IO Blox 4 1137 1144 Using Digital I O on Robot XIO Connector The XIO connector on the robot interface panel offers access to digital I O 12 inputs and 8 outputs These signals can be used by V eV to perform various functions in the workcell See the following table for the XIO signal designations e 12 Inputs signals 1097 to 1108 e 8 Outputs signals 0097 to 0104 Table 4 5 XIO Signal Designations V eV Signal Number S eee 13 Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 45 of 142 Chapter 4 System Operation V eV Designation Signal Number XIO 26 pin female connector on Robot Interface Panel GQ OO OOO OO 0 CO000000 0 GO DO OO OO 0 Optional I O Products These optional products are also available for use with digital I O e XIO Breakout Cable 5 meters long with flying leads on user s end See XIO Breakout Cable on page 50 for information This cable is not compatible with the XIO Termination Block e XIO Termination Block with terminals for user wiring plus input and output status LEDs Connects to the XIO connector with 1 8 M 6 foot cable See the Adept X
110. tion of the robot joint locations The Adept Cobra s800 Inverted robots require an Adept SmartController motion controller The robots are programmed and controlled using the SmartController running on the Adept SmartServo distributed motion control platform Mechanical specifications for the Adept Cobra s800 Inverted robots are provided in Robot Specifications on page 113 Figure 1 1 Adept Cobra s800 Inverted Robot Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 11 of 142 Chapter 1 Introduction C1 Joint 2 gt Joint 3 Inner Link gt Joint 4 Figure 1 2 Robot Joint Motions Adept AIB eAIB The amplifiers for the Adept Cobra s800 Inverted robot are embedded in the base of the robot This amplifier section is known as the amps in base AIB or eAIB There are two versions offered the AIB and the eAIB Both provide power amplifiers and full servo control The Adept AIB and eAIB feature e On board digital I O e 8 kHz servo rate to deliver low positional errors and superior path following e Low EMI for use with noise sensitive equipment e No external fan for quiet robot operation e Sine wave commutation to lower cogging torque and improve path following Digital feed forward design to maximize efficiency torque and velocity e Temperature sensors on all amplifiers and motors for maximum reliability and easy troubleshooting Adept eAIB only e Hardware based E Stop and Teach Restrict contro
111. troller SmartController 8 outputs User s Guide Optional IO Blox Device 8 inputs 8 outputs per device up see Adept IO Blox User s Guide connects to robot to four IO Blox devices per robot Optional sDIO Module 32 inputs 32 outputs per see Adept SmartController_ connects to controller module up to eight sDIO per User s gu ee system Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 43 of 142 Chapter 4 System Operation Cobra s800 Inverted Robot f P IO Blox 1 T S 8 Input signals 1113 to 1120 8 Output signals 0105 to 0112 A B IL 6 Optional IO Blox Device sDIO 1 32 Input signals 1033 to 1064 32 Output signals 0033 to 0064 Optional J gt sDIO 1 RES OO CE gt gt Cop SmartController XIO Connector XDIO Connector 12 Input signals 1097 to 1108 12 Input signals 1001 to 1012 8 Output signals 0097 to 0104 8 Output signals 0001 to 0008 Figure 4 4 Connec
112. ubber Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 139 of 142 Chapter 9 IP 65 Option Reinstall the pressure screw Tighten it hard to compress the gland 15 Install the pressure screw Tighten it securely to seal the modules around the cables Use the wrench p n 09030 000 shipped with IP 65 robot to tighten the Roxtec pressure screw to 18 24 ft lbf 25 32 N m 9 10 Removing the Roxtec Cable Seal Assembly Removal disassembly of the Roxtec Cable Seal Assembly is the reverse of the Assembly with the following important note When removing the pressure screw hold the Roxtec body with one of the supplied wrenches p n 09030 000 so that the connection between the body and the lock nut is not disturbed The Roxtec body should stay attached to the cable entry housing cover See Figure 9 13 for an exploded view of the Roxtec assembly Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 140 of 142 adept 5960 Inglewood Drive Pleasanton CA 94588 P N 06937 000 Rev H1 925 245 3400
113. ure 6 5 NOTE On the IP 65 version robot the connectors are under the outer link cover see Figure 9 10 e The two larger connectors are 6 mm diameter e The three smaller connectors are 4 mm diameter Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 76 of 142 Chapter 6 Optional Equipment Installation User Electrical 10 Blox User Air Lines User Air Lines 6mm 4mm Figure 6 2 User Connector Panel standard version User Electrical DeviceNet 10 Blox IP 65 Compressed Air Fitting User Air Lines User Air Lines 6mm 4mm Figure 6 3 User Connector Panel IP 65 version The connector covers plugs and caps can be removed from the IP 65 version panel if needed If the connections are not to be used the covers must remain in place Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 77 of 142 Chapter 6 Optional Equipment Installation 4 mm Air Lines 6 mm Air Lines DeviceNet User Electrical 4 mm Air Line Figure 6 4 User Connectors on standard Joint 2 IP 65 Joint 2 on right NOTE The connectors shown in Figure 6 4 are not available on the outside of this link for the IP 65 version Cobra s800 Inverted Refer to User Connectors on page 133 NOTE See Connecting Digital I O to the System on page 43 for information on the IO Blox connector Also refer to the Adept IO Blox User s Guide for details User Electrical Lines There is a 25 pin male connector 24 conductor on the robot user p
114. way sensor Pin 1 iti ircui o _ to cause an E Stop condition when circuit is open THE Note This function is disabled by default it must be enabled in software Figure 6 8 Internal E Stop Connector Circuit NOTE This circuit will trigger an emergency stop of the local robot only It does not link to the E Stop chain of the host SmartController Procedure to Enable Break away E Stop Function To enable the Break away E Stop function you have to use the Adept ACE software to change the default configuration NOTE This requires that you have Expert access From the Adept ACE software To get into Expert mode 1 Click on Object 2 Click Expert Access You will be asked for a password to enter Expert Access 3 Enter the Expert Access password To change the Break away E Stop parameter Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 83 of 142 Chapter 6 Optional Equipment Installation Double click the robot in the structure pane This will open up the object editor for the robot Select Break away E Stop Enable Change the value of this field to True amp jSmartController 84 SmartController 84 g SmartController 84 R2 Cobra600 Object Configure Control El 3D Visualization Visible True Configuration Enabled True Robot Number 2 D Joints 4 item collection Motors 4 item collection Model Number 570 Serial Number 895 Default Hand Open Signal 3001 Default Hand Close
115. www adept com support service and support main Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 17 of 142 Chapter 1 Introduction e For user discussions support and programming examples http www adept com forum Related Manuals This manual covers the installation operation and maintenance of an Adept Cobra s800 Inverted robot system There are additional manuals that cover programming the system reconfiguring installed components and adding other optional components See the following table These manuals are available on the Adept Document Library CD ROM shipped with each system Table 1 2 Related Manuals Adept Robot Safety Guide Contains safety information for Adept robots Adept SmartController User s Contains information on the installation and operation of the Guide Adept SmartController and the optional sDIO product Adept T2 Pendant User s Describes the use of the optional Adept manual control Guide pendant Adept ACE User s Guide Instruction for the use of the Adept ACE software Adept Dual Robot Contains cable diagrams and configuration procedures for a Configuration Procedure dual robot system Adept IO Blox User s Guide Describes the IO Blox product Adept Document Library The Adept Document Library ADL contains documentation for Adept products You can access the ADL from e the Adept Software CD shipped with your system e the Adept website Select Document Library from the A
116. y Output voltage at inductive load V 65 lt V demae V 45 turnoff 1 0 5 A Load 1 mH g DC short circuit current limit 0 7 A lt Tim lt 25A Peak short circuit current I lt 4A ovpk Adept Cobra s800 Inverted Robot User s Guide Rev H1 Page 49 of 142 Chapter 4 System Operation Typical Output Wiring Example Adept Supplied Equipment User Supplied Equipment 2 Wiring LD Terminal 1 a 424 VDC Block e E Ev Signal 0097 412 l S U Typical User Loads o i i LC a Signal 0098 20 LS Q circui EB Signal 0099 amp 21 S Q m o Signal 0100 22 S Load A amp Signal 0101 22 S 2 po Signal 0102 4 S g Signal 0103 2 S Signal 0104 e S 3 b Customer GND 6 S AC Power L ANN S GND Supply ad Ld Figure 4 6 Typical User Wiring for XIO Output Signals XIO Breakout Cable The XIO Breakout cable is available as an option see the following figure This cable connects to the XIO connector on the AIB eAIB and provides flying leads on the user s end for connecting input and output signals in the workcell The cable length is 5 M 16 4 ft See the following table for the wire chart on the cable NOTE This cable is not compatible with the XIO Termination Block Figure 4 7 Optional XIO Breakout Cable Adept Cobra s800 Inverted Robot U

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