Adept s800 User Manual

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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 • Fax925.960.0452

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 II• Singapore 569870 • Phone +65.6755 2258 • Fax +65.6755 0598

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.

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 Technology, 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

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Table of Contents

Chapter 1: Introduction 11

1.1 Product Description

Adept Cobra s800 Inverted™ Robots 11 Adept AIB™, eAIB™ 12 Adept SmartController 13

1.2 Dangers, Warnings, Cautions, and Notes in Manual

1.3 Safety Precautions

1.4 What to Do in an Emergency Situation

1.5 Additional Safety Information

Manufacturer’s Declaration of Compliance (MDOC) 16 Adept Robot Safety Guide 16

1.6 Intended Use of the Robots

1.7 Installation Overview

1.8 Manufacturer’s Declaration

1.9 How Can I Get Help?

Related Manuals 18 Adept Document Library 18

Chapter 2: Robot Installation 19

2.1 Transport and Storage

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking 20 Upon Unpacking 20

2.3 Repacking for Relocation

2.4 Environmental and Facility Requirements

2.5 Mounting the Robot

Mounting Surface 21 Mounting Procedure 22

2.6 Connectors on Robot Interface Panel

Chapter 3: System Installation 27

3.1 System Cable Diagram

3.2 Cable and Parts List

3.3 Installing the SmartController

3.4 Connecting User-Supplied PC to Robot

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Table of Contents

PC Requirements 29

3.5 Installing Adept ACE Software

3.6 Cable Connections from Robot to SmartController

3.7 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power 31 Details for 24 VDC Mating Connector 31 Creating 24 VDC Cable 32 Installing 24 VDC Robot Cable 32

3.8 Connecting 200-240 VAC Power to Robot

Specifications for AC Power 34 Details for AC Mating Connector 36 Creating the 200-240 VAC Cable 36 Installing AC Power Cable to Robot 37

3.9 Grounding the Adept Robot System

Ground the Robot Base 37 Grounding Robot-Mounted Equipment 38

3.10 Installing User-Supplied Safety Equipment

Chapter 4: System Operation 39

4.1 Robot Status LED Description

4.2 Status Panel Fault Codes

4.3 Brakes

Programmable E-Stop Delay 41 Brake Release Button 42

4.4 Front Panel

4.5 Connecting Digital I/O to the System

Using Digital I/O on Robot XIO Connector 45 Optional I/O Products 46 XIO Input Signals 46 XIO Output Signals 48 XIO Breakout Cable 50

4.6 Starting the System for the First Time

Verifying Installation 52 Turning on Power and Starting Adept ACE 53 Enabling High Power 54 Verifying E-Stop Functions 54 Verify Robot Motions 54

4.7 Learning to Program the Robot

Chapter 5: Maintenance 55

5.1 Field-replaceable Parts

5.2 Periodic Maintenance Schedule

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Table of Contents

5.3 Checking Safety Systems

5.4 Checking Robot Mounting Bolts

5.5 Checking for Oil Around Harmonic Drives

5.6 Lubricating Joint 3 Ball Screw

Lubrication Procedure 57

5.7 Replacing the AIB or eAIB Chassis

Removing the AIB or eAIB Chassis 60 Installing a New AIB or eAIB Chassis 64

5.8 Commissioning a System with an eAIB

Safety Commissioning Utilities 65 E-Stop Configuration Utility 67 E-Stop Verification Utility 68 Teach Restrict Configuration Utility 68 Teach Restrict Verification Utility 69

5.9 Replacing the Encoder Battery Pack

Battery Replacement Time Periods 71 Battery Replacement Procedure 71 Installing an Encoder Battery in the Inner Link 73

Chapter 6: Optional Equipment Installation 75

6.1 Installing End-Effectors

6.2 Removing and Installing the Tool Flange

Removing the Flange 75 Installing the Flange 76

6.3 User Connections on Robot

User Air Lines 76 User Electrical Lines 78

6.4 Internal User Connectors

SOLND Connector 80 OP3/4 Connector 80 EOAPWR Connector 81 Internal User Connector Output Specifications 82 ESTOP Connector 82

6.5 Mounting Locations for External Equipment

6.6 Installing Robot Solenoid Kit

Introduction 85 Tools Required 86 Procedure 86

6.7 Installing Camera Bracket Kit

Introduction 90 Tools Required 90 Procedure 90

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Table of Contents

6.8 DeviceNet Communication Link

Recommended Vendors for Mating Cables and Connectors 93

6.9 Installing Adjustable Hardstops

Joint 1 Adjustable Hardstops 94 Joint 2 Adjustable Hardstops 98

Chapter 7: Technical Specifications 105

7.1 Dimension Drawings

7.2 Cobra s800 Inverted Robot Internal E-STOP Connections

7.3 XSYS/XSYSTEM Connector

7.4 XSLV Connector

7.5 Robot Specifications

105

112

113

Chapter 8: Cleanroom Robots 117

8.1 Cobra s800 Inverted Cleanroom Option

Introduction 117

8.2 Connections

8.3 Requirements

8.4 Exclusions and Incompatibilities

8.5 Maintenance

Bellows Replacement 119 Lubrication 121

117

118

119

Chapter 9: IP-65 Option 123

9.1 IEC IP-65 Classification

9.2 Modifications to Meet IP-65 Classification

Outer link 124 AIB/eAIB Cable Seal 124 Controller 124 Hard Stop, Rotation Range 124

9.3 AIB/eAIB Cable Seal Overview

9.4 Removing/Installing the Cable Entry Housing

Removing the Cable Entry Housing Cover 126 Installing the Cable Entry Housing Cover 128 Removing the Cable Entry Housing Body 128 Installing the Cable Entry Housing Body 128

9.5 Removing/Installing Outer Link Cover

Removing Outer Link Cover 128 Installing Outer Link Cover 130

9.6 Customer Requirements

Sealing the Tool Flange 131

123

124

128

131

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Table of Contents

Pressurizing the Robot 132

9.7 User Connectors

User Electrical and DeviceNet 133 User Air Lines 134 Robot Solenoid Option 134

9.8 Maintenance

Replacing IP-65 Bellows 134

9.9 Installing the Roxtec Cable Seal Assembly

9.10 Removing the Roxtec Cable Seal Assembly

133

134

135

140

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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 illustration 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.

Chapter 1: Introduction

Figure 1-1. Adept Cobra s800 Inverted Robot

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Chapter 1: Introduction

Joint 1

Inner Link

Outer Link

Joint 2

Joint 4

Joint 3

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:

On-board digital I/O

8 kHz servo rate to deliver low positional errors and superior path following.

Low EMI for use with noise sensitive equipment

No external fan for quiet robot operation

Sine wave commutation to lower cogging torque and improve path-following

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

Temperature sensors on all amplifiers and motors for maximum reliability and easy troubleshooting

Adept eAIB only:

Hardware-based E-Stop and Teach Restrict controls

For improved safety relative to European standards implemented in 2012

The two amplifiers look very similar, and both fit the Cobra s800 Inverted robot.

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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:

Adept Cobra s-Series robots

Adept Quattro robots

Adept Viper s-Series robots

Adept Python linear modules

Adept MotionBlox-10

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.

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Chapter 1: Introduction

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.

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NOTE:Notes provide supplementary information, emphasize a point or procedure, or give a tip for easier operation.

1.3 Safety Precautions

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.

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:

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.

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.

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.

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

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

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 CO2to extinguish the fire.

1.5 Additional Safety Information

Adept provides other sources for more safety information:

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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 lb). 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 Reference Location

Mount the robot to a flat, secure mounting surface. Mounting the Robot on

page 21.

Install the SmartController, Front Panel, pendant (optional), and Adept ACE user interface.

Install 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.

Installing the SmartController on page

28.

Cable Connections from Robot to SmartController on page 30.

Installing the SmartController on page

28.

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.

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Connecting 24 VDC Power to Robot on page

31.

Connecting 200-240 VAC Power to Robot on page

33.

Chapter 1: Introduction

Task to be Performed Reference Location

Install user-supplied safety barriers in the workcell. Installing User-Supplied

Safety Equipment on page

38.

Read System Operation on page 39 to learn about connecting digital I/O through the XIO connector on the robot.

Read System Operation on page 39 to learn about starting the system, including system start-up and testing.

Read Optional Equipment Installation on page 75 if you need to install optional equipment, including end-effectors, user air and electrical lines, external equipment, solenoids, 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.

From the Download Types drop-down list, select Manufacturer Declarations.

From the Product drop-down list, select your Adept robot product.

Connecting Digital I/O to the System on page 43.

Starting the System for the First Time on page 52.

Installing End-Effectors on page 75.

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.

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.

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

For Contact information:

http://www.adept.com/contact/americas

For Product Support information: http://www.adept.com/support/service-and-

support/main

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Chapter 1: Introduction

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

Manual Title Description

Adept Robot Safety Guide Contains safety information for Adept robots.

Adept SmartController User's Guide

Adept T2 Pendant User's Guide

Contains information on the installation and operation of the Adept SmartController and the optional sDIO product.

Describes the use of the optional Adept manual control pendant.

Adept ACE User's Guide Instruction for the use of the Adept ACE software.

Adept Dual-Robot Configuration Procedure

Contains cable diagrams and configuration procedures for a 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:

the Adept Software CD shipped with your system.

the Adept website. Select Document Library from the Adept home page. To go directly to the Adept Document Library, type the following URL into your browser:

http://www.adept.com/Main/KE/DATA/adept_search.htm

To locate information on a specific topic, use the Document Library search engine on the ADL main page. To view a list of available product documentation, use the menu links located above the search field.

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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 lb) with no options installed.

Chapter 2: Robot Installation

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 locations.

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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. Specify 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)

Humidity 5 to 90%, non-condensing

Altitude up to 2000 m (6500 ft)

Pollution degree 2 (IEC 1131-2/EN 61131-2)

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Robot protection class (ISO)

107

160

205

160

189

4X Ø 14 Thru

Ø 8

2X R 4

+ 0.015

0.000

+ 0.015

0.000

Standard version IP-20

IP-65 version IP-65

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.

Chapter 2: Robot Installation

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.

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Mounting Procedure

183.2

278

500

778

Always use at least two people, and preferably three, to mount the robot.

The robot should be in the folded position when lifting. See the following figure.

Chapter 2: Robot Installation

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

Standard Size Specification Torque

Metric M12 x P1.75 ISO Property Class 8.8

SAE 7/16-14 UNC SAE J429 Grade 5 or

85 N·m

65 ft-lbf

ASTM A449

Using the dimensions shown in Figure 2-2, drill and tap the mounting surface for four M12 - 1.75 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.

Remove the four screws on top of the wooden robot base protection box (see Figure 2-4).

Remove the robot base protection box.

Retain the four screws and box for possible later relocation of the equipment.

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Chapter 2: Robot Installation

Figure 2-4. Robot on a Transportation Pallet

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.

Slowly lift the robot while aligning the base and the tapped mounting holes in the mounting surface.

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.

Remove the bolts securing the robot to the pallet.

Retain these bolts for possible later relocation of the equipment.

Move the pallet out of the way.

Tighten the user-supplied mounting bolts to the torque specified in Table 2-2.

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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

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.

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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 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.

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Chapter 3: System Installation

Ethernet to PC

IEEE 1394 Cable Controller SmartServo (Port 1.1) to AIB/eAIB SmartServo

Adept SmartController

Adept Cobra s800 Inverted Robot

User-Supplied 24 VDC Power Supply

User-Supplied 200-240 VAC, single-phase

Controller (XFP) to Front Panel (XFP)

Front Panel

XSYS/eAIB XSYS Cable Controller (XSYS) to AIB/eAIB (XSLV/XSYSTEM)

24 VDC Power to Controller (XDC1)

24 VDC Power to Robot (+24 VDC Input)

User-Supplied PC running Adept ACE software

Terminator Installed

User-Supplied Ground Wire

Pendant (optional)

Controller (XMCP) to Pendant

STOP

SmartServo IEEE-1394

1 2 3 4

SF ES HD

SW1

1.1 1.2 2.1 2.2

1 2 3

XDIO

LANHPE

OFF

XSYS

CAMERA

Eth 10/100

XUSR

Device Net

XFP

RS-232/TERM

RS-232-1

XMCP

BELT ENCODER

SmartController CX

-+ -+

RS-422/485

XDC1 XDC2

24V 5A

*S/N 3562-XXXXX*

RS-232-2

User-Supplied Ground Wire

3.1 System Cable Diagram

Figure 3-1. System Cable Diagram—AIBShown

NOTE:See Installing 24 VDC Robot Cable on page 32 for additional system grounding information.

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3.2 Cable and Parts List

Part Description Notes

IEEE 1394 Cable, 4.5 M Standard cable—

XSYS Cable, AIB only, 4.5 M Standard cable—

eAIB XSYS Cable, 4.5 M Standard cable—

Chapter 3: System Installation

Table 3-1. Cable and Parts List

supplied with system

supplied with AIB system

supplied with eAIB system

eAIB XSLV Adapter Cable, 250 mm

Front Panel Cable, 3 M Supplied with Front

T1/T2 Pendant Adapter Cable Supplied with Adept

Power Cable Kit - contains

24VDC and AC power cables

XIO Breakout Cable, 12 inputs/ 8 outputs, 5 M

Y Cable, for XSYS cable connections to dual robots— requires two eAIB XSLV cables 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.

Standard adapter cable for AIB-eAIB upgrade

Panel

T2™ pendant (option)

Available as option

Available as option—see XIO Breakout Cable on page 50.

Available as option—see

Adept Dual-Robot Configuration Procedure.

Mount the SmartController and Front Panel.

WARNING:Ensure that the front panel is located outside of the workcell and outside of the work envelope.

Connect the Front Panel to the SmartController.

Connect the pendant, if purchased, to the SmartController.

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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.

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 ACE 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

Processor: Core2Duo 2.0 GHz or better

Disk Space: 500 MB recommended minimum

RAM: 2 GB or more

Monitor: SVGA, minimum resolution 800 x 600

Ethernet: IEEE 1394 or Gigabit-Ethernet support

Software

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

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.

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.

Especially if you are upgrading your Adept ACE software installation: from the Adept

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Chapter 3: System Installation

ACE software CD-ROM menu, click Read Important Information.

From the Adept Software CD-ROM menu, click Install the Adept ACE Software.

The Adept ACE Setup wizard opens. Follow the instructions as you step through the installation process.

When the install is complete, click Finish.

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:

Locate the IEEE 1394 cable (length 4.5 M)

For an AIBsystem, locate the XSYS cable

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 AIB or eAIB interface panel, as shown in Figure 3-1.

AIBonly:

l 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:

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. Connect the XSYSTEM end to the eAIB, and the XSYS end to the SmartController.

For a 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.

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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)

Circuit Protection

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

Shield Termination Braided shield connected to ‘-’ terminal at

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.)

(21.6 V< Vin< 26.4 V)

Output must be less than 300 W peak

or

8 Amp in-line fuse

both ends of cable—see Figure 3-2.

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 recommends 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

Vendor Name Model Ratings

XPiQ JMP160PS24 24 VDC, 6.7 A, 160 W

AstroDyne SP-150-24 24 VDC, 6.3 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.

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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 Crimper

NOTE:The 24 VDC cable is not supplied with the system, but is available in the optional Power Cable kit, see Table 3-1.

Creating 24 VDC Cable

Locate the connector and pins from Table 3-4.

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.

Crimp the pins onto the wires using the crimping tool recommended in Table 3-4.

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

Prepare the opposite end of the cable for connection to your user-supplied 24VDC power supply.

Molex p/n 63811-0400

Digi-Key p/n WM9907-ND

Installing 24 VDC Robot Cable

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.

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–

24 V, 8 A

Frame Ground

24 V, 5 A

–

User-Supplied Power Supply 24 VDC

Adept Cobra s800 Inverted Robot

User-Supplied Shielded Power Cable

Adept SmartController

User-Supplied Shielded Power Cable

Attach shield from user-supplied cable to side of controller using star washer and M3 x 6 screw.

Attach shield from usersupplied cables to frame ground on power supply.

Attach shield from usersupplied cable to ground screw on Cobra s800 Inverted robot interface panel.

–

GND

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.

3.8 Connecting 200-240 VAC Power to Robot

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.

WARNING:Appropriately sized branch circuit protection and Lockout / Tagout capability must be provided in accordance with the National Electrical Code and any local codes.

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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

Auto-Ranging

Nominal Voltage

Ranges

Minimum

Operating

Voltage

Maximum Operating

Voltage

Frequency/

Phasing

Recommended External Circuit

Breaker, User-

Supplied

200 V to 240 V 180 V 264 V 50/60 Hz,1-phase 10 Amps

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

performance.

Table 3-6. Typical Robot Power Consumption

Move

Average

Power (W)

RMS Current

(A)

Peak Power

(W)

No load - Adept cycle 377 1.71 1406

5.5 kg - Adept cycle 531 2.41 1955

5.5 kg - all joints move 794 3.61 2110

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.

WARNING:Adept systems require an isolating transformer for connection to mains systems that are asymmetrical or use an isolated (impedant) neutral. Many parts of Europe use an impedant neutral.

DANGER:AC power installation must be performed by a skilled and instructed person—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.

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EENNL

F1 10 A

Adept Cobra s800 Inverted Robots 1Ø 200–240 VAC

User-Supplied AC Power Cable

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

1 Ø 200–240 VAC 20 A

L = Line N = Neutral E = Earth Ground

EENL3L

F5 10 A

F4 10 A

Adept Cobra s800 Inverted Robots 1Ø 200–240 VAC

User-Supplied AC Power Cable

Note: F4 and F5 are user-supplied, must be slow blow.

3 Ø 200–240 VAC

L = Line 1 N = Line 2 E = Earth Ground

200–240 VAC

Facility Overvoltage Protection

The user must protect the robot from excessive overvoltages and voltage spikes. If the country of installation requires a CE-certified installation, or compliance with IEC1131-2, the following information may be helpful: IEC 1131-2 requires that the installation must ensure that CategoryII overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltage CategoryII, i.e., not higher than the impulse voltage corresponding to the rated voltage for the basic insulation. The user-supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient.

In the industrial environment, 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

Figure 3-3. Typical AC Power Installation with Single-Phase Supply

Figure 3-4. Single-Phase Load across L1 and L2 of a Three-Phase Supply

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NOTE:If a three-phase power source is used, it must be symmetrically-earthed (with grounded neutral). Connections called out as single-phase can be wired Lineto-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

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

Locate the AC mating connector shown in Table 3-7.

Open the connector by unscrewing the screw on the shell and removing the cover.

Loosen the two screws on the cable clamp—see Figure 3-5.

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.

Strip 18 to 24 mm insulation from each of the three wires.

Insert the wires into the connector through the removable bushing.

Connect each wire to the correct terminal screw, and tighten the screw firmly.

Tighten the screws on the cable clamp.

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

10.

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

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Figure 3-5. AC Power Mating Connector

Installing AC Power Cable to Robot

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.

Plug the AC connector into the AC power connector on the interface panel on the robot.

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.

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Figure 3-6. Ground Point on Robot Base (standard robot shown)

See Installing 24 VDC Robot Cable on page 32 for additional system grounding information.

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 usersupplied 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.

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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.

Figure 4-1. Robot Status LED Indicator Location

Table 4-1. Status LED Definitions on UL-Certified Robots

LED Status

Off (No display) 24 VDC not present

Off OK High Power Disabled

Amber, Solid ON High Power Enabled

Amber, Slow Blink OK Selected Configuration Node

Amber, Fast Blink Fault Code(s) Fault

Amber, Solid Fault Code(s) Fault

See Status Panel Fault Codes on page 40 for information on Fault Codes.

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Description

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.

Figure 4-2. Status Panel

Table 4-2. Status Panel Code

LED Status Code LED Status Code

OK No Fault (High Power OFF) H# High Temp Encoder (Joint #)

ON High Power ON hV High Voltage Bus Fault

MA Manual Mode I# Initialization Stage (Step #)

24 24 V Supply Fault M# Motor Stalled (Joint #)

A# Amp Fault (Joint #) NV Non-Volatile Memory

B# IO Blox Fault (Address #) P# Power System Fault (Code #)

AC AC Power Fault PR Processor Overloaded

D# Duty Cycle Exceeded (Joint #) RC RSC Fault

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

ES E-Stop SW Watchdog Timeout

F# External Sensor Stop S# Safety System Fault (Code #)

FM Firmware Mismatch T# Safety System Fault

FW 1394 Fault TR Teach Restrict Fault

h# High Temp Amp (Joint #) V# Hard Envelope Error (Joint #)

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.

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.

Chapter 4: System Operation

LED Status Code LED Status Code

(Code 10 + #)

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, highinertia 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 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):

Auto Mode E-Stop Shutdown Timeout

Hold-to-Run E-Stop Shutdown Timeout

Manual Mode E-Stop Shutdown Timeout

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Chapter 4: System Operation

Auto Mode

Manual Mode

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 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

XFP connector

Connects to the XFP connector on the SmartController.

System 5 V Power-On LED

Indicates whether or not power is connected to the robot.

Figure 4-3. Front Panel

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Manual/Automatic Mode Switch

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

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 usersupplied 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.

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 12 inputs

8 outputs

XDIO Connector on SmartController

Optional IO Blox Device, connects to robot

Optional sDIO Module, connects to controller

12 inputs 8 outputs

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

32 inputs, 32 outputs per module; up to eight sDIO per system

see Using Digital I/O on Robot XIO Connector on page 45

see Adept SmartController

User's Guide

see Adept IOBlox User's Guide

see Adept SmartController

User's Guide

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Chapter 4: System Operation

IEEE-1394

SC-DIO

LINK

*S/N 3563-XXXXX*

24V 0.5A

- + - +

1.1 1.2 XDC1 XDC2

SmartServo IEEE-1394

1 2 3 4

SF ES HD

SW1

1.1 1.2 2.1 2.2

1 2 3

XDIO

LANHPE

OFF

XSYS

CAMERA

Eth 10/100

XUSR

Device Net

XFP

RS-232/TERM

RS-232-1

XMCP

BELT ENCODER

SmartController CX

-+ -+

RS-422/485

XDC1 XDC2

24V 5A

*S/N 3562-XXXXX*

RS-232-2

Optional IO Blox Device

Optional sDIO #1

SmartController

Cobra s800 Inverted Robot

IO Blox #1 8 Input signals: 1113 to 1120 8 Output signals: 0105 to 0112

sDIO #1 32 Input signals: 1033 to 1064 32 Output signals: 0033 to 0064

XDIO Connector 12 Input signals: 1001 to 1012 8 Output signals: 0001 to 0008

XIO Connector 12 Input signals: 1097 to 1108 8 Output signals: 0097 to 0104

Location Type Signal Range

Controller XDIO connector Inputs 1001 - 1012

sDIO Module 1 Inputs 1033 - 1064

sDIO Module 2 Inputs 1065 - 1096

Robot 1 XIO connector

IO Blox 1 Inputs 1113 - 1120

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

Table 4-4. Default Digital I/O Signal Configuration, Single Robot System

Outputs 0001 - 0008

Outputs 0033 - 0064

Outputs 0065 - 0096

Inputs 1097 - 1108

Outputs 0097 - 0104

Outputs 0105 - 0112

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Location Type Signal Range

IO Blox 2 Inputs 1121 - 1128

Outputs 0113 - 0120

IO Blox 3 Inputs 1129 - 1136

Outputs 0121 - 0128

IO Blox 4 Inputs 1137 - 1144

Outputs 0129 - 0136

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.

12 Inputs, signals 1097 to 1108

8 Outputs, signals 0097 to 0104

Table 4-5. XIO Signal Designations

Pin No.

Designation

Signal

Bank

1 GND

2 24 VDC

3 Common 1 1

4 Input 1.1 1 1097

5 Input 2.1 1 1098

6 Input 3.1 1 1099

7 Input 4.1 1 1100

8 Input 5.1 1 1101

9 Input 6.1 1 1102

10 GND

11 24 VDC

12 Common 2 2

V+/eV+

Signal

Number

13 Input 1.2 2 1103

14 Input 2.2 2 1104

15 Input 3.2 2 1105

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Pin 1Pin 9

Pin 10Pin 18

Pin 26 Pin 19

Pin No.

Designation

Signal

Bank

V+/eV+

Signal

Number

16 Input 4.2 2 1106

17 Input 5.2 2 1107

18 Input 6.2 2 1108

19 Output 1 0097

20 Output 2 0098

21 Output 3 0099

22 Output 4 0100

23 Output 5 0101

24 Output 6 0102

25 Output 7 0103

26 Output 8 0104

XIO 26-pin female connector on

Robot Interface Panel

Optional I/O Products

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

XIO Breakout Cable, 5 meters long, with flying leads on user’s end. See XIO Breakout Cable on page 50 for information. This cable is not compatible with the XIO Termination Block.

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 XIO

Termination Block Installation Guide for details.

XIO Input Signals

The 12 input channels are arranged in two banks of six. Each bank is electrically isolated from the other bank and is optically isolated from the 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.

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XIO Input Specifications

Parameter Value

Operational voltage range 0 to 30 VDC

OFF state voltage range 0 to 3 VDC

ON state voltage range 10 to 30 VDC

Typical threshold voltage Vin= 8 VDC

Operational current range 0 to 7.5 mA

OFF state current range 0 to 0.5 mA

ON state current range 2.5 to 7.5 mA

Typical threshold current 2.0 mA

Chapter 4: System Operation

Table 4-6. XIO Input Specifications

Impedance (Vin/I

Current at Vin= +24 VDC I

Turn-on response time (hardware)

Software scan rate/response time

) 3.9 KΩ minimum

≤ 6 mA

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

Turn-off response time (hardware)

Software scan rate/response time

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

NOTE:The input current specifications are provided for reference. Voltage sources are typically used to drive the inputs.

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Typical Input Wiring Example

Adept-Supplied Equipment

User-Supplied Equipment

Signal 1097

Part Present Sensor

Signal 1098

Feeder Empty Sensor

Signal 1099

Part Jammed Sensor

Signal 1100

Sealant Ready Sensor

Signal 1101

Signal 1102

+24 V

GND

Bank 1

Common

Bank 2

Common

Signal 1103

Signal 1104

Signal 1105

Signal 1106

Signal 1107

Signal 1108

GND

+24 V

Wiring Terminal Block

Typical User Input Signals

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

Bank 1 configured for

Sinking (NPN) Inputs

Bank 2 configured for

Sourcing (PNP) Inputs

Input Bank 2 Input Bank 1

XIO Connector – 26-Pin Female D-Sub

(equivalent circuit)

Chapter 4: System Operation

XIO Output 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.

The eight digital outputs share a common, high side (sourcing) driver IC. The driver is designed to supply any kind of load with one side connected to ground. It is designed for a range of user-provided voltages, from 10 to 24 VDC, and each channel is capable of up to

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

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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

Parameter Value

Power supply voltage range See Table 3-2.

Operational current range, per channel

Total Current Limitation, all channels on

On state resistance (I

out

= 0.5 A)

Output leakage current I

≤ 700 mA

out

≤ 1.0 A @ 50° C ambient

total

≤ 1.5 A @ 25° C ambient

total

≤ 0.32 Ω @ 85° C

≤ 25 µA

out

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

(hardware only)

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

(hardware only)

Output voltage at inductive load turnoff (I

= 0.5 A, Load = 1 mH)

out

DC short circuit current limit 0.7 A ≤ I

Peak short circuit current I

(+V - 65) ≤V

LIM

≤ 4 A

ovpk

demag

≤ 2.5 A

≤ (+V - 45)

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Chapter 4: System Operation

Adept-Supplied Equipment User-Supplied Equipment

Outputs 1-8

Typical User Loads

XIO Connector – 26-Pin Female D-Sub

+24 VDC

Signal 0097

Signal 0098

Signal 0099

Signal 0100

Signal 0101

Signal 0102

Signal 0103

Signal 0104

GND

Load

Customer AC Power Supply

Load

(equivalent circuit)

Wiring Terminal Block

Typical Output Wiring Example

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

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Chapter 4: System Operation

Pin 9

Pin 1

Pin 18

Pin 10

Pin 19

Pin 26

Table 4-8. XIO Breakout Cable Wire Chart

Pin No.

Signal

Designation Wire Color Pin Locations

1 GND White

2 24 VDC White/Black

3 Common 1 Red

4 Input 1.1 Red/Black

5 Input 2.1 Yellow

6 Input 3.1 Yellow/Black

7 Input 4.1 Green

8 Input 5.1 Green/Black

9 Input 6.1 Blue

10 GND Blue/White

11 24 VDC Brown

12 Common 2 Brown/White

13 Input 1.2 Orange

14 Input 2.2 Orange/Black

15 Input 3.2 Gray

26-pin male connector on XIO Breakout Cable

16 Input 4.2 Gray/Black

17 Input 5.2 Violet

18 Input 6.2 Violet/White

19 Output 1 Pink

20 Output 2 Pink/Black

21 Output 3 Light Blue

22 Output 4 Light Blue/Black

23 Output 5 Light Green

24 Output 6 Light Green/Black

25 Output 7 White/Red

26 Output 8 White/Blue

Shell Shield

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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:

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

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

Verifying all E-Stops in the system function correctly.

Moving each 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

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

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

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

System Cable Checks

Verify the following connections:

Front Panel to the SmartController

Pendant to the SmartController, via the pendant-adapter cable

User-supplied 24 VDC power to the controller

User-supplied ground wire between the SmartController and ground

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

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.

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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.

User-supplied 24 VDC power to the robot 24 VDC connector

User-supplied 200/240 VAC power to the robot 200/240 VAC 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.

Manually move the robot joints away from the folded shipping position, which is shown in Figure 2-3.

Turn on the 200/240 VAC power. See Connecting 200-240 VAC 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.

Double-click the Adept ACE icon on your Windows desktop,

From the Windows Start menu bar, select:

Start > Programs > Adept Technology > Adept ACE > Adept ACE.

On the Adept ACE Getting Started screen:

Select New SmartController Workspace

Select Create Workspace for Selected Controller: to make the connection to the controller.

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”.

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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

From the Adept ACE main menu, click the Enable High Power icon ( ).

Press and release the blinking High Power 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 reference guides in the Adept Document Library (ADL) on the Adept website. For more details on the ADL, see Adept Document Library on page 18.

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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:

Part Adept Part Number

Encoder battery pack 09977-000 (3.6 V, 6.8 Ah)

AIB (Amp-In-Base) 04900-000

eAIB (Amp-In-Base) 19800-800

Chapter 5: Maintenance

Table 5-1. Field-replaceable Parts

(This has replaced part number 02704-000)

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

Item Period Reference

Check E-Stop, enable, key switches, and barrier interlocks 6 months See Section 5.3

Check robot mounting bolts 6 months See Section 5.4

Check for signs of oil around the harmonic drives 3 months See Section 5.5

Lubricate Joint 3 (Z-axis) ball screw 3 months See Section 5.6

Replace Encoder battery 5 to 10

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.

See Section 5.9

years

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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.

Test operation of:

E-Stop button on Front Panel

E-Stop button on the optional pendant

Enabling switch on the optional pendant

Auto/Manual switch on Front Panel

NOTE:Operating any of the above switches should disable high power.

Test operation of any external (user supplied) E-Stop buttons.

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.

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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:

the area around Joint 1

the area around Joint 2

inside 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

Lubrication Procedure

Turn off main power to the controller and robot.

Lock out and tag out power.

Remove the outer link cover by removing six screws located on the sides and top of the cover. Carefully remove the cover.

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.

CAUTION:Using improper lubrication products on the Adept Cobra s800 Inverted robot may cause damage to the robot.

WARNING:When the Outer link cover is removed, you see the label shown in Figure 2-3. Do not remove the J3ENC 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 Cleanroom version, refer to Maintenance on page 119 for instructions on removing the bellows. The outer link cover is standard.

Switch on 24 VDC power to the robot

Press the brake button and move Joint 3 to the top of its travel. Remove any existing

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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.

10. Reinstall the outer link cover.

For the Cleanroom and IP-65 versions, replace the bellows.

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Joint 3 Ball Screw Lubrication Points

NOTE:

Apply grease to the

three vertical grooves

and the spiral groove

Section A-A

Top View Looking Down

Quill Shaft

Vertical Groove Lube Point A

Vertical Groove Lube Point B

Vertical Groove Lube Point C

Upper Quill Grease Locations

Lower Quill Grease Locations

Joint 3 Ball Screw Lubrication Points

Chapter 5: Maintenance

Figure 5-1. Lubrication of Joint 3 Quill

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Chapter 5: Maintenance

5.7 Replacing the AIB or eAIB Chassis

CAUTION:Follow appropriate ESD procedures during this procedure.

Removing the AIB or eAIB Chassis

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.

10.

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.

Figure 5-2. Securing Screw on Chassis

11.

Lift up the chassis and lift out the bottom of the chassis so the bottom shelf clears the robot base—see the following figure.

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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.

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.

Screw the support bolt into the side of the robot body.

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.

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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.

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:

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Chapter 5: Maintenance

15.

Carefully disconnect the following cables from their connectors on the PMAI/ePMAI board, by disengaging the securing latches:

INT1

INT2

ENC1

ENC2

16.

Disconnect and 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

Figure 5-8. Ground Screw Hole on eAIB Chassis

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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:

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.

Hang the chassis on the Supporting Bolt located on the side of the robot base. Refer to Figure 5-4.

Connect the ground wire to the chassis.

Carefully reconnect the cables you removed from their connectors on the PMAI/ePMAI board (see Figure 5-5). Engage the securing latches on the connectors.

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.

Figure 5-9. Installing Chassis in Robot Base

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-

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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).

Connect the eAIB XSYS cable or XSYS cable with eAIB XSLV Adapter to the chassis XSYSTEM connector (eAIB).

10.

Connect the 1394 cable to the chassis SmartServo connector.

11.

Connect any other cables, which may be connected to the chassis, such as XIO, or any others.

12.

Connect the 24 VDC supply cable to the chassis +24 VDC input connector.

13.

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.

14.

Switch on the 200/240 VAC input supply to the chassis.

15.

Switch on the 24 VDC input supply to the chassis.

16.

Switch on the SmartController.

17.

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 need the Adept ACE commissioning.

For a new system with an eAIB, 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.

If the system will not power up, and the robot status display shows SE, you need to commission the system.

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-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.

Teach Restrict

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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 apply to those amplifiers.

These two functions are supported by four wizards:

E-Stop Configuration

This sets the E-Stop hardware delay to factory specifications.

E-Stop Verification

This verifies that the hardware E-Stop is functioning correctly.

Teach Restrict Configuration

This sets the hardware Teach Restrict maximum speed to factory specifications.

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

The robot must be set up and functional.

The robot must use eAIB amplifiers.

The AIB amplifiers do not support these hardware functions, and these wizards will not run.

Adept ACE software must be installed.

The Front Panel keyswitch must be in Auto mode.

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No E-Stops can be activated.

Chapter 5: Maintenance

Figure 5-10. Adept Front Panel

For Configuration (E-Stop and Teach Restrict), the eAIB Commissioning Jumper must be plugged into the XBELTIO jack on the eAIB.

NOTE:This is the only time that this jumper will be used. It is part number 11901-000, and must be removed for Verification and normal operation.

Figure 5-11. eAIB Commissioning Jumper

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.

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Procedure

From within the Adept ACE software:

Open the robot object editor.

Select Configure > Safety Settings > Configure ESTOP Hardware Delay, then click Next.

This procedure will configure Channel A and then Channel B. It will then report the delay that it set for each.

Reboot the SmartController.

On some systems, the SmartController will reboot automatically.

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:

Open the robot object editor.

Select Configure > Safety Settings > Verify ESTOP Hardware Delay, then click Next.

Enable high power, if not already enabled, then click Next.

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.

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.

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Procedure

NOTE:This procedure takes 2 or 3 minutes to complete.

From within the Adept ACE software:

Open the robot object editor.

Select Configure > Safety Settings > Configure Teach Restrict, then click Next.

From the Prerequisite screen, click Next.

The wizard will go through all of the robot's motors, and display messages that it is configuring Channel A and B for each.

It will then record the configuration, and display the target times that it set.

Click Finish.

Reboot the SmartController.

On some systems, the SmartController will reboot automatically.

Chapter 5: Maintenance

Teach Restrict Verification Utility

This utility verifies that the Teach Restrict parameters are set correctly and that 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:

Open the robot object editor.

Select Configure > Safety Settings > Verify Teach Restrict, then click Next.

Teach a Start Position.

This can be any position that does not conflict with obstacles or the limits of joint movements.

If the robot is already in such a position, you can just click Next.

Otherwise, move the robot to such a position, then click Next.

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The screen will display the number of degrees that each joint is expected to move during the verification process.

You can click Preview Motions on this screen to view the motions at slow speed. The default speed is 10, but you can change that speed with this screen's speed control.

You can click Move to Ready, to move the robot to the Ready position.

The robot will move each joint, in succession. It will generate an over-speed condition for each, and verify that the hardware detected the over-speed condition.

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.

From the Introduction screen, click Next.

Set the pendant to Joint mode.

Set the pendant manual control speed to 100.

Click Next.

Using the pendant, jog any of the robot's joints until power is disabled.

This indicates that the Teach Restrict function is working.

Click Next.

The results of the verification will be displayed.

Click Finish.

Reboot the SmartController.

On some systems, the SmartController will reboot automatically.

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.

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NOTE:The previous battery, P/N 02704-000, has been superseded by this battery pack. The battery replacement interval and procedure 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

Obtain the replacement battery pack.

Switch off the SmartController.

Switch off the 24 VDC input supply to the robot.

Switch off the 200/240 VAC input supply to the robot.

Disconnect the 24 VDC supply cable from the robot +24 VDC input connector—see Figure 2-5 for locations of the connectors.

Disconnect the 200/240 VAC supply cable from the robot AC input connector.

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.

While holding the chassis 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.

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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.

10.

Place the new battery pack next to the original one, but do not disconnect the original one.

11.

Connect the new battery pack to the connectors on the secondary (unused) battery cable. Make sure that the positive and negative connections are correct.

12.

Once the new battery pack is connected, disconnect and remove the original battery pack.

13.

Place the new battery pack in the original location on the fan bracket inside the base of the robot.

14.

Close the robot and reconnect the cables by reversing the steps in the beginning of this procedure.

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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 encoder 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.

Obtain the replacement battery pack, p/n 09977-000.

Turn off all power to the robot.

Remove 10 screws on the bottom of the inner link cover and remove the inner link cover.

Locate the battery cable in the wire bundle in the inner link.

Figure 5-13. Location of Encoder Battery Cable in Inner Link

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.

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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 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 RobotMounted 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

Turn off high power and system power to the robot.

Remove any attached end-effectors or other tooling from the flange.

Use a 2.5 mm hex driver to loosen the setscrew (see Figure 6-1).

Note the vertical-spline groove that is in line with the setscrew. You must replace the flange in the same position.

Use a socket driver to loosen the two M4 socket-head screws.

Slide the flange down slowly until it is off the shaft. Be careful not to lose the ball bearing (3.5 mm) that is inside the flange behind the setscrew.

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Tool flange assembly

Setscrew

M4 Socket-head cap screws

Quill shaft

Installing the Flange

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.

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.

Chapter 6: Optional Equipment Installation

Figure 6-1. Tool Flange Removal Details

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.

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 Figure 6-5.

NOTE:On the IP-65 version robot, the connectors are under the outer link cover— see Figure 9-10.

The two larger connectors are 6 mm diameter.

The three smaller connectors are 4 mm diameter.

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Figure 6-2. User Connector Panel, standard version

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.

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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 panel 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 mm2(27 AWG), Pin Numbers 1-24, 12 pairs, twisted in

pairs as 1&2, 3&4, 5&6, .... 23&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.

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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.

Figure 6-6. SOLND Connector

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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

Pin # Description Pin Location

1 Output 3001

2 Ground

3 Output 3002

4 Ground

SOLND Connector

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

Pin # Description Pin Location

1 Output 3003

2 Ground

3 Output 3004

4 Ground

OP3/4 Connector

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

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Pin 1

Pin 2

Pin 3

Pin 4

For optional second set of solenoids, or other user supplied devices.

Pin 1

Pin 2

Pin 3

Pin 4

For optional Robot Solenoid Kit installation, or other user supplied devices.

+24VDC

OP3/4 Connector Circuit

Signal 3003

GND

Signal 3004

GND

Load

(equivalent circuit)

+24VDC

SOLND Connector Circuit

Signal 3001

GND

Signal 3002

GND

Load

(equivalent circuit)

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.

Figure 6-7. OP3/4 and SOLND Circuits

Table 6-3. EOAPWR Connector Pinout

Pin # Description Pin Location

1 24 VDC (see Table 6-4 for

current specs)

2 Ground

3 24 VDC (see Table 6-4 for

current specs)

4 Ground

Mating Connector: AMP/Tyco #172167-1, 4-pin Mini-Universal Mate-N-Lok AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok

EOAPWR Connector

as viewed on robot

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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

Parameter Value

Power supply voltage range See Table 3-2

Operational current range, per channel

Total Current Limitation, all channels on

On state resistance (I

= 0.5 A)

out

Output leakage current I

≤700 mA

out

≤1.0 A @ 50° C ambient

total

≤1.5 A @ 25° C ambient

total

≤0.32 Ω @ 85° C

≤25 µA

out

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

(hardware only)

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

(hardware only)

Output voltage at inductive load turnoff (I

= 0.5 A, Load = 1 mH)

out

DC short circuit current limit 0.7 A ≤ I

Peak short circuit current I

NOTE: Total current is the sum of the output current used by output

(+V - 65) ≤V

LIM

≤ 4 A

ovpk

demag

≤ 2.5 A

≤ (+V - 45)

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 EStop 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.

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Pin 1

Pin 2

User-supplied normally-closed contact. Can be connected to a break-away sensor to cause an E-Stop condition when circuit is open.

Note: This function is disabled by default - it must be enabled in software.

Typical ESTOP Connector Circuit

Table 6-5. ESTOP Connector

Pin # Description Pin Location

1 ESTOP_INPUT

2 24 V

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

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:

Click on Object.

Click Expert Access.

You will be asked for a password, to enter Expert Access.

Enter the Expert Access password.

To change the Break-away E-Stop parameter:

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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.

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.

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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 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.

Open the gripper object editor.

Select the Open/Close tab.

Set the signal values for Open, Close, and Release.

Figure 6-10. Setting Solenoid Signal Values

The Adept-supplied solenoids each draw a nominal 75 mA at 24 VDC.

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The solenoid valve assembly consists of two independent valves (Valve #1 and Valve #2) on a 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 (MPa)

28 - 114 0.19 - 0.786

Tools Required

Assorted hex drivers

Cable ties

Diagonal wire cutters

Solenoid Valve Upgrade Kit (Adept p/n 02853-000)

Procedure

Turn off all power to the robot.

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.

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.

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Figure 6-11. Solenoid Mounting Bracket with Connector and Spare Air Line

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).

Mount the solenoid manifold onto the bracket using the supplied M3 x 25 mm screws and washers (see Figure 6-12).

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 different 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.

Plug the connector plug into the female connector jack (marked SOLND) on the bracket.

Use cable ties to secure the air line to the bracket as needed.

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Figure 6-12. Solenoid Placement Using Mounting Hardware

Install the appropriate lengths of 5/32 inch plastic tubing (supplied) into the two output ports on the manifold.

Route the tubing up along the tower bracket next to the quill and down through the center of the quill.

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.

Figure 6-13. Connecting Spare Air Line to User Connector

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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-lb).

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:

Click the Digital I/O button in the controller toolbar:

The Digital I/O window will open.

Check Robot.

Select Signal 3001 and Signal 3002 (the first two blocks) to activate the solenoids one at a time.

The selected blocks will turn green, to indicate they are active.

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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:

One camera plate

Two camera brackets

One camera mount slide bracket

One camera mount channel

M4 x 12 mm screws

M4 stainless steel flat washers

M5 x 12 mm screws

Tools Required

M4 hex wrench

M3 hex wrench

Procedure

Install the camera plate to the outer link with four M5 x 12 mm screws (see Figure 6-14 as you perform this procedure).

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.)

Mount the camera channel to the camera brackets or camera plate with M4 x 12 mm screws.

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Camera Plate

Camera Brackets (optional)

Camera Channel

Camera Mount

Mount the camera to the camera mount.

Mount the camera and camera mount to the camera channel using M5 x 12 mm screws.

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 messagepacketing 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:

Male micro-style 12 mm thread DIN connector at the robot base (see Figure 6-2).

Female micro-style 12 mm thread DIN connector for joint 2 of the robot (see Figure 6-5 and Figure 6-15).

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:

Wire Adept DeviceNet

Power pairs 24 AWG 22 AWG

Signal pairs 28 AWG 24 AWG

“thin cable”

This means that total current on the power pairs must be limited to 2 A instead

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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 achievable. 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:

Double-click on the controller in the tree structure pane. This opens the object editor for the controller.

Select Configure > Configure V+ (or eV+).

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"

Parameter Description Range

local_id MACID for the Adept controller on the bus 0 - 63

baud_rate 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.

Use Add or Edit to set the values for DeviceNet.

The fields that need to be entered are:

Index - a unique number for this mapping

Byte - usually starts at 1

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Male Connector (pins)

Female Connector (sockets)

Micro-Style Connector

LEGEND:

1 Drain (bare) 2 V+ (red) 3 V- (black) 4 CAN_H (white) 5 CAN_L (blue)

(VIEWED FROM CONTACT END)

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.

Bit - usually starts at 1

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.

Signal - the input or output signal number (e.g. 1013 or 013) where mapping starts.

Bit_length - the number of input or output signals to map.

MACID - the MACID returned by the Scan.

When you are finished, click Done.

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.

Figure 6-15. Micro-Style Connector Pinouts for DeviceNet

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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.

Figure 6-16. Joint 1 Adjustable Hardstops

Installation Procedure

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.

Install the adjustable hardstop into the threaded hole using an 8 mm hex wrench. Tighten to a torque of 5.1 N•m (45 in-lbf).

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 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.

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Chapter 6: Optional Equipment Installation

From Adept ACE, select the robot in the tree structure pane.

Open the robot editor.

Figure 6-17. Robot Editor, with Joints Closed

Click the ‘+’ in front of Joints, to display all of the joints.

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Chapter 6: Optional Equipment Installation

Figure 6-18. Robot Editor, with Joints Expanded

Click the ‘+’ in front of [1], to open the values for joint 1.

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Chapter 6: Optional Equipment Installation

Figure 6-19. Robot Editor, with Joint 1 Expanded

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

Recommended

Hardstop Value

Joint Limit Softstop

J1 Hardstop Position 1 ± 93.5° Lower limit: – 92.5°

Upper limit: + 92.5°

J1 Hardstop Position 2 ± 114° Lower limit: – 113°

Upper limit: + 113°

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.

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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.

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 from 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.

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Installation Procedure

Remove the bottom cover from the underside of the inner link.

Chapter 6: Optional Equipment Installation

Figure 6-21. IP-65 Arcs

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.

Save the screws and IP-65 arcs for use later in this procedure.

Leave the two gaskets in place at Joint 2 on the inner link.

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.

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 does not have to be symmetrical.

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Chapter 6: Optional Equipment Installation

12 thru holes for M5 x 10 screws, for installing Joint 2 hardstops, located 30 degrees apart

Joint 2 Left Hardstop Plate, installed in +81 degree position

Joint 2 Fixed Hardstop Device

Joint 2 Positive direction

Joint 2 Negative direction

Joint 2 Right Hardstop Plate, installed in -81 degree position

View of under side of Inner Link, looking up

Figure 6-22. Joint 2 Adjustable Hardstop Locations

Figure 6-23. Screw Locations for Joint 2 Adjustable Hardstops

Use a 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-lb).

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Adept s800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Product Description

Adept Cobra s800 Inverted™ Robots

Chapter 1: Introduction

Adept AIB™, eAIB™

Adept SmartController

1.2 Dangers, Warnings, Cautions, and Notes in Manual

1.3 Safety Precautions

1.4 What to Do in an Emergency Situation

1.5 Additional Safety Information

Manufacturer’s Declaration of Compliance (MDOC)

Adept Robot Safety Guide

1.6 Intended Use of the Robots

1.7 Installation Overview

1.8 Manufacturer’s Declaration

1.9 How Can I Get Help?

Related Manuals

Adept Document Library

2.1 Transport and Storage

Chapter 2: Robot Installation

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking

Upon Unpacking

2.3 Repacking for Relocation

2.4 Environmental and Facility Requirements

2.5 Mounting the Robot

Mounting Surface

Mounting Procedure

2.6 Connectors on Robot Interface Panel

Chapter 3: System Installation

3.1 System Cable Diagram

3.2 Cable and Parts List

3.3 Installing the SmartController

3.4 Connecting User-Supplied PC to Robot

PC Requirements

3.5 Installing Adept ACE Software

3.6 Cable Connections from Robot to SmartController

3.7 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power

Details for 24 VDC Mating Connector

Creating 24 VDC Cable

Installing 24 VDC Robot Cable

3.8 Connecting 200-240 VAC Power to Robot

Specifications for AC Power

Details for AC Mating Connector

Creating the 200-240 VAC Cable

Installing AC Power Cable to Robot

3.9 Grounding the Adept Robot System

Ground the Robot Base

Grounding Robot-Mounted Equipment

3.10 Installing User-Supplied Safety Equipment

Chapter 4: System Operation

4.1 Robot Status LED Description

4.2 Status Panel Fault Codes

4.3 Brakes

Programmable E-Stop Delay

Brake Release Button

4.4 Front Panel

4.5 Connecting Digital I/O to the System

Using Digital I/O on Robot XIO Connector

Optional I/O Products

XIO Input Signals

XIO Output Signals

XIO Breakout Cable

4.6 Starting the System for the First Time

Verifying Installation

Turning on Power and Starting Adept ACE

Enabling High Power

Verifying E-Stop Functions

Verify Robot Motions

4.7 Learning to Program the Robot

5.1 Field-replaceable Parts

Chapter 5: Maintenance

5.2 Periodic Maintenance Schedule

5.3 Checking Safety Systems

5.4 Checking Robot Mounting Bolts

5.5 Checking for Oil Around Harmonic Drives