Adept Technology 300CR User Manual

AdeptSix 300CR Robot

Instruction Handbook

AdeptSix 300CR Robot

Instruction Handbook

P/N 01600-000

Rev. A

August 2002

3011 Triad Drive • Livermore, CA 94550 • USA • Phone [phone] • Fax [phone]

Otto-Hahn-Strasse 23 • 44227 Dortmund • Germany • Phone [phone] • Fax[phone]

41, rue du Saule Trapu • 91300 • Massy • France • Phone [phone] • Fax [phone]

The information contained herein is the property of Adept Technology, Inc., and shall not be repro­duced in whole or in part without prior written approval of Adept Technology, Inc. The informa­tion herein is subject to change without notice and should not be construed as a commitment by
Adept Technology, Inc. This manual is periodically reviewed and revised.

Adept Technology, Inc., assumes no responsibility for any errors or omissions in this document.
Critical evaluation of this manual by the user is welcomed. Your comments assist us in preparation
of future documentation. Please email your comments to: [e-mail].

Copyright

2002 by Adept Technology, Inc. All rights reserved.

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Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Overview of Typical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Read Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Controller and PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . . 14

Installing System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adding End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Turning On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Locating the Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 How Can I Get Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.6 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.7 Knowledge Express . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 Dangers, Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Precautions and Required Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Definition of a Manipulating Industrial Robot . . . . . . . . . . . . . . . . . . . . . . . 20

Safety Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3 Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Severity of Injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Control System Behavior Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4 Intended Use of the Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.5 Robot Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Acceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unacceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.6 AdeptSix 300CR Hazards and Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.8 Safety Requirements for Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.9 Working Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.10 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.11 Safety Equipment for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.12 Protection Against Unauthorized Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

AdeptSix 300CR Robot Instruction Handbook, Rev. A 5

Table of Contents

2.13 Safety Aspects While Performing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 30

2.14 Risks That Cannot Be Avoided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.15 Risks Due to Incorrect Installation or Operation . . . . . . . . . . . . . . . . . . . . . . . . 30

2.16 What to Do in an Emergency Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 Safety Guard Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Standard Information (ISO10218) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Using the Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3 Shipping Bracket and Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.5 Types of Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.6 Mounting Procedures for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

When the Robot and Mounting Fixture are

Installed on a Common Installation Base . . . . . . . . . . . . . . . . . . . . . . . . . . 37

When the Robot is Mounted Directly on the Floor . . . . . . . . . . . . . . . . . . . . 38

3.7 Axis Naming Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.8 Grounding the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.9 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4 System Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 System Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adept MV Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adept SmartController System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.2 Cable Connections from Robot to PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . 43

Connection to the Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connection to the PA-4 Power Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.3 Cable Connections to MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cable Connections to MV Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connecting User-Supplied Safety and I/O Equipment. . . . . . . . . . . . . . . . . 46

4.4 Cable Connections to SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Installing the SmartController. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cable Connections to SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Connecting User-Supplied Safety and I/O Equipment. . . . . . . . . . . . . . . . . 47

5 End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Table of Contents

5.2 Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.3 End of Arm Tooling Load Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.4 Calculating the Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.5 Mounting Equipment - Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.6 User Electrical Lines and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6 System Operation - MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

AC Power to Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

User-Supplied Safety Equipment on JUSER and JSIO Connector Checks . 63

6.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.7 Learning to Operate/ Program the AdeptSix 300CR Robot . . . . . . . . . . . . . . . 66

7 System Operation - SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Power to the Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

User-Supplied Safety Equipment on XUSR Connector Checks . . . . . . . . . . 69

E-Stop Button and Switch Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.7 Learning to Operate/ Program the AdeptSix 300CR Robot . . . . . . . . . . . . . . . 72

8 Using the Manual Control Pendant (MCP) . . . . . . . . . . . . . . . . . . . . . . 73

8.1 MCP Usage for Six-Axis Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Joint Mode (Single-Axis Movement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

AdeptSix 300CR Robot Instruction Handbook, Rev. A 7

Table of Contents

WORLD Coordinate System (WORLD Mode on the MCP) . . . . . . . . . . . . . . 75

TOOL Coordinate System (TOOL Mode on the MCP) . . . . . . . . . . . . . . . . . 76

Coordinate System Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

9 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Grease Replenishment for Axis 1 Speed Reducer . . . . . . . . . . . . . . . . . . . . 84

Grease Replenishment for Axis 2 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 85

Grease Replenishment for Axis 3 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 86

Grease Replenishment for Axis 4 and Axis 5 Speed Reducers . . . . . . . . . . 87

Grease Replenishment for Axis 6 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 88

Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Installing and Using Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

9.3 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

10.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

10.2 Robot Cleanroom Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

10.3 Part Names and Working Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

10.4 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

10.5 Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

10.6 Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

10.7 Axis 2 and 3 Effect on Axis 4 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8 AdeptSix 300CR Robot Instruction Handbook, Rev. A

List of Figures

Figure 1-1. Robot ID Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 2-1. AdeptSix 300CR — Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 3-1. Transporting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 3-2. Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 3-3. Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 3-4. Mounting the Robot Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 3-5. Direct Mounting on the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 3-6. Grounding Method for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 4-1. System Cable Diagram with Adept MV Controller . . . . . . . . . . . . . . . . . . . . 41

Figure 4-2. System Cable Diagram with Adept SmartController . . . . . . . . . . . . . . . . . . 42

Figure 4-3. Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 4-4. Interconnect Cable Connection to the Robot . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 4-5. PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 5-1. Moment Arm Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 5-2. Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 5-3. Center of Gravity: Calculating Tool Load Information . . . . . . . . . . . . . . . . . 51

Figure 5-4. Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 5-5. Center of Gravity: Sealing Gun Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 5-6. Moment of Inertia for Hexahedron and Cylinder . . . . . . . . . . . . . . . . . . . . . 54

Figure 5-7. Center of Gravity: Large Tool and Workpiece Example . . . . . . . . . . . . . . . 55

Figure 5-8. Center of Gravity: Dual End Effector Example . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 5-9. Installing Peripheral Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Figure 5-10. User Electrical and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Figure 5-11. Detailed Drawing of Connector Pin Numbers . . . . . . . . . . . . . . . . . . . . . . . . 60

Figure 8-1. Joint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Figure 8-2. World Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Figure 8-3. Tool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 8-4. Right Hand Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 9-1. Inspection Parts and Inspection Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Figure 9-2. Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Figure 9-3. Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Figure 9-4. Axis 1 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Figure 9-5. Axis 2 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Figure 9-6. Axis 3 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Figure 9-7. Axis 4 and Axis 5 Speed Reducers Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 87

Figure 9-8. Axis 6 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Figure 9-9. Encoder Connector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Figure 9-10. Manual Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Figure 10-1. Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

AdeptSix 300CR Robot Instruction Handbook, Rev. A 9

List of Figures

Figure 10-2. Baseplate Dimensions (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Figure 10-3. Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Figure 10-4. Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Figure 10-5. Axis 2 and Axis 3 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

10 AdeptSix 300CR Robot Instruction Handbook, Rev. A

List of Tables

Table 1-1. Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Table 2-1. Sources for International Standards and Directives . . . . . . . . . . . . . . . . . . . . .22

Table 2-2. Partial List of Robot and Machinery Safety Standards . . . . . . . . . . . . . . . . . . .23

Table 3-1. Maximum Repulsion Forces of the AdeptSix 300CR . . . . . . . . . . . . . . . . . . . . .37

Table 3-2. Axis Naming Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Table 5-1. Moment and Total Inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 6-1. LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items . . . . . . . . . . .78

Table 9-2. Inspection Parts and Grease Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Table 10-1. Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

AdeptSix 300CR Robot Instruction Handbook, Rev. A 11

1.1 Product Description

The AdeptSix 300CR is a compact, high-performance cleanroom robot that provides the
application flexibility of six axis articulation running on the Adept platform. The arm
design provides superior reach capability with a very small footprint to maximize system
flexibility and minimize cell layout size. The AdeptSix 300CR is available with either the
Adept MV controller or the Adept SmartController.

Adept software and controllers simplify integration of the robot by combining all of the
functions found in a typical robot work cell, which is common across the extensive Adept
Product Line. Available options for the AdeptSix 300CR include integral AVI vision,
adaptive Force Sensing, and real-time Conveyor Tracking.

The overall reach of the AdeptSix 300CR is 677 mm with a footprint of 300 mm. Maximum
payload is 3 kg. The AdeptSix 300CR comes standard with the ability to be mounted
either in a tabletop, side or overhead position providing maximum application flexibility.
Applications include assembly, packaging, machine load/unload, quality inspection,
sorting and other high performance tasks.

Introduction 1

1.2 Overview of Typical System Installation

This section provides an overview of the installation process for a typical AdeptSix 300CR
system.

Read Safety Information

1. Read Chapter 2 to understand general safety information about the AdeptSix
300CR robot system.

Installing the Robot

1. Prepare for installation, including installing safeguards, by following Section 3.1
to Section 3.3.

2. Mount the robot according to procedures described in Section 3.4. to Section 3.6

3. Install grounding cable on the robot. See Section 3.8.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 13

Chapter 1 - Introduction

Installing the Controller and PA-4 Power Chassis

Adept MV Controller

1. Refer to the AdeptSix Controller Installation Guide to install the Adept MV
controller and the PA-4 power chassis.

2. Install the AdeptWindows PC user interface according to instructions in the
controller manual.

Adept SmartController

1. Refer to the AdeptSix Controller Installation Guide to install the SmartController
and the PA-4 power chassis.

2. Install the AdeptWindows PC user interface according to instructions in the
controller manual.

Installing System Cables

1. Connect the system cables between the robot, controller, and PA-4 power chassis.
See Chapter 4.

2. See Figure 4-1 on page 43 for the system cable diagram for an Adept MV
controller.

3. See Figure 4-2 on page 44 for the system cable diagram for an SmartController.

Adding End of Arm Tooling

Refer to Chapter 5 for complete information on adding end of arm tooling to the robot.

Turning On the System

Refer to Chapter 6 for an Adept MV controller or Chapter 7 for an SmartController. These
chapters contain checklists to verify the installation is correct and to test all safety circuits
before using the robot.

1.3 Checking Package Contents

When the package arrives, check the contents for the following standard items (check any
other options ordered, as well):

• AdeptSix 300CR Robot

• Adept MV controller or SmartController

• Adept PA-4 power chassis

• Manual Control Pendant (MCP) (optional)

• Controller Interface Panel (CIP2) or Adept Front Panel

• Interconnect cables between controller and robot

14 AdeptSix 300CR Robot Instruction Handbook, Rev. A

WARNI NG: Confirm that the robot and the controller have

the same serial number. Special care must be taken when
more than one robot is to be installed. If the numbers do
not match, robots may not perform as expected and cause
injury or damage.

1.4 Locating the Serial Number

The ID serial number of the AdeptSix 300CR robot corresponds to the ID number of the
controller. You can check the controller ID using the V+ ID command. The robot’s ID serial
number is located on a label on the robot base. See Figure 1-1.

Locating the Serial Number

Location
of serial
label

Figure 1-1. Robot ID Serial Number

AdeptSix 300CR Robot Instruction Handbook, Rev. A 15

Chapter 1 - Introduction

1.5 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 the following information sources on Adept’s corporate web
site:

• For Contact information: http://www.adept.com/main/contact/index.html

• For Product Support information: http://www.adept.com/main/services/index.asp

• For general information about Adept Technology, Inc.: http://www.adept.com

1.6 Related Manuals

This manual covers the installation and maintenance of an AdeptSix 300CR system. There
are additional manuals that cover programming the system, reconfiguring installed
components, and adding other optional components. The following manuals (available on
the Knowledge Express CD-ROM provided with each system) provide information on
advanced configurations and system specifications.

Table 1-1. Related Manuals

Manual Title Description

AdeptSix Controller
Installation Guide

Adept MV Controller User’s
Guide

Adept SmartController
User’s Guide

AdeptWindows Installation
Guide

AdeptWindows User’s
Guide

Instructions for Adept
Utility Programs

V+ Operating System User’s
Guide

V+ Language User’s Guide Describes the V

Describes the installation process for the Adept MV controller
and the Adept SmartController.

Describes the configuration and interface options for all
Adept-supplied processor boards and components that can be
installed in an Adept control system.

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

Describes the basic installation process for the AdeptWindows
PC user interface.

Describes complex network installations, installation and use
of NFS server software, the Adept Windows Offline Editor, and
the AdeptWindows DDE software.

Describes the utility programs used for advanced system
configurations, system upgrades, file copying, and other
system configuration procedures

Describes the V
operations, monitor commands, and monitor command
programs.

control system.

+

operating system, including disk file

+

language and programming of an Adept

16 AdeptSix 300CR Robot Instruction Handbook, Rev. A

1.7 Knowledge Express

In addition to the Knowledge Express CD-ROM containing Adept manuals, you can find
Adept product documentation on the Adept web site in the Knowledge Express area. The
Knowledge Express search engine allows you to locate information on a specific topic.
Additionally, the Library menu provides a list of available product documentation.

To access Adept’s Knowledge Express, type the following URL into your browser:

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

or, select the Knowledge Base link from the Services area of the Adept web site.

Knowledge Express

AdeptSix 300CR Robot Instruction Handbook, Rev. A 17

Safety 2

2.1 Dangers, Warnings, Cautions, and Notes

There are four levels of special alert notation used in this manual. In descending order of
importance, they are:

DANGER: This indicates an imminently hazardous

situation which, if not avoided, will result in death or
serious injury.

WARNI NG: This indicates a potentially hazardous

situation which, if not avoided, could result in serious
injury or major damage to the equipment.

CAUTION: This indicates a situation which, if not avoided,

could result in minor injury or damage to the equipment.

NOTE: This provides supplementary information, emphasizes a point or
procedure, or gives a tip for easier operation.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 19

Chapter 2 - Safety

2.2 Precautions and Required Safeguards

This manual must be read by all personnel who install, operate, or maintain Adept
systems, or who work within or near the workcell.

CAUTION: Adept Technology strictly prohibits installation,

commissioning, or operation of an Adept robot without
adequate safeguards. These must be compliant with applicable
local and national standards. Installations in EU and EEA
countries must comply with EN 775/ISO 10218, especially
sections 5,6; EN 292-2; and EN 60204-1, especially section 13.

Definition of a Manipulating Industrial Robot

The definition of a manipulating robot according to (ISO 10218:1992(E)) is as follows:

“A manipulating robot is an automatically controlled, reprogrammable, multipurpose,
manipulative machine with several degrees of freedom, which may be either fixed in
place or mobile for use in industrial automation applications.”

Safety Barriers

Safety barriers must be provided that prevent personnel from entering the workcell
whenever power is applied to the equipment. Adept systems are computer-controlled and
may activate remote devices under program control at times or along paths not
anticipated by personnel. It is critical that safeguards be in place to prevent personnel
from entering the workcell whenever power to the equipment is present.

The robot system integrator (user or operator) must ensure that adequate safeguards,
safety barriers, light curtains, safety gates, safety floor mats, etc., are installed. The robot
workcell must comply with applicable local and national standards (see Section 2.8 on

page 28).

The height and the distance of the safety fence from the robot must ensure that personnel
cannot reach the danger zone of the robot.

The Adept control system has features that aid the user in constructing system safeguards,
including customer emergency stop circuitry and digital input and output lines. The
emergency power-off circuitry is capable of switching external power systems and can be
interfaced to the appropriate user-supplied safeguards. See the AdeptSix Controller

Installation Guide for additional information.

Impact and Trapping Points

Adept robots are capable of moving at high speeds. If a person is struck by a robot
(impacted) or trapped (pinched) serious injury could occur. Robot configuration, joint
speed, joint orientation, and attached payload all contribute to the total amount of energy
available to cause injury.

20 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Precautions and Required Safeguards

Hazards From Expelling a Part or Attached Tooling

The maximum joint tip speeds that can be achieved by the AdeptSix 300CR robot are
listed in Table 10-1 on page 95. Any tooling, fixtures, end effectors, etc., mounted to the
user flange, or one of the other axes of the robot must be attached by sufficient means to
resist being expelled from the robot. Additionally, any payload must be held by the end
effector in a manner that prevents the payload from being expelled accidentally.

The safety fence or barrier constructed around the robot must be designed to withstand
the impact of any item expelled accidentally from the robot. Projectile energy can be
calculated using the formula E = mv

2

1

.

--­2

NOTE: In the Projectile energy formula above:

•E = Energy

•m = Mass

•v = Velocity

Additional Safety Information

The standards and regulations listed in this handbook contain additional guidelines for
robot system installation, safeguarding, maintenance, testing, startup, and operator
training. Table 2-1 on page 22 lists some sources for the various standards.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 21

Chapter 2 - Safety

Table 2-1. Sources for International Standards and Directives

SEMI International Standards
3081 Zanker Road
San Jose, CA 95134
USA

Phone: [phone]
Fax: [phone]

http://www.semi.org/web/wcontent.nsf/url/stds_home

BSI Group (British Standards)
389 Chiswick High Road
London W4 4AL
United Kingdom

Phone [phone]
Fax [phone]

http://www.bsi-global.com

DIN, Deutsches Institut für Normung e.V.
German Institute for Standardization
Burggrafenstrasse 6
10787 Berlin
Germany

Phone.: [phone]
Fax: [phone]

http://www.din.de

American National Standards Institute (ANSI)
11 West 42nd Street, 13th Floor
New York, NY 10036
USA

Phone [phone]
Fax [phone]

http://www.ansi.org

Document Center, Inc.
1504 Industrial Way, Unit 9
Belmont, CA 94002
USA

Phone [phone]
Fax [phone]

http://www.document-center.com

Global Engineering Documents
15 Inverness Way East
Englewood, CO 80112
USA

Phone [phone]
Fax [phone]

http://global.ihs.com

http://www2.beuth.de/ (publishing)

IEC, International Electrotechnical Commission
Rue de Varembe 3
PO Box 131
CH-1211 Geneva 20
Switzerland

Phone [phone]
Fax [phone]

http://www.iec.ch

Robotic Industries Association (RIA)
900 Victors Way
PO Box 3724
Ann Arbor, MI 48106
USA

Phone [phone]
Fax [phone]

http://www.robotics.org

22 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Risk Assessment

2.3 Risk Assessment

Without special safeguards in its control system, the AdeptSix 300 robot could inflict
serious injury on an operator working within its work envelope. Safety standards in
several countries require appropriate safety equipment to be installed as part of the
system. Table 2-2 lists some of the safety standards that affect industrial robots. It is not a
complete list. Safeguards must comply with all applicable local and national standards for
the location where the robot is installed.

Table 2-2. Partial List of Robot and Machinery Safety Standards

International USA Canada Europe Title of Standard

ISO 10218 EN 775 Manipulating Industrial Robots -

Safety

ANSI/RIA
R15.06

Adept has performed a Risk Assessment for this product, based on the intended
applications of the robot. The conclusions are summarized below.

CAN/CSA­Z434-94

Industrial Robots and Robot
Systems - Safety Requirements

EN 292-2 Safety of Machinery - Basic

Concepts, General Principles for
Design

EN 954-1 Safety Related Parts of Control

Systems - General Principles for
Design

EN 1050 Safety of Machinery - Risk

Assessment

Exposure

When arm power is on, all personnel must be kept out of the robot work envelope by
interlocked perimeter barriers. The only permitted exception is for teaching the robot in
Manual Mode by a skilled programmer (see “Qualification of Personnel” on page 29),
who must wear safety equipment (see “Safety Equipment for Operators” on page 29)
and carry the Manual Control Pendant (MCP). Therefore, exposure of personnel to
hazards related to the robot is limited (seldom and/or short exposure time).

Severity of Injury

Provided that skilled personnel who enter the AdeptSix 300CR robot work envelope are
wearing protective headgear, eyeglasses, and safety shoes, it is likely that any injuries
caused by the robot would be slight (normally reversible).

AdeptSix 300CR Robot Instruction Handbook, Rev. A 23

Chapter 2 - Safety

Avoidance

Due to its light payload capacity, it is likely that such personnel could avoid being hit by
the robot even in a high-acceleration, runaway, failure condition. However, the
programmer must always carry the MCP when inside the work envelope, as the MCP
provides both E-Stop and Enabling switch functions.

For normal operation (AUTO mode), user-supplied interlocked guarding must be installed
to prevent any person entering the workcell while Arm Power is on.

DANGER: The Adept-supplied system components

provide a Category 1 control system as defined by EN 954.
The robot system must be installed with user-supplied
interlock barriers. The interlocked barrier should interrupt
the DC and AC supplies to the control system in the event
of personnel attempting to enter the workcell when Arm
Power is enabled, except for teaching in Manual Mode.
Failure to install suitable guarding could result in injury or
death.

The Risk Assessment for teaching this product depends on the application. In many
applications, the programmer will need to enter the robot workcell while Arm Power is
enabled to teach the robot. Other applications can be designed so that the programmer
does not have to enter the work envelope while Arm Power is on. Examples of alternative
methods of programming include:

1. Programming from outside the safety barrier.

2. Programming with Arm Power off.

3. Copying program from another (master) robot.

4. Off-line or CAD programming.

Control System Behavior Category

The following paragraphs relate to the requirements of European (EU/EEA) directives for
Machinery, Electric Safety, and Electromagnetic Compatibility (EMC).

In situations with low exposure consideration factors, European Standard EN 1050
specifies use of a Category 1 Control System per EN 954. EN 954 defines a Category 1
Control System as one that employs Category B components designed to withstand
environmental influences, such as voltage, current, temperature, EMI, and well-tried
safety principles. The standard AdeptSix 300 robot control system described in this
handbook employs hardware components in its safety system that meet or exceed the
requirements of the EU Machinery Directive and Low Voltage Directive.

The standard control system is fully hardened to all EMI influences per the EU EMC

Directive and meets all functional requirements of ISO 10218 (EN 775) Manipulating Robots
Safety. In addition, a software-based reduced speed mode has been incorporated to limit

speed and impact forces on the Operator and production tooling when the robot is
operated in Manual Mode.

24 AdeptSix 300CR Robot Instruction Handbook, Rev. A

The standard AdeptSix 300 robot control system meets or exceeds the requirements
imposed by the EN 954 specified Category 1 level of safety.

2.4 Intended Use of the Robots

The installation and use of Adept products must comply with all safety instructions and
warnings in this manual. Installation and use must also comply with all applicable local
and national requirements and safety standards (see Section 2.8 on page 28).

The AdeptSix 300CR Robot robots are intended for use in parts assembly and material
handling for payloads less than 3 kg. See Chapter 5 for complete information tooling and
payloads.

CAUTION: For safety reasons, it is prohibited to make

certain modifications to Adept robots (see Section 2.5).

Intended Use of the Robots

The Adept controller is a component subassembly of a complete industrial automation
system. The controller subassembly must be installed inside a suitable enclosure. The
controller subassembly must not come into contact with liquids. Additionally, the robot
must not come into contact with liquids.

The Adept equipment is not intended for use in any of the following situations:

• In hazardous (explosive) atmospheres

• In mobile, portable, marine, or aircraft systems

• In life-support systems

• In residential installations

• In situations where the Adept equipment will be subject to extremes of heat or
humidity.

CAUTION: The instructions for operation, installation, and

maintenance given in this Instruction Handbook must be
strictly observed.

Non-intended use of an AdeptSix 300 robot can:

• Cause injury to personnel

• Damage the robot or other equipment

• Reduce system reliability and performance

All persons that install, commission, operate, or maintain the robot must:

AdeptSix 300CR Robot Instruction Handbook, Rev. A 25

Chapter 2 - Safety

• Have the necessary qualifications

• Read and follow the instructions in this Instruction Handbook exactly

If there is any doubt concerning the application, ask Adept to determine if it is an
intended use or not.

2.5 Robot Modifications

It is sometimes necessary to modify the robot in order to successfully integrate it into a
workcell. Unfortunately, many seemingly simple modifications can either cause a robot
failure or reduce the robot’s performance, reliability, or lifetime. The following
information is provided as a guideline to modifications.

Acceptable Modifications

In general, the following robot modifications do not cause problems, but may affect robot
performance:

• Attaching tooling, utility boxes, solenoid packs, vacuum pumps, cameras, lighting,
etc., to the robot tool mount flange.

• Attaching hoses, pneumatic lines, or cables to the robot. These should be designed
so they do not restrict joint motion or cause robot motion errors.

Unacceptable Modifications

The modifications listed below may damage the robot, reduce system safety and
reliability, or shorten the life of the robot. The warranty of the entire robot or certain parts
may be voided.

CAUTION: Making any of the modifications outlined

below voids the warranty of any components that Adept
determines were damaged due to the modification. You
must contact Adept Customer Service if you are
considering any of the following modifications:

• Modifying any of the robot harnesses or robot-to-controller cables.

• Modifying any robot access covers or drive system components.

• Modifying, including drilling or cutting, any robot surface.

• Modifying any robot electrical component or printed-circuit board.

• Routing additional hoses, air lines, or wires through the inside of the robot.

• Modifications that compromise EMC performance, including shielding.

26 AdeptSix 300CR Robot Instruction Handbook, Rev. A

AdeptSix 300CR Hazards and Warning Labels

2.6 AdeptSix 300CR Hazards and Warning Labels

Risks from injury are clearly identified on the AdeptSix 300CR by warning labels. The
location of these labels is illustrated in Figure 2-1.

2BC

1BC

3BC

2.7 Transport

Always use adequate equipment to transport and lift Adept products. See Chapter 3 for
more information on transporting, lifting, and installing.

WARNING

Moving parts may
cause injury

WARNING

Do not enter
robot work area

Figure 2-1. AdeptSix 300CR — Warning Labels

AdeptSix 300CR Robot Instruction Handbook, Rev. A 27

Chapter 2 - Safety

2.8 Safety Requirements for Additional Equipment

Additional equipment used with the AdeptSix 300 robot (grippers, conveyor belts, etc.)
must not reduce the workcell safeguards.

Emergency stop switches must be accessible at all times.

If the robot is to be used in an EU or EEA member country, all components in the robot
workcell must comply with the safety requirements in the European Machine Directive
89/392/EEC (and subsequent amendments) and related harmonized European,
international, and national standards. For robot systems, these include: EN 775/ISO
10218, sections 5,6; EN 292-2; and EN 60204. For safety fences, see EN 294.

In other countries, Adept strongly recommends, that a similar level of safety be obtained
as well as complying with the applicable local and national regulations, including
SEMI-S2.

In the USA, applicable standards include ANSI/RIA R15.06 and ANSI/UL 1740.

In Canada, applicable standards include CAN/CSA Z434.

2.9 Working Areas

Adept robots have a Manual and an Automatic (AUTO) operating mode. While in
Automatic Mode, personnel are not allowed in the workcell.

In Manual Mode, operators with additional safety equipment (see Section 2.11 on page

29) are allowed to work in the robot workcell. For safety reasons the operator should,

whenever possible, stay outside of the robot work envelope to prevent injury. The
maximum speed and power of the robot is reduced, but it could still cause injury to the
operator.

Before performing maintenance in the working envelope of the robot, High Power must
be switched off and the power supply of the robot must be disconnected. After these
precautions, a skilled person is allowed to perform maintenance on the robot. See

Section 2.10 for the specifications.

CAUTION: Never remove any safeguarding and never

make changes in the system that will decommission a
physical safeguard.

28 AdeptSix 300CR Robot Instruction Handbook, Rev. A

2.10 Qualification of Personnel

This manual assumes that all personnel have attended an Adept training course and have
a working knowledge of the system. The user must provide the necessary additional
training for all personnel who will be working with the system.

As noted in this handbook, certain procedures should be performed only by skilled or
instructed persons. For a description of the level of qualification, Adept uses the standard
terms:

• Skilled persons have technical knowledge or sufficient experience to enable them
to avoid the dangers, electrical and/or mechanical.

• Instructed persons are adequately advised or supervised by skilled persons to
enable them to avoid the dangers, electrical and/or mechanical.

All personnel must observe industry-prescribed safety practices during the installation,
operation, and testing of all electrically powered equipment. To avoid injury or damage to
equipment, always remove power by disconnecting the AC power from the source before
attempting any repair or upgrade activity. Use appropriate lockout procedures to reduce
the risk of power being restored by another person while you are working on the system.

Qualification of Personnel

WARNI NG: The user must get confirmation from every

entrusted person before they start working with the robot
that the person:

1. Has received the instruction handbook

2. Has read the instruction handbook

3. Understands the instruction handbook

4. Will work in the manner specified by the instruction handbook.

2.11 Safety Equipment for Operators

Operators must wear safety equipment in the workcell. For safety reasons, operators must
wear the following when they are in the robot workcell.

• Safety glasses

• Protective headgear (hard hats)

•Safety shoes

Warning signs should be posted around the workcell to ensure that anyone working
around the robot system knows they must wear safety equipment.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 29

Chapter 2 - Safety

2.12 Protection Against Unauthorized Operation

The system must be protected against unauthorized use. The user or operator must
restrict access to the keyboard and the Manual Control Pendant by locking them in a
cabinet or use another adequate method to prevent access to them.

2.13 Safety Aspects While Performing Maintenance

Only skilled persons with the necessary knowledge about the safety and operating the
equipment are allowed to maintain the robot, controller, and power chassis.

CAUTION: During maintenance and repair, the power of

the Adept controller must be turned off. Lockout measures
must be used to prevent unauthorized personnel from
turning on power.

2.14 Risks That Cannot Be Avoided

The AdeptSix 300 robot control system includes devices that disable High Power if a
system failure occurs. However, certain residual risks or improper situations could cause
hazards. The following situations may result in risks that cannot be avoided:

• Failure of software or electronics that may cause high-speed robot motion in
Manual Mode

• Failure of hardware associated with enabling device or E-Stop system

2.15 Risks Due to Incorrect Installation or Operation

Take precautions to ensure that the following situations do not occur:

• Purposely defeating any aspect of the safety E-Stop system

• Improper installation or programming of the robot system

• Unauthorized use of cables other than those supplied or use of modified
components in the system

• Defeating interlock so that operator can enter workcell with High Power ON

• Ejection of workpiece (see “Hazards From Expelling a Part or Attached Tooling”

on page 21).

30 AdeptSix 300CR Robot Instruction Handbook, Rev. A

What to Do in an Emergency Situation

2.16 What to Do in an Emergency Situation

Press any E-Stop button (a red push-button on a yellow background/field) and then
follow the internal procedures of your company or organization for an emergency
situation. If a fire occurs, use CO

to extinguish the fire.

2

AdeptSix 300CR Robot Instruction Handbook, Rev. A 31

Chapter 2 - Safety

32 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Robot Installation 3

3.1 Safety Guard Installation

To ensure safety, make sure to install safety guards, which prevent unforeseen accidents
with personnel and damage to equipment. The following standard is noted below for
your information and guidance.

Safety Standard Information (ISO10218)

Responsibility for Safeguarding

The user of a manipulator or robot system shall ensure that safeguards are provided and
used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of
safeguarding, including any redundancies, shall correspond directly to the type and level
of hazard presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices, barriers, interlock
barriers, perimeter guarding, awareness barriers, and awareness signals.

WARNI NG: Install the safety guards. Failure to observe

this warning may result in injury or damage.

WARNI NG: Install the robot in a location where the fully

extended arm and end-of-arm tooling will not reach the
wall, safety guards, or controller. Failure to observe this
warning may result in injury or damage.

WARNI NG: Do not start the robot or even turn on the

power before it is firmly anchored. The robot may
overturn and cause injury or damage.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 33

Chapter 3 - Robot Installation

WARNI NG: When mounting the robot on the ceiling or

wall, the base section must have sufficient strength and
rigidity to support the weight of the robot. Also, it is
necessary to consider countermeasures to prevent the
robot from falling. Failure to observe these warnings may
result in injury or damage.

WARNI NG: Do not install or operate a robot that is

damaged or lacking parts. Failure to observe this caution
may cause injury or damage.

CAUTION: Before turning on the power, make sure that

the shipping bracket and jig have been removed. Failure to
observe this caution may result in damage to the gear
train, motors, and other key system components.

3.2 Transporting Method

Using the Crane

As a rule, a crane should be used to remove the robot from its package and to move the
robot into position. The robot should be lifted using wire slings threaded through the
attached eyebolts. Make sure the robot is fixed with jigs before transporting, and lift it into
the position shown in Figure 3-1 on page 35. Points A and B in Figure 3-1 identify the
locations of the shipping bracket and jig.

34 AdeptSix 300CR Robot Instruction Handbook, Rev. A

1X Urethane washer

2X M6 Coned disc springs
(anti-corrosive)

2X Urethane washers

2X Urethane washers

2X M5 10 mm Hexagon
socket head cap bolts
(anti-corrosive)

2X M5 Washers
(anti-corrosive)

M6 8 mm Hexagon
socket head cap bolt
(anti-corrosive)

Details of C

2X M6 40 mm Hexagon
socket head cap bolts
(anti-corrosive)

Details of D

Transporting Method

A

C

2X M8 Eyebolts

D

(provided at factory)

B

Details of E

E

Figure 3-1. Transporting Position

WARNI NG: Sling applications via crane or forklift must be

performed by authorized personnel only. Failure to
observe this caution may result in injury or damage.

CAUTION: Avoid excessive vibration or shock during

transporting. The system consists of precision
components, so failure to observe this caution may
adversely affect performance.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 35

Chapter 3 - Robot Installation

Using the Forklift

When using a forklift, the robot should be fixed on a pallet with its shipping bracket and
jig, as shown in Figure 3-2. Insert the forklift blades under the pallet and lift it. The pallet
must be strong enough to support the robot. Transportation of the robot must be
performed slowly in order to avoid overturning, slippage, or damage.

4 x M10 Bolts

Pallet

Forklift Blade Entry

Figure 3-2. Using the Forklift

When using the forklift, note the following:

• Check that the eyebolts are securely fastened.

• Use a wire sling that is strong enough to withstand the weight. (The weight of the
robot is approximately 35 kg, including the shipping bracket and jig.)

• Attached eyebolts are designed to support the robot’s weight. Do not use them for
anything other than transporting the robot.

• Mount the shipping bracket and jig for transporting the robot.

• Avoid exerting force on the arm or motor unit when transporting. Exercise caution
when using transporting equipment other than a crane or forklift, as injury may
occur.

36 AdeptSix 300CR Robot Instruction Handbook, Rev. A

3.3 Shipping Bracket and Jig

The robot is provided with a shipping bracket and jig at points A and B. See Figure 3-3 on

page 38 for details.

• The shipping bracket and jig are painted yellow.

• The number of hexagon socket head cap screws are: A: M6 X 2, B: M5 X 2.

• To prevent the jigs from damaging the paint of the robot, the resin washers are
inserted between the robot and the jigs.

NOTE: Before turning on the power, make sure that the robot is securely
mounted to its mounting base and that the shipping bracket and jig have
been removed. Then store the shipping bracket and jig for future use (in
the event that the robot must be moved again).

NOTE: Remove the protective covers from the 1BC and 2BC connectors
prior to installing the power and signal interconnect cables.

Shipping Bracket and Jig

3.4 Installing Cover Bolts

After mounting the robot, remove the shipping bolts and jigs that were attached when
using the crane, and insert the cover bolts. When transporting the robot again, replace
them with the shipping bolts and jigs. Figure 3-3 illustrates the procedure for installing
the cover bolts

AdeptSix 300CR Robot Instruction Handbook, Rev. A 37

Chapter 3 - Robot Installation

A

B

( Attached with shipping products)

2X M8 Eyebolts

Shipping jig

Detail A

Detail B

Shipping jig

Remove shipping jig and
insert the cover bolts

2X M5 Hexagon socket head bolts (anti-corrosive)
2X M5 Washers (anti-corrosive)
2X Urethane washers

Use shipping bolts

Remove shipping jig and
insert the cover bolts

Figure 3-3. Installing Cover Bolts

2X M6 Hexagon socket head bolts (anti-corrosive)

2X Urethane washers

Detail A

Detail B

3.5 Types of Mounting

The robot can be mounted in three different ways: floor-mounted (standard),
wall-mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted
types, contact Adept.

38 AdeptSix 300CR Robot Instruction Handbook, Rev. A

3.6 Mounting Procedures for Robot

The robot should be firmly mounted on a baseplate or foundation strong enough to
support the robot and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand maximum
repulsion forces of the robot as shown in Table 3-1.

During installation, if the level of the mounting plane is not right, the robot’s functional
ability may be compromised. The level of the plane of installation must be kept at 0.5 mm
or less. Mount the baseplate in either of the two ways described on page 40.

Table 3-1. Maximum Repulsion Forces of the AdeptSix 300CR

Mounting Procedures for Robot

Maximum horizontal rotating torque

500 N·m (51.0 kgf·m)

(direction of motion Axis 1)

Maximum vertical rotating torque

700 N·m (71.4 kgf·m)

(direction of motion Axes 2 and 3)

When the Robot and Mounting Fixture are Installed on a Common Installation Base

The common base should be rugged and durable to prevent shifting of the robot or the
mounting fixture. The thickness of the common base should be 30 mm or more, and an
M10 size or larger anchor bolt is recommended. Affix the robot by fastening the plate with
the M10 (mm) anchor bolts. The plate is tapped for M10 (35 mm length) bolts. Tighten the
plate fixture, mounting bolts, and anchor bolts securely so that they will not work loose
during operation. See Figure 3-4 for details.

4X M10 35 mm Hexagon socket head cap bolts
(anti-corrosive, provided at factory)

4X M10 Spring washers
(anti-corrosive, provided at factory)

4X M10 Washers
(anti-corrosive, provided at factory)

Details of A

A

Anchor bolts M10 or more

Common installation base

Figure 3-4. Mounting the Robot Baseplate

AdeptSix 300CR Robot Instruction Handbook, Rev. A 39

Chapter 3 - Robot Installation

e

When the Robot is Mounted Directly on the Floor

The floor should be strong enough to support the robot. Construct a solid foundation with
the appropriate thickness to withstand maximum repulsion forces of the robot as shown
in Table 3-1 on page 39. As a rough standard, when there is a concrete thickness (floor) of
150 mm or more, the base of the robot can be fixed directly to the floor with M10 anchor
bolts. Before mounting the robot, however, check that the floor is level and that all cracks,
etc. are repaired. Any thickness less than 150 mm is insufficient for mounting, even if the
floor is concrete.

4X M10 35 mm Hexagon
socket head cap bolts (anti-corrosive)

4X M10 Spring washers
(anti-corrosive)

4X M10 Washers
(anti-corrosive)

A

Details of A

150 mm
or more

Figure 3-5. Direct Mounting on the Floor

3.7 Axis Naming Conventions

The robot’s six axes are referred to throughout this documentation as either Axis 1-6 or
Joint (J) 1-6. These terms are used interchangeably. For legacy reasons, these axes are
labelled on the robot as S-axis, L-axis, U-axis, R-axis, B-axis, and T-axis. The table below
shows how these current axis labels correspond to the legacy labels.

Installation base

Grating

Anchor bolts M10 or mor

40 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Table 3-2. Axis Naming Conventions

Grounding the Robot

Current Axis

Labels

Axis 1 (J1) S-axis

Axis 2 (J2) L-axis

Axis 3 (J3) U-axis

Axis 4 (J4) R-axis

Axis 5 (J5) B-axis

Axis 6 (J6) T-axis

See Figure 10-1 on page 96 for a drawing that identifies the various axes.

3.8 Grounding the Robot

Follow local regulations for grounding line size.

NOTE: Do not use this line in common with other ground lines or
grounding electrodes for other electric power, motor power, welding
devices, etc.

Legacy Axis

Labels

NOTE: Where metal ducts, metallic conduits, or distributing racks are
used for cable laying, ground in accordance with Electric Equipment
Technical Standards.

WARNI NG: Ground resistance must be 100 Ω or less.

Failure to observe this warning may result in fire or
electric shock.

WARNI NG: Before wiring, make sure to switch off the

primary power supply, and place a warning sign (for
example, Do not switch on the power). Failure to observe this
warning may result in fire or electric shock.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 41

Chapter 3 - Robot Installation

WARNI NG: Wiring must be performed by authorized or

certified personnel. Failure to observe this caution may
result in fire or electric shock.

A

5.5 mm2 or more

Figure 3-6. Grounding Method for Robot

3.9 Environmental Requirements

The environmental conditions of the area in which the robot is installed must satisfy the
conditions listed below:

• Ambient temperature must be from 0° to +45° C

• No moisture should be present (20 to 80% RH)

• Level of the mounting plane for installation must be 0.5 mm or less

• System must be isolated from excessive electrical interference or noise (plasma)

• The area must be free from:

• Dust, soot, and water

• Corrosive gases and liquids, as well as explosive gases

• Excessive vibration (less than 0.5 G)

View A

M8 Bolt - for grounding
(provided at factory)

42 AdeptSix 300CR Robot Instruction Handbook, Rev. A

System Cable Installation 4

ENC

PORTS

1394

ENC

MAI STATUS

DSP STATUS

B
R
A
K

R
S
2
3

X
S
L
V

X
S
L
V

5

C

6

C

3

ON

G/O

O NO

S

SHO

O

ODU

D

D

G

ON

CH2

P

2

C2BC

C

2

-+

4.1 System Cable Diagrams

Adept MV Controller System

CIP (JSLV) to MAI-2 (XSLV1)

AWC IEEE 1394 (Port 1) to
MAI-2 IEEE 1394 (Port 1)

CIP (JAWC) to AWC (CIP)

Ethernet to PC

AWC II

STP

SF

SCR

A

C

B

VME

D

USE ONLY WITH

WARNING:

FOR CONTINUED PROTECTION

250V FUSES

AGAINST RISK OF FIRE,
REPLACE ONLY WITH SAME
TYPE AND RATING OF FUSE.

5AF

~100-240V
50/60HZ

Adept MV
Controller

Dual E Amp #1

Dual E Amp #2

Dual E Amp #3

MAI-2 Module

DUAL E AMP

DUAL E AMP

DUAL E AM

-

D

DO NOT REMOVE OR INSTALL THIS

DO NOT REMOVE OR INSTALL THIS

CH2

adept
technology, i nc.

T REMOVE OR INSTALL THI

MODULE UNLESS HIGH VOLTS LED

M

LE UNLESS HIGH VOLTS LE

IS COMPLETELY DISTINGUISHED

IS COMPLETELY DISTINGUISHE

HIGH VOLTS ON

PWM ON
LOW VOLTS ON
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT

A
M
P
L
I
F
I
E
R
C
O
N
T
R
O
L

H VOLTS

HIGH VOLTS ON

HI

PWM ON

PWM ON

LOW VOLTS ON

LOW VOLTS

OPEN CKT FAULT

PEN CKT FAULT
HV SA

VER TEMP FAULT

HV SAG/OVER TEMP FAULT

RT FAULT

SHORT FAULT

CH2

CH1

CH2

CH1

A

A

M

M

P

P

L

L

I

I

Þ

F

F

I

I

E

E

R

R

C

C

O

O

N

N

T

T

R

R

O

O

L

L

N
P
G
4
5

CH1

CH2CH1

CH2CH1
M
O
T
O
R
P
O
W
E
R
O
U
T
P
U
T

C

M

N

O
T

2

O
R
P
O
W
E

N

R

P

O

G

U
T

C

1

P

N

2

U
T

2
9

Cable

Arm Power Cable

CN29

MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED

CH1

M
O
T
O
R
P
O
W
E
R
O
U
T
P
U
T

®

AdeptSix 300CR
Robot

Adept PA-4
Power Chassis

STOP

< 250 mm/s 100%

MCP

CIP-

NET

IP

MCP

Desktop or Laptop PC

Arm
Signal
Cable

1B

User-Supplied
Ground Wire

Figure 4-1. System Cable Diagram with Adept MV Controller

AdeptSix 300CR Robot Instruction Handbook, Rev. A 43

Chapter 4 - System Cable Installation

ENC

PORTS

1394

ENC

MAI STATUS

DSP STATUS

B
R
A
K

R
S
2
3

X
S
L
V

X
S
L
V

C

5

C

6

C

3

ON

G/O

T

S

SHO

T

O

T

D

D

G

ON

CH2

P

C

2

Adept

r

(

(

)

el

C

e

STOP

CS

356

*

-+

Adept SmartController System

Controller (XSYS) to MAI-2 (XSLV1)

User-Supplied Ground Wire

Controller

XFP) to

Front Panel

Ethernet to PC

Front Pan

M

P Adapter Cabl

Controller (XMCP) to MCP

Controller SmartServo (Port 1.1) to
MAI-2 IEEE 1394 (Port 1)

User-Supplied Ground Wire
Between PA-4 and SmartController

Adept PA-4
Power Chassis

rtControlle

XFP

*S/N

1-XXXXX

ntroller

24VDC Power from
User-Supplied
Power Supply to
Controller (XDC1)

DUAL E AMP

DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

HIGH VOLTS ON

PWM ON
LOW VOLTS ON
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT

CH1

CH2

A
M
P

F
E
R
C
O
N
T
R
O

M
O
T
O
R
P
O
W
E
R
O
U
T
P
U
T

adept
technology, inc.

User-Supplied
Power Supply

Dual E Amp #1

DUAL E AMP

DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED

HIGH VOLTS ON

PWM ON
LOW VOLTS ON
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT

CH1

CH2

A
M
P

L

L

I

I
F

I

I
E
R
C
O
N
T
R
O

L

L

CH2CH1

CH2CH1
M
O
T
O
R
P
O
W
E
R
O
U
T
P
U
T

Dual E Amp #2

Dual E Amp #3

MAI-2 Module

DUAL E AM

-

DO NOT REMOVE OR INSTALL THI

MODULE UNLESS HIGH VOLTS LE
IS COMPLETELY DISTINGUISHE

H VOLTS

HI

PWM ON
LOW VOLTS

PEN CKT FAUL

HV SA

VER TEMP FAUL

RT FAUL

CH1

CH2

A
M
P
L
I

Þ

F
I
E
R
C
O
N
T
R
O
L

N
P
G
4
5

CH1

M

N

O
T

2

O
R
P
O
W
E

N

R

P

O

G

U
T

C

1

P

N

2

U
T

2
9

CN29

Cable

AdeptSix 300CR
Robot

Arm
Power
Cable

MCP

Arm
Signal
Cable

1B

User-Supplied
Ground Wire

Desktop or Laptop PC

Figure 4-2. System Cable Diagram with Adept SmartController

44 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Cable Connections from Robot to PA-4 Power Chassis

4.2 Cable Connections from Robot to PA-4 Power Chassis

There are two interconnect cables: the arm signal cable (1BC) and the arm power cable
(2BC). Connect these cables to the robot base connectors and the PA-4 power chassis. Refer
to Figure 4-3 and Figure 4-4 on page 46.

Connection to the Robot

1. Remove the protective covers from the 1BC and 2BC connectors on the back plate
of the robot prior to installing the power and signal cables.

2. Before connecting the two cables described above to the robot, verify the
numbers, 1BC and 2BC, on both interconnect cables and the robot base
connectors.

3. When connecting, adjust the cable connector positions to the main key positions
of the robot, and insert the cables in the following order: Arm Power (2BC), Arm
Signal (1BC).

4. Secure the cables via the locking latch.

CNPG123

CNPG456

Ground

CN29

CN1

CN2

CN3
CN4

CN5

Connection to PA-4 Chassis Connection to the Robot

M3 Bolt

Connector

A

Robot Base Side

B

Robot Base Side

Ground

Connector

Terminal

1BC

1 BC

Arm Signal
Cable

2BC

2BC

Arm Power
Cable

CN6

Motor Output
Connector Clamp

Figure 4-3. Interconnect Cables

AdeptSix 300CR Robot Instruction Handbook, Rev. A 45

Chapter 4 - System Cable Installation

C

y

(

)

C

C

1B

1BC2B

onnection details

of the power suppl

robot

cable

Figure 4-4. Interconnect Cable Connection to the Robot

Connection to the PA-4 Power Chassis

Refer to the following information for details on connecting the cabling between the robot
and the Adept PA-4 power chassis, and peripheral equipment. See Figure 4-1 on page 43
or Figure 4-2 on page 44, depending on which controller you are using.

1. Connect the end of the Arm Power cable with the motor output connector clamp
to the six connectors on the three Dual E amp modules.

NOTE: The CH connectors on all the Dual E Amps are labelled CH1 and
CH2. For reference, Figure 4-5 on page 47 matches CN plugs 1 to 6 with
the CH connectors (labelled CH 1 to 6 in the drawing).

2. Install the plug labeled CN29 on the Arm Power cable in the CN29 connector on
the Multi-Axis Interface (MAI-2) module.

3. Connect the end of the Arm Signal cable with two plugs to the two connectors on
the MAI-2 module in the following order.

a. Install the plug labeled CNPG456 in the CNPG456 connector.

b. Install the plug labeled CNPG123 in the CNPG123 connector.

4. Install one ground wire each from the Arm Signal Cable and the Arm Power
Cable to the front right screw on the top of the Adept PA-4 power chassis.

NOTE: Provide strain relief for the motor power and signal cable
connectors at the amplifier modules.

46 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Cable Connections from Robot to PA-4 Power Chassis

ENC

ENC

MAI STATUS

DSP STATUS

B
R
A
K

R
S
2
3

X
S
L
V

X
S
L
V

C
N
2
5

C

6

C

3

ON

G/O

T

S

SHO

T

O

T

D

D

G

ON

CH2

P

e

Dual E Amp #3

Dual E Amp #2

Dual E Amp #1

MAI-2 Modul

CH1

CH2

CH4

CH3

CH5

DUAL E AMP

DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

HIGH VOLTS ON

PWM ON
LOW VOLTS ON
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT

CH1

CH2

A
M
P
L
I
F
I
E
R

C
O
N
T
R
O
L

CH2CH1

M
O
T
O
R

P
O
W
E
R

O
U
T
P
U
T

adept
technology, inc.

DUAL E AMP

DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

HIGH VOLTS ON

PWM ON
LOW VOLTS ON
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT

CH1

CH2

A
M
P
L
I
F
I
E
R

C
O
N
T
R
O
L

CH2CH1

M
O
T
O
R

P
O
W
E
R

O
U
T
P
U
T

DUAL E AM

DO NOT REMOVE OR INSTALL THI

MODULE UNLESS HIGH VOLTS LE
IS COMPLETELY DISTINGUISHE

H VOLTS

HI

PWM ON
LOW VOLTS

PEN CKT FAUL

HV SA

VER TEMP FAUL

RT FAUL

CH2

CH1

A

M

P
L
I

Þ

F
I
E
R

C
O
N
T
R
O
L

CH1

M
O
T
O
R

P
O
W
E
R

O
U
T
P
U
T

-

Status LEDs
Break Release Box

RS-232

XSLV2
XSLV1

CNPG456

N

P

G

4
5

IEEE 1394 Port 1
IEEE 1394 Port 2

CN25 (Future options)

N

P

G

C

1

N

2

CN29 Arm Brake

2
9

CNPG123

CH6

Figure 4-5. PA-4 Power Chassis

AdeptSix 300CR Robot Instruction Handbook, Rev. A 47

Chapter 4 - System Cable Installation

4.3 Cable Connections to MV Controller

Installing the MV Controller

Refer to the AdeptSix Controller Installation Guide for complete information on
installing the Adept MV controller. This list summarizes the main steps.

1. Connect the CIP-2 to the AWC-II in the MV controller.

2. Connect the MCP to the CIP-2.

3. Connect AC power to the controller.

4. Install the AdeptWindows PC user interface.

Cable Connections to MV Controller

See Figure 4-1 on page 43.

1. Install one end of the IEEE 1394 cable into the top (upper-most) 1394 connector on
the AWC-II board, and install the other end into the IEEE 1394 port 1 connector on
the MAI-2.

2. Install the cable between the MAI-2 module XSLV-1 safety interlock connector
and CIP-2 (JSLV) connector, and tighten the latching screws.

3. Install the cable between the AWC-II (CIP-2) and CIP-2 (JAWC). Verify that the
plug is latched on both ends of the cable.

Connecting User-Supplied Safety and I/O Equipment

Refer to the Adept MV Controller User’s Guide for information on connecting the
following equipment:

• safety equipment incorporated into the E-Stop system

• digital I/O equipment

• serial I/O equipment

48 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Cable Connections to SmartController

4.4 Cable Connections to SmartController

Installing the SmartController

Refer to the AdeptSix Controller Installation Guide for complete information on
installing the Adept SmartController. This list summarizes the main steps.

1. Mount the SmartController and Front Panel.

2. Connect the Front Panel to the SmartController.

3. Connect the MCP to the SmartController.

4. Connect user-supplied 24 VDC power to the controller.

5. Install a user-supplied ground wire between the SmartController and ground.

6. Install a user-supplied ground wire between the SmartController and the PA-4
chassis.

7. Install the AdeptWindows PC user interface.

Cable Connections to SmartController

See Figure 4-2 on page 44.

1. Install one end of the IEEE 1394 cable into the SmartServo port 1.1 connector on
the SmartController, and install the other end into the IEEE 1394 port 1 connector
on the MAI-2 module.

2. Install the cable between the MAI-2 module XSLV1 safety interlock connector and
XSYS connector on the SmartController, and tighten the latching screws.

Connecting User-Supplied Safety and I/O Equipment

Refer to the Adept SmartController User’s Guide for information on connecting the
following equipment:

• safety equipment incorporated into the E-Stop system

• digital I/O equipment

• serial I/O equipment

AdeptSix 300CR Robot Instruction Handbook, Rev. A 49

Chapter 4 - System Cable Installation

50 AdeptSix 300CR Robot Instruction Handbook, Rev. A

End of Arm Tooling 5

5.1 Allowable Wrist Load

The allowable wrist load is 3 kg. If force is applied to the wrist instead of the load, force on
Axes 4, 5, and 6 should be within the values shown in Table 5-1. Contact your Adept
representative for further information or assistance.

Table 5-1. Moment and Total Inertia

Axis

Moment N·m (kgf·m)

a

2

/4 Total Inertia kg·m

GD

2

Axis 4 5.39 (0.55) 0.1

Axis 5 5.39 (0.55) 0.1

Axis 6 2.94 (0.3) 0.03

a

Values that appear inside parentheses are given in gravitational units.

When the volume load is small, refer to the moment arm rating shown in Figure 5-1.

The allowed total inertia is calculated when the moment is at the maximum. Contact your
Adept representative when:

• Only load moment is small and inertia moment is large

• The load mass is combined with an outside force

Load Gravity Position

200

90

L

Axis 5

Axis 5 Rotation
Centerline

AdeptSix 300CR Robot Instruction Handbook, Rev. A 51

Axis 6

L

Axis 6 Rotation
Centerline

L

Axis6

(mm)

Figure 5-1. Moment Arm Rating

100

W=1.5 kg

W=3 kg

0

100

200

L

Axis5

(mm)

300

Chapter 5 - End of Arm Tooling

5.2 Wrist Tool Flange

The wrist tool flange dimensions are shown in Figure 5-2. In order to see the tram marks,
it is recommended that the attachment be mounted inside the fitting. The fitting depth of
the inside and outside fittings must be 6 mm or less.

5

6

4-M5 x P0.8 Depth 9 mm

45˚

Tram mark

P.C.D31.5

45°

Ø40H6

Ø5H7 Depth 7 mm

Ø20H6

Figure 5-2. Wrist Tool Flange

NOTE: Clean off the anticorrosive material on the tool flange area prior to

mounting the end of arm tooling. This anticorrosive material is only used
to protect the robot during shipping.

52 AdeptSix 300CR Robot Instruction Handbook, Rev. A

5.3 End of Arm Tooling Load Definitions

The end of arm tooling payload includes weight, location of the center of gravity, and the
moment of inertia at the center of gravity of the installed tool. See Figure 5-3.

End of Arm Tooling Load Definitions

Inertia moment around center of gravity
Ix, Iy, Iz

XF

* Flange Coordinates
XF: Direction right above when Axis 6 (T axis)
is at 0 pulse position and the flange surface
of the robot is turned to the front.
YF: Y axis led by XF, ZF
ZF: Perpendicular direction from flange surface

YF*

ZF*

XF*

Ix

Iy

YF

Iz

Weight: W

ZF

Center of Gravity Position

(Xg, Yg, Zg)

Figure 5-3. Center of Gravity: Calculating Tool Load Information

Weight: W (kg)

The total weight of the installed tooling is set based on the above calculations.

For rough calculations, set a slightly larger value and keep increasing the value for each
unit by 0.5 to 1 kg for small to medium size robots; for larger robots, increase the value by

0.5 to 5 kg units.

Center of Gravity: xg, yg, zg (mm)

The location of the center of gravity of the installed tool is set based on the position of the
tool flange coordinates.

Moment of inertia at the center of gravity: lx, ly, lz (kg.m²)

This is the moment of inertia of the tool based on the location of the center of gravity. The
value is calculated around each axis of the coordinate system, which is in parallel to the
flange coordinates, with its origin at the center of gravity of the tool.

This is used to calculate the moment of inertia and provide verification based on the
arm-specification requirements. The moment of inertia is typically not critical; in many
cases, calculated moment of inertia values are small, based on the payload and the center
of gravity. However, this is extremely critical when either the payload, or specifically the
moment of inertia, is exceeded. This condition has a drastic impact on arm performance
and reliability. See Figure 5-4.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 53

Chapter 5 - End of Arm Tooling

The size of the tool is not too big.
Setting the inertia moment at the
center or gravity is not necessary.

Figure 5-4. Moment of Inertia

The size of the tool is sufficiently large
that setting the inertia moment at the
center of gravity is necessary.

5.4 Calculating the Moment of Inertia

The following methods can be used to calculate the rough values for the moment of
inertia, based on the center of gravity.

• Approximate the entire tool as a hexahedron or cylinder.

• Calculate the center of gravity position (plural mass) for each part weight.

The following examples provide details on the calculation methods.

Example 1

In this example, a sealing gun is utilized. It is assumed that the location of the center of
gravity is slightly offset from the centerline of the head, based on the tool flange
coordinates. See Figure 5-5.

In this case, there seems to be no problem, based on the size and weight of the gun, and
the moment of inertia with respect to the center of gravity.

54 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Calculating the Moment of Inertia

Y

F

Center of Gravity Position
= (100, 0, 70)

X

F

70

T otal W eight
Approx. 6.3 [kg]

7.00 [kg]

Figure 5-5. Center of Gravity: Sealing Gun Example

Tooling Details

• W:7.000 kg

• Xg:100.000 mm

• Yg:0.000 mm

• Zg:70.000 mm

• lx:0.000 kg.m²

• ly:0.000 kg.m²

• lz: 0.000 kg.m²

100

Z

F

AdeptSix 300CR Robot Instruction Handbook, Rev. A 55

Chapter 5 - End of Arm Tooling

The following figures show examples of the moment of inertia for a hexahedron and
cylinder.

Z

Ly

Lx

Iz

Ix

X

Ly

2

+ Lz

Iy

Weight: W

2

Lz

Ix = * W

12

2

Lx

+ Lz

2

Iy = * W

12

2

Lx

+ Ly

2

Iz = * W

12

Z

r

Iz

Y

H

Ix

X

Iy

3 r 2 + H

Y

Weight: W

2

Ix = Iy = * W
12

r

2

Iz = * W
2

* Unit of Weight: [kg]
* Unit of Length: [m]

2

* Unit of Ix, Iy, Iz: [kg.m

]

Figure 5-6. Moment of Inertia for Hexahedron and Cylinder

56 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Calculating the Moment of Inertia

Example 2

It is necessary to set the moment of inertia at the center of gravity when the entire size of
the tool and workpiece are large compared with the distance from the tool flange relative
to the position of the center of gravity. See Figure 5-7.

Roughly calculate the moment of inertia at the center of gravity based on “Example 1” on

page 54, using the hexahedron and cylinder concept for the entire tool.

XF

YF

ZF

250

1000

500

400

Figure 5-7. Center of Gravity: Large Tool and Workpiece Example

Tooling Details

• W:100.000 kg

• Xg:0.000 mm

• Yg:0.000 mm

• Zg:250.000 mm

• lx:10.000 kg.m²

• ly:3.500 kg.m²

Weight of Hand:
Approx. 55 kg

Weight of Workpiece:
Approx. 40 kg

• lz: 10.500 kg.m²

Weight: W=55 + 40 = 95, approximated to 100 kg.
Center of gravity: Z offset position (Xg, Yg, Zg) = (0, 0, 250)
Moment of inertia at the center of gravity:

• The hexahedron of 0.500 x 0.400 x 1.000(m), which encloses the entire tool

including the assumed workpiece.

• Use the following formula to calculate the moment of inertia of a hexahedron.

lx = (Ly²*Lz²/12) * W = ((0.400²+1.000²)/12) * 100=9.667 Approx. 10.000

ly = (Lx²*Lz²/12) * W = ((0.500²+0.400²)/12) * 100=3.417 Approx. 3.500

lz = (Lx²*Ly²/12) * W = ((0.500²+1.000²)/12) * 100=10/417

AdeptSix 300CR Robot Instruction Handbook, Rev. A 57

Chapter 5 - End of Arm Tooling

The steps below describe how to calculate the center of gravity, including the moment of
inertia, based on the center of gravity of the plural mass. This can be calculated based on
the weight and the center of gravity of each mass, when the tool is considered to consist of
two or more large mass objects, like a dual gun system.

1. Divide the tool into individual parts, so as to calculate the weight and center of
gravity of each part.

2. Calculate the weight and center of gravity of each part, based on the tool flange
coordinates. Refer to “Example 1” on page 54 for details on how to use the
hexahedron and cylinder examples to calculate these values.

Wi: Weight of the i-th parts (kg)
(xi, yi, zi): Center of gravity of the i-th parts (mm)
lcxi, lcyi, lczi: Moment of inertia of each i-th parts (kg.m²)

3. The position of the center of gravity for the entire tool is calculated using the
following formula.

xg={w1*x1+w2*x2+…+wi*xi}/(w1+w2+…+wi)

yg={w1*y1+w2*y2+…+wi*yi}/(w1+w2+…+wi)

zg={w1*z1+w2*z2+…+wi*zi}/(w1+w2+…+wi)

4. The moment of inertia at the center of gravity for the entire tool is calculated
using the following formula.

lx = {w1*((y1-yg)²+(z1-zg)²)*10

+ {w2*((y2-yg)²+(z2-zg)²)*10

-6

+lcx1}

-6

+lcx2}

………………………………….

+ {wi*((yi-yg)²+(zi-zg)²)*10-6 +lcxi}

-6

ly = {w1*((x1-xg)²+(z1-zg)²)*10

+ {w2*((x2-xg)²+(z2-zg)²)*10-6 +lcy2}

+lcy1}

………………………………….

+ {wi*((xi-xg)²+(zi-zg)²)*10

lz = {w1*((x1-xg)²+(y1-yg)²)*10

+ {w2*((x2-xg)²+(y2-yg)²)*10

-6

+lcyi}

-

6 +lcz1}

-

6 +lcz2}

………………………………….

+ {wi*((xi-xg)²+(yi-yg)²)*10-6 +lczi}

58 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Calculating the Moment of Inertia

Example 3

The following example shows how to calculate the center of gravity in cases where more
then two workpieces, such as the dual end effector system shown in Figure 5-8, are
utilized.

1. Define the center of gravity, based on the position of the center of gravity of the
tool being used, and define the moment of inertia based on the center of gravity of
the entire tool. Use the hexahedron and cylinder principle as described in

“Example 1” on page 54.

2. When the weight of each part and the center of gravity have been defined, the
position of the center of gravity, including the moment of inertia at the center of
gravity, can be calculated for the entire tool. Refer to “Example 1” on page 54 and

“Example 2” on page 57 for details.

Figure 5-8 shows how to calculate the required values.

Y

F

F

Gun 1

40

Gun 2

70

(Gun 1)

Z

F

Weight: w1 = 3 kg
Center of Gravity:

x1 = 100 mm
y1 = 50 mm
z1 = 40 mm

X

Figure 5-8. Center of Gravity: Dual End Effector Example

Weight: W=w1+w2 = 3+6 = 9. Approx. 10 kg
Center of gravity: g=(w1*x1+w2*x2)/(w1+w2)

= (3*100+6*100)/(3+6) = 100 mm
Yg= (3*50+6*(-150))/(3+6) = -83.333 mm
Zg= (3*40+6*70)/(3+6) = 60 mm

The moment of inertia at the center of gravity:

Center of Flange

Y

F

Gun 1

(T op Vie w)

100

50 150

X

F

(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:

x2 = 100 mm
y2 = -150 mm
z2 = 70 mm

Gun 2

lx = {w1*((y1-Yg)²+(z1-Zg)²)*10

+ {w2*((y2-Yg)²+(z2-Zg)²)*10-6 +lcx2}

= 3*((50(-83))² + (40-60)²* 10
+ 6*(((-150) – (-83))²+(70-60)²)* 10

-6

-6

+lcx1}

-6

= 0.082 = Approx. 0.100
ly = 3*((100-100)²+(40-60)²)* 10
+ 6*((100-100)²+(70-60)²)* 10

-6

-6

AdeptSix 300CR Robot Instruction Handbook, Rev. A 59

Chapter 5 - End of Arm Tooling

= 0.002 = Approx. 0.010
lz = 3*((100-100)²+(50-(-83))²)* 10
+ 6*((100-100)²+((-150)-(-83))²)* 10

-6

-6

= 0.080 = Approx. 0.100

Tooling Details:

• W:10.000 kg

• Xg:100.000 mm

• Yg:-83.333 mm

• Zg:60.000 mm

• lx:0.100 kg.m²

• ly:0.010 kg.m²

• lz: 0.100 kg.m²

5.5 Mounting Equipment - Allowable Load

When peripheral equipment is attached to Axis 3, the following conditions must be
observed:

The allowable load on Axis 3 is a maximum of 4 kg, including the wrist load.

For instance, when the mass installed at the wrist point is 3 kg, the mass which can be
installed on the upper arm becomes 1 kg.

A

119

49

Axis 3 Rotation Center

2-M6XP1.0 Tapped
Depth 12 mm

View A

Figure 5-9. Installing Peripheral Equipment

60 AdeptSix 300CR Robot Instruction Handbook, Rev. A

5.6 User Electrical Lines and Air Lines

2

4

)

)

et

et

1

s

)

2

)

)

m

e

m

S

0

S

g:

P

A

B

aus

t

g

)

gs

e

2

1

4

5

There are 9 electrical cables (0.2mm) and an 1 air line that are used in the robot for the
peripheral devices mounted on the arm, as shown in Figure 5-10

The connector pins (1 to 9) are assigned as shown in Figure 5-11. Wiring must be
performed by user.

• The allowable current for cables is 2.5A or less for each cable

• The maximum pressure for the air hose is 490kPa (5 kgf/cm

is φ2.5 mm.

Barb couplings for flexible tube (4 couplings

se a tube with an inner diameter of 2.5 m

ser cable connector: HR10A-10TR-12

User Electrical Lines and Air Lines

2

). The inside diameter

Air Inl
Port 1 (IN

Air Inl
Port 2 (IN

OUT

Barb couplings for flexible tub

se a tube with an inner diameter of 2.5 m

Air Intake Inlets (2
Tapped holes PT1/8 - with cover plu
Upper inlet: Port 1
Low

r inlet: Port

ser cable connector:

A-10TR-12

HR1
Mating plu
HR10A-10TP-12

Internal Air Intake Port
Outer diameter: 34 mm

View

Air Exh

t Por
Tapped hole PT1/8
with cover plu

Axis

Air Duct

Valve type: 10-VQD1151W-5M-M5(SMC

f

Valve

Air supply inlet 1
Air supply inlet

Air supply inlet
Air supply inlet 5

Figure 5-10. User Electrical and Air Lines

AdeptSix 300CR Robot Instruction Handbook, Rev. A 61

Chapter 5 - End of Arm Tooling

Pin numbers

Figure 5-11. Detailed Drawing of Connector Pin Numbers

1

2

3

4

5

6

7

8

9

10 (For incorporated valve)  24VDC, common

11 (For incorporated valve)  For driving the valve 1 (24VDC, 4W)

12 (For incorporated valve)  For driving the valve 2 (24VDC, 4W)

9

8

7

12

6

1

10

5

2

3

11

4

Pins number (1 to 9) of both connectors are used for end-of-arm tooling signals (0.2 mm

2

).

62 AdeptSix 300CR Robot Instruction Handbook, Rev. A

6.1 Introduction

This chapter covers system operation for AdeptSix robot systems using the Adept MV
Controller. If you have an Adept SmartController, refer to Chapter 7.

Verifying that the system is correctly installed and that all safety equipment is working
correctly is a three-step process. This chapter discusses the first two steps.

• Step one reviews starting the control system for the first time and verifying that all
components have been correctly installed.

• Step two (referred to as “commissioning the system”) verifies that all safety
equipment is working properly, after the safe initialization of the control system
has been verified.

• Step three verifies that the robot moves correctly. The Manual Control Pendant is
used for this step and is reviewed in Chapter 8.

System Operation -

MV Controller 6

WARNI NG: After installing the robot, it must be tested

before it is used for the first time. Failure to do this could
cause serious injury or equipment damage.

6.2 Installation Check List

Before using the robot, make the following checks to ensure that the robot and controller
have been properly installed.

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.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 63

Chapter 6 - System Operation - MV Controller

AC Power to Adept Components Checks

Verify that the Adept controller is correctly connected to the AC power source.

1. Make sure that AC power is shut off to the Adept controllers (MV and PA-4
power chassis).

2. Verify that the single phase AC power (180-245 VAC) is connected to the Adept
power controller.

3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected
to the Adept PA-4 power chassis. For information on single-phase AC power to
the PA-4, see the AdeptSix Controller Installation Guide.

4. If the System Power On/Off switch on the CIP-2 is used, check the connections to
this switch.

Board and Cable Installation Checks

Make sure that all the boards in the Adept controller and PA-4 power chassis are secured
and the connection cables are correctly installed.

1. Secure all boards and blank front panels to the Adept controller chassis. Tighten
both the top and bottom mounting screws on each front panel. This ensures
proper grounding of the controller from an EMC standpoint and ensures good
connection to the controller backplane.

2. Secure all amplifier modules and the MAI-2 (multi-axis interface) module in the
amp chassis. Tighten both the top and bottom mounting screws on each front
panel. This ensures proper grounding of the amplifier controller subsystems from
an EMC standpoint and ensures good connection to the drawer connectors at the
rear of the chassis. The drawer connectors carry power and interlock signals
from/into the power chassis from the amplifiers.

NOTE: There is a safety interlock built into the amp chassis that prevents
high power from being applied if the amplifier modules, or the MAI-2
module are not correctly screwed into place.

3. Verify the following cable connections. Check to see that the plugs are latched on
both ends of the cables. See Figure 4-1 on page 43.

• Robot to amps in PA-4 power chassis (Arm Power Cable)

• Robot CN29 connector to MAI-2 CN29 connector (Arm Power Cable)

• Robot to PA-4 power chassis MAI-2 (Arm Signal Cable)

• Install one ground wire each from Arm Signal Cable and Arm Power Cable
to front right screw on the top of the Adept PA-4 power chassis.

• 1394 AWC-II connector to MAI-2 IEEE 1394 connector

• CIP-2 to optional MCP (install bypass plug if not used)

• CIP-2 (JAWC connector) to AWC-II (CIP) connector

• CIP-2 (JSLV connector) to MAI-2 (XSLV1) connector

• JUSER to user-supplied equipment (install jumper plug if not used)

64 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Installation Check List

4. Check the manual brake release box cable into the MAI-2 connector marked

Manual Brake Release. (if used)

5. If you are using the AdeptWindows PC user interface, connect a shielded

Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the
AWC-II board. Unshielded cables will degrade the integrity of the
AdeptWindows PC link, particularly when power is applied to the robot or
mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone
PC.

User-Supplied Safety Equipment on JUSER and JSIO Connector Checks

Check the following safety equipment connected to the JUSER and JSIO connectors on the
CIP-2:

1. There are eight pairs of contacts that must be connected on the JUSER connector

(see Adept MV Controller User’s Guide) to ensure proper continuity of the
emergency stop circuitry. Verify that these connections are secure and reliable and
that a redundant pair of contacts is installed, one for each E-Stop channel. Double
check that the state of the contacts on each pair matches and the contacts are
closed. Each contact is separately connected to its respective E-Stop channel.
Inadvertent connection between the E-Stop channels will short the E-Stop power
supply, making it impossible to apply High Power.

2. There are two pairs of contacts in the JSIO connector that must be connected to

ensure proper continuity of the emergency stop circuitry. Verify that these
connections are secure, reliable, and closed prior to enabling power.

3. Make sure that guarding around the workcell is properly connected to either the

Muted Safety gate inputs on the JUSER connector or, if appropriate, to the User
E-Stop connections on the JUSER connector. Make sure that all gate, E-Stop push
button switches, and other interlocks have two independent electrical poles.
Make sure that a pair of redundant contacts is installed and that these contacts are
separately connected to their respective E-Stop channels. Make sure that all
interlock or emergency stop devices are wired in series (not in parallel) before
connecting to the User E-Stop connections. Identify all wiring with Channel 1 or
Channel 2. Inadvertent connection between the channels will short the E-Stop
power supply, making it impossible to apply High Power.

4. Make sure that workcell components have been properly interlocked to avoid

hazards when the robot/motion system is operated in Manual Mode. (Per “ISO
10218 Manipulating Robots Safety”, the robot control system must employ a
“single point of control” when operated in Manual Mode.)

AdeptSix 300CR Robot Instruction Handbook, Rev. A 65

Chapter 6 - System Operation - MV Controller

E-Stop Button and Switch Checks

1. Verify that the red E-Stop push buttons on the CIP-2, MCP, and User Panel (if
installed) are in the normal, unlatched (electrically closed) position.

2. Verify that the MCP jumper plug on the CIP-2 is installed or that the optional
MCP is mounted on a rack that holds the MCP Enable switch in the ON position.

3. Verify that the user panel (if installed) enable contacts are closed, that a pair of
redundant contacts is installed and that these contacts are separately connected to
their respective E-Stop channels. Inadvertent connection between the channels
will short the E-Stop power supply, making it impossible to apply High Power to
the robot.

6.3 Applying Power to the Adept Control System

After you have made the checks listed above, system power is ready to be turned on.

CAUTION: All safety systems must be in place and

operating before applying power to the system. Extra care
should be taken during the initial tests of the robot system.

1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (
position.

2. Turn the AC power switch on the Adept MV controller to the ON (

3. Turn the System Power switch on the CIP-2, if used, to the ON (

4. The AWC-II will execute its boot sequence. When the boot sequence has
completed, the SF/OK LED should be green. If this LED is red, the AWC-II has
not booted properly. Turn off power to the controller and reboot. If the problem
persists, call Adept Customer Service. Note the state of the LEDs marked 1 to 3,
which indicate the problems shown in Table 6-1 on page 67.

5. The other LEDs should be off. If the ES (E-Stop) LED on the AWC-II board is
flickering red, this could result from:

a. An oscillation may be the result of a mismatch between the contacts forming

a “pair of contacts” in the two E-Stop channels. Perhaps on one channel, the
user E-Stop contacts are closed, and on the other they are open. Check each
pair of contacts to make sure that they match and that they are all closed per

Adept MV Controller User's Guide.

b. Also, a short between the two E-Stop channels may sometimes result in this

oscillating red ES LED. If the problem persists, call Adept Customer Service.

6. If the E-Stop LED is continuously red, then at least one pair of E-Stop contacts is
open or the E-Stop contacts on the JSIO connector are open. Review the checklist
items above to resolve the problem. If the problem persists, call Adept Customer
Service.

l) position.

l)

l) position

66 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Checks After Applying Power

LED Status Indicators on the AWC-II

The LEDs on the front of the AWC-II indicate the following conditions:

O = off G = green R = red

Table 6-1. LED Status Indicators

LED Display Error # Description

O-O-O 0 No error.

O-O-R 1

O-R-O 2 Hardware configuration error. Address switches/SYSCTL wrong.

O-R-R 3 Graphics board failure. VGB not responding.

R-O-O 4 Memory test failure. Free storage error.

R-R-O 6 Software serial I/O configuration error.

G-O-O C Uninitialized trap.

G-O-G D Bus error detected.

System clock is dead or too fast. Clock interrupts are not being
received.

If the AWC-II displays any of the above errors, contact Adept Customer Service (see

“How Can I Get Help?” on page 16).

6.4 Checks After Applying Power

1. Verify that High Power can be enabled:

a. Enter the following command at the dot prompt in the monitor window:

enable power

Or press the COMP/PWR button on the MCP

b. When the High Power push button/light on the CIP-2 begins flashing, press

and hold the push button for 1 - 2 seconds. When you release the push
button, the light should remain lit continuously indicating that High Power
has successfully been enabled.

c. If the light does not stay on, the High Power enable process has failed and a

message will be displayed on the monitor and MCP indicating why.

2. Verify that all E-Stop devices are functional (MCP, CIP-2, and user supplied). Test
each mushroom button, safety gate, light curtain, etc., by enabling High Power
and opening the safety device. The High Power push button/light on the CIP-2
should go out and the red ES LED on the AWC-II should be lit.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 67

Chapter 6 - System Operation - MV Controller

6.5 Calibrate Robot

The AdeptSix robot uses optical absolute encoders to determine position of each axis, and
establish commutation reference for the phases of the motors. Since the motors are
brushless AC, the rotor must be commutated by electronics rather that using physical
brushes to switch current from phase to phase. The absolute encoders have the ability to
determine position for a full turn of the motor rotor. Built into the absolute encoder is a
multiple turn counter that keeps track of the number of times the absolute encoder has
completed a full revolution. The encoder system is powered by the Adept PA-4 power
chassis, and also has a battery backup to maintain position tracking during shipment of
the robot, or periods when the system is turned off.

1. Verify that you have enabled power as described above.

2. Enter the following command at the dot prompt in the monitor window:

calibrate

When calibration is complete, the monitor displays the dot prompt. This means
the system is ready for operation.

6.6 Turning Off the System

Follow these steps to turn off power to the robot system.

1. Make sure that robot motion has stopped.

2. Abort any programs that are running using the abort command.

3. Turn off High Power to the robot using the disable power command, or by
pressing the DIS PWR button on the MCP.

4. Turn off the AC power switch on the Adept MV controller.

5. Turn off the AC power switch on the PA-4 power chassis.

6.7 Learning to Operate/ Program the AdeptSix 300CR Robot

When the robot has been calibrated, refer to Chapter 8 to learn how to move the robot
with the optional MCP or go to the V+ Operating System User’s Guide to find information
on basic operation of the V

Utility Programs for information on using the Adept utility programs.

For additional programming information you need to refer to the following list of
optional manuals:

+

Operating System. Also refer to the Instructions for Adept

• V+ Language User’s Guide

• V+ Language Reference Guide

• V+ Operating System Reference Guide

68 AdeptSix 300CR Robot Instruction Handbook, Rev. A

7.1 Introduction

This chapter covers system operation for AdeptSix 300CR robot systems using the Adept
SmartController. If you have an Adept MV Controller, refer to Chapter 6.

Verifying that the system is correctly installed and that all safety equipment is working
correctly is a three-step process. This chapter discusses the first two steps.

• Step one reviews starting the control system for the first time and verifying that all
components have been correctly installed.

• Step two (referred to as “commissioning the system”) verifies that all safety
equipment is working properly, after the safe initialization of the control system
has been verified.

• Step three verifies that the robot moves correctly. The Manual Control Pendant is
used for this step. For more information about the MCP, see the Chapter 8 in this
manual and the Adept SmartController User’s Guide.

System Operation -

SmartController 7

WARNI NG: After installing the robot, it must be tested

before it is used for the first time. Failure to do this could
cause serious injury or equipment damage.

7.2 Installation Check List

Before using the robot, make the following checks to ensure that the robot and controller
have been properly installed.

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.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 69

Chapter 7 - System Operation - SmartController

Power to the Adept Components Checks

Verify that the Adept control system is correctly connected to the DC and AC power
sources.

1. Make sure that power is shut off to the Adept SmartController and the PA-4
power chassis).

2. Verify that 24 DC power is connected to the Adept SmartController.

3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected
to the Adept PA-4 power chassis. For information on single-phase AC power to
the PA-4, see the AdeptSix Controller Installation Guide.

Board and Cable Installation Checks

Make sure that all the boards in the Adept SmartController and PA-4 power chassis are
secured and the connection cables are correctly installed.

1. Secure all amplifier modules and the MAI-2 (multi-axis interface) module in the
amp chassis. Tighten both the top and bottom mounting screws on each front
panel. This ensures proper grounding of the amplifier controller subsystems from
an EMC standpoint and ensures good connection to the drawer connectors at the
rear of the chassis. The drawer connectors carry power and interlock signals
from/into the power chassis from the amplifiers.

NOTE: There is a safety interlock built into the amp chassis that prevents
high power from being applied if the amplifier modules, or the MAI-2
module are not correctly screwed into place.

2. Secure the motor output connector clamp of the arm power cable onto the six
motor power output (Motor Power Outlet) connections on the three Dual E amps.
Verify that the clamp is securely latched.

3. Verify the following cable connections. Check to see that the plugs are latched on
both ends of the cables. See Figure 4-2.

• Robot to amps in PA-4 power chassis (Arm Power Cable)

• Robot CN29 connector to MAI-2 CN29 connector (Arm Power Cable)

• Robot to PA-4 power chassis MAI-2 CNPG123 and CNPG456 (Arm Signal
Cable)

• Install one ground wire each from Arm Signal Cable and Arm Power Cable
to front right screw on the top of the Adept PA-4 power chassis.

• SmartController SmartServo port 1.1 connector to MAI-2 1394 connector

• SmartController XSYS connector to MAI-2 XSLV1 connector

• SmartController XFP to Front Panel XFP

• SmartController XMCP to optional MCP, requires MCP adapter cable and
MCP3 dongle (install bypass plug if not used)

• SmartController XUSR to user-supplied equipment (install jumper plug if
not used)

70 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Installation Check List

4. Secure the optional manual brake release box cable into the MAI-2 connector

marked Manual Brake Release. (if used)

5. If you are using the AdeptWindows PC user interface, connect a shielded

Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the
AWC-II board. Unshielded cables will degrade the integrity of the
AdeptWindows PC link, particularly when power is applied to the robot or
mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone
PC.

User-Supplied Safety Equipment on XUSR Connector Checks

Check the following safety equipment connected to the XUSR connector on the
SmartController.

1. There are eight pairs of contacts that must be connected on the XUSR connector

(see Adept SmartController User’s Guide) to ensure proper continuity of the
emergency stop circuitry. Verify that these connections are secure and reliable and
that a redundant pair of contacts is installed, one for each E-Stop channel. Double
check that the state of the contacts on each pair matches and the contacts are
closed. Each contact is separately connected to its respective E-Stop channel.
Inadvertent connection between the E-Stop channels will short the E-Stop power
supply, making it impossible to apply High Power.

2. Make sure that guarding around the workcell is properly connected to either the

Muted Safety gate inputs on the XUSR connector or, if appropriate, to the User
E-Stop connections on the XUSR connector. Make sure that all gate, E-Stop push
button switches, and other interlocks have two independent electrical poles.
Make sure that a pair of redundant contacts is installed and that these contacts are
separately connected to their respective E-Stop channels. Make sure that all
interlock or emergency stop devices are wired in series (not in parallel) before
connecting to the User E-Stop connections. Identify all wiring with Channel 1 or
Channel 2. Inadvertent connection between the channels will short the E-Stop
power supply, making it impossible to apply High Power.

3. Make sure that workcell components have been properly interlocked to avoid

hazards when the robot/motion system is operated in Manual Mode. (Per “ISO
10218 Manipulating Robots Safety”, the robot control system must employ a
“single point of control” when operated in Manual Mode.)

AdeptSix 300CR Robot Instruction Handbook, Rev. A 71

Chapter 7 - System Operation - SmartController

E-Stop Button and Switch Checks

1. Verify that the red E-Stop push buttons on the Front Panel, MCP, and User Panel
(if installed) are in the normal, unlatched (electrically closed) position.

2. Verify that the MCP jumper plug is installed on the controller or that the optional
MCP is mounted on a rack that holds the MCP Enable switch in the ON position.

3. Verify that the user panel enable contacts are closed, that a pair of redundant
contacts is installed and that these contacts are separately connected to their
respective E-Stop channels. Inadvertent connection between the channels will
short the E-Stop power supply, making it impossible to apply High Power to the
robot.

7.3 Applying Power to the Adept Control System

After you have made the checks listed above, system power is ready to be turned on.

CAUTION: All safety systems must be in place and

operating before applying power to the system. Extra care
should be taken during the initial tests of the robot system.

1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (
position.

2. Turn on DC power to the Adept SmartController.

3. The SmartController will execute its boot sequence. When the boot sequence has
completed, the OK/SF LED should be green. If this LED is red, the
SmartController has not booted properly. Turn off power to the controller and
reboot. If the problem persists, call Adept Customer Service. Note the state of the
LEDs marked 1 to 3.

4. If the HPE/ES LED is continuously red, then at least one pair of E-Stop contacts is
open. Check all E-stops.

NOTE: For information on the Status LEDs, refer to the Adept

SmartController User’s Guide.

7.4 Checks After Applying Power

1. Verify that High Power can be enabled:

a. Enter the following command at the dot prompt in the monitor window:

enable power

l)

Or press the COMP/PWR button on the MCP

72 AdeptSix 300CR Robot Instruction Handbook, Rev. A

b. When the High Power push button/light on the Front Panel begins flashing,

press and hold the push button for 1 - 2 seconds. When you release the push
button, the light should remain lit continuously indicating that High Power
has successfully been enabled.

c. If the light does not stay on, the High Power enable process has failed and a

message will be displayed on the monitor and MCP indicating why.

2. Verify that all E-Stop devices are functional (MCP, Front Panel, and user
supplied). Test each mushroom button, safety gate, light curtain, etc., by enabling
High Power and opening the safety device. The High Power push button/light on
the Front Panel should go out and the red HPE/ES LED on the SmartController
should be lit.

7.5 Calibrate Robot

The AdeptSix robot uses optical absolute encoders to determine position of each axis, and
establish commutation reference for the phases of the motors. Since the motors are
brushless AC, the rotor must be commutated by electronics rather that using physical
brushes to switch current from phase to phase. The absolute encoders have the ability to
determine position for a full turn of the motor rotor. Built into the absolute encoder is a
multiple turn counter that keeps track of the number of times the absolute encoder has
completed a full revolution. The encoder system is powered by the Adept PA-4 power
chassis, and also has a battery backup to maintain position tracking during shipment of
the robot, or periods when the system is turned off.

Calibrate Robot

1. Verify that you have enabled power as described above.

2. Enter the following command at the dot prompt in the monitor window:

calibrate

When calibration is complete, the monitor displays the dot prompt. This means
the system is ready for operation.

7.6 Turning Off the System

Follow these steps to turn off power to the robot system.

1. Make sure that robot motion has stopped.

2. Abort any programs that are running using the abort command.

3. Turn off High Power to the robot using the disable power command, or by
pressing the DIS PWR button on the MCP.

4. Turn off DC power to the SmartController.

5. Turn off the AC power switch on the Adept PA-4 power chassis.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 73

Chapter 7 - System Operation - SmartController

7.7 Learning to Operate/ Program the AdeptSix 300CR Robot

When the robot has been calibrated, refer to the MCP chapter to learn how to move the
robot with the optional MCP or go to the V+ Operating System User’s Guide to find
information on basic operation of the V

for Adept Utility Programs for information on using the Adept utility programs.

For additional programming information you need to refer to the following list of
optional manuals:

• V+ Language User’s Guide

• V+ Language Reference Guide

• V+ Operating System Reference Guide

+

Operating System. Also refer to the Instructions

74 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Using the Manual Control

Pendant (MCP) 8

8.1 MCP Usage for Six-Axis Robots

This section describes the coordinate system used by the AdeptSix 300CR robot. This
information is necessary when using the MCP to control the robot. See the Adept MV

Controller User’s Guide or the Adept SmartController User’s Guide for general details on

using and programming the MCP.

Joint Mode (Single-Axis Movement)

Joint motion is made around the axes of the various joints J1, J2, J3, etc. Use the + or ­speed bar key to specify rotational direction. See Figure 8-1 on page 76.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 75

Chapter 8 - Using the Manual Control Pendant (MCP)

J1

Axis 1

(J1)

Rotates main body

X-

J1-

Axis 2

(J2)

Axis 3

(J3)

X+

J1+

Axis 4

(J4)

J4

Axis 5

(J5)

Axis 6

(J6)

Rotates upper arm

x

J4-

Moves lower arm forward/

J2

backward

Y-

J2-

J3

Moves upper arm up/

down

Z-

J3-

Z+

J3+

J5

Y+

J2+

J6

Figure 8-1. Joint Mode

x

J4+

Moves wrist up/down

y

J5-

y

J5+

Rotates wrist

z

J6-

z

J6+

76 AdeptSix 300CR Robot Instruction Handbook, Rev. A

MCP Usage for Six-Axis Robots

WORLD Coordinate System (WORLD Mode on the MCP)

The WORLD coordinate system is fixed. All translation motions are parallel to the
WORLD coordinates. The RX, RY, and RZ rotations are made with respect to the WORLD
coordinates. Use the + or - speed bar key to specify motions. See Figure 8-2.

Z-Axis

Y-Axis

X-Axis

X

Moves in parallel with X- Axis

X-

Y Moves in parallel with Y- Axis

Y-

Figure 8-2. World Mode

Y+

X+

Z

Moves in parallel with
Z-Axis

Z+

Z-

AdeptSix 300CR Robot Instruction Handbook, Rev. A 77

Chapter 8 - Using the Manual Control Pendant (MCP)

TOOL Coordinate System (TOOL Mode on the MCP)

All motions are parallel to the TOOL coordinates. Joint X is attached by the groove in the
tool attachment clamp. Specify RX, RY, and RZ rotations with respect to the TOOL
coordinates. Use the + or - speed bar key to specify motions. See Figure 8-3.

RX

RY RZ

Rotates around Y- axisRotates around X- axis

RY-

RX-

RX+

Figure 8-3. Tool Mode

Coordinate System Definitions

The points below provide information about the coordinate system.

• To locate a point in space (3D), a coordinate system is used.

• The coordinate system is represented by the origin and the X Y Z perpendicular
axis.

• The orientation of these 3 axes follows the RIGHT HAND rule. See Figure 8-4.

RY+

Rotates around Z -axis

RZ+ RZ-

X: Thumb
Y: Index Finger
Z: Middle Finger

Y

Z

X

OR

X

Y

Figure 8-4. Right Hand Rule

X: Index Finger

Z

Y: Middle Finger
Z: Thumb

78 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Maintenance and Inspection 9

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period, but also to prevent malfunctions and assure safe operation.
Inspection intervals are displayed in six levels. Conduct periodic inspections according to
the inspection schedule in Table 9-1 on page 80.

In Table 9-1, the inspection items are classified into three types of operations: operations
which can be performed by personnel authorized by the user, operations which can be
performed by trained personnel, and operations which can be performed by service
company or factory-trained personnel. Only specified personnel are to do inspection work

WARNI NG: Before maintenance or inspection, make sure

to switch off the main power supply, and place a warning
sign (for example, Do not switch on the power). Failure to
observe this warning may result in electric shock or injury.

WARNI NG: Maintenance and inspection must be

performed by specified personnel. Failure to observe this
caution may result in electric shock or injury.

CAUTION: For disassembly or repair, contact your Adept

representative.

CAUTION: The battery unit must be connected before

removing the detection connector when performing
maintenance and inspection. Failure to observe this
caution may result in the loss of home-position data.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 79

Chapter 9 - Maintenance and Inspection

NOTE: The inspection interval must be based on the servo power supply
on time. These inspections were developed for applications where the
robot is used for high duty cycle applications. For any different or special
applications, the inspection process should be developed on a
case-by-case basis. For axes which are used very frequently (in handling
applications, etc.), it is recommended that inspections be conducted at
shorter Intervals. Contact your Adept representative for more
information.

Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items

Items

Tram ma rk

1

Wo rk in g
area and
robot

2

Baseplate
mounting

3

bolts

Cover
mounting

4

screws

Base

5

connectors

Schedule

90

30

a

Da
ily

0
H
Cy
cle

00
H
Cy
cle

00
H
Cy
cle

X

X

X

X

X

50

18
00
0
H

36

Metho

00

d

0
H

Visual Check tram mark

Visual Clean the work

Spanner
Wre nc h

Screw­driver,
Wre nc h

Manual Check for loose

Operation

alignment and
damage at the
home position.

area if dust or
spatter is present.
Check for damage
and outside
cracks.

Tighten l oose
bolts. Replace if
necessary.

Tighten l oose
bolts. Replace if
necessary.

connectors.

Inspection Charge

Spe
cifie
d
Pers
on

Lice
nsee

Serv
ice
Com
pany

XXX

XXX

XXX

XXX

XXX

Axes 4 & 5

6

timing belt

Wire
harness in
robot
(Axis 1)

7

X

X

X

Manual Check for belt

Visual
Multi­meter

tension and wear.

Check for
conduction
between the main
connector of the
base and the
intermediate
connector by
manually shaking
the wire. Check for
wear of the
protective spring.

Replace.

c

80 AdeptSix 300CR Robot Instruction Handbook, Rev. A

XX

XX

b

Inspection Schedule

Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items

Items

Wire
harness in
robot
(Axis 2)

8

Wire
harness in
robot
(Axis 3)

9

Battery unit
in robot

1
0

Schedule

90

30

a

Da
ily

0
H
Cy
cle

00
H
Cy
cle

00
H
Cy
cle

X

X

X

50

18
00
0
H

X

X

36
00
0
H

Metho

d

Visual
Multi­meter

Operation

Check for
conduction
between terminals
and wear of the
protective spring.

b

c

Replace.

Check for
conduction
between terminals
and wear of the
protective spring.

b

c

Replace.

Replace the battery
unit when the
battery alarm
occurs or when the
robot has operated
for 36000 H.

Inspection Charge

Spe
cifie
d
Pers
on

Lice
nsee

Serv
ice
Com
pany

X

XX

X

XX

1
1

1
2

1
3

Axis 1
speed
reducer

Axis 2
speed
reducer

Axis 3
speed
reducer

Grease
Gun

X

Grease
Gun

X

Grease
Gun

X

Check for
malfunction
Replace if
necessary. Supply

d

(9000 H

grease
cycle). See

91

Check for
malfunction.
Replace if
necessary. Supply
grease.
cycle). See

86

Check for
malfunction.
Replace if
necessary. Supply
grease.
cycle). See

88

.

.

.

page

d

(9000 H

page

d

(9000 H

page

XX

XX

XX

AdeptSix 300CR Robot Instruction Handbook, Rev. A 81

Chapter 9 - Maintenance and Inspection

Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items

Schedule

90

30

50

Items

a

Da
ily

0
H
Cy
cle

Axes 4 and
5 speed
reducers

1
4

Axis 6
speed
reducer

1
5

Overhaul

1
6

a

Inspection item numbers correspond to the numbers in Figure 9-1 on page 83.

b

When checking for conduction with a multimeter, connect the battery to “BAT” and “OBT” of

00
H
Cy
cle

00
H
Cy
cle

X

X

36

18
00
0
H

00
0
H

Metho

d

Grease
Gun

Grease
Gun

Operation

Check for
malfunction.
Replace if
necessary. Supply

d

(9000 H

grease.
cycle). See

89

Check for
malfunction.
Replace if
necessary. Supply
grease.
cycle). See

90

.

.

page

d

(9000 H

page

XX

Inspection Charge

Spe
cifie
d
Pers

Lice
nsee

on

XX

XX

the connectors on the motor side for each axis, and then remove the connectors from the motor
on the detector side for each axis. Otherwise, the home position may be lost. (Refer to “Notes for

Maintenance” on page 91 for more information).

c

Replace the wire harness in the robot at the 24000 H inspection.

d

For the grease, refer to Table 9-2 on page 83.

Serv
ice
Com
pany

82 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Inspection Schedule

Axis 1

1

1

Axis 5

5

10

13

6

9

6

3

14

Axis 5

Axis 4

14

15

1

Axis 6

Axis 5

11

7

Axis 4

1

1

Axis 3

8

1

12

Figure 9-1. Inspection Parts and Inspection Numbers

Table 9-2. Inspection Parts and Grease Used

No. Grease Used Inspected Parts

11, 12, 13, 14, 15 Harmonic Grease SK-1A Axes 1, 2, 3, 4, 5, and 6 speed

reducers

The numbers in the above table correspond to the item numbers in Table 9-1 on page 80.

Axis 2

AdeptSix 300CR Robot Instruction Handbook, Rev. A 83

Chapter 9 - Maintenance and Inspection

9.2 Maintenance Procedures

Battery Unit Replacement

If the battery alarm occurs in the controller, replace the battery according to the following
procedures.

1. Switch off the main power supplies to the controller and PA-4 power chassis.

2. Remove the connector base plate and grease tube from the union.

3. Remove the battery-unit mounting screw on the Connector Base.

4. Remove the plastic tape (insulation tape) protecting the connector of the battery

unit in the robot.

5. Connect the new battery.

6. Remove the old battery and washer.

NOTE: Remove the old battery unit after connecting the new one so that
the encoder absolute data does not disappear.

7. Protect the connector of the battery unit in the robot with plastic tape (insulation

tape).

8. Mount the battery unit and washer with the screws, connect the grease tube to the

union, and then mount the connector base plate.

Connector Base (Top View)

1BC

A

B

3BC2BC

A

Connector Base Bolt
Mounting Screw
60660-00010

Washer

60660-00020

Battery Unit

Base

Connector base

Figure 9-2. Battery Location

84 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Maintenance Procedures

See Procedure 6

See Procedure 7

0BT1

BAT1

0BT1

hw27230hw927089401hw721.0y

BAT1

See Procedure 4

See Procedure 6

See Procedure 7

0BT4

BAT4

0BT4

BAT4

See Procedure 4

NOTE: The procedures referenced in the above figure refer to the
numbered steps on page 84.

Battery Unit for Axes 1, 2, and 3
Before Replacement

a: Insertion-type Pin Terminal (Male)

a

b

0BT1

a

b

a

b

BAT1

b: Insertion-type Pin Terminal (Female)

b

0BT1

a

BAT1

Battery Unit for Axes 4, 5, and 6
Before Replacement

a

See Procedure 5

b

0BT4

a

b

a

b

BAT4

b
a

0BT4
BAT4

New Battery Unit

Figure 9-3. Battery Connection

AdeptSix 300CR Robot Instruction Handbook, Rev. A 85

Chapter 9 - Maintenance and Inspection

Grease Replenishment for Axis 1 Speed Reducer

Si: Grease Inlet
G Nipple A-PT1/8

So: Air flow
Hexagon socket head plug PT1/8

Figure 9-4. Axis 1 Speed Reducer Diagram

NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are

inverted.

Axis 1 Speed
Reducer

Replenish the grease according to the following procedure. Refer to Figure 9-4.

1. Remove the So plug (hexagon socket head plug PT 1/8).

NOTE: It is absolutely necessary that you remove the So plug. If grease is
added without removing it, the internal pressure will increase and this
may case damage to the seals.

2. Replace the PT 1/8 socket head plug (Si) with a A-PT1/8 grease nipple

3. Inject the grease into the Si grease inlet using a grease gun.

Grease type: Harmonic grease SK-1A

Amount of grease: 20 cc

NOTE: Grease is not evacuated by the So exhaust port. Do not inject
excessive grease into the Si grease inlet.

4. Remove the G Nipple from the Si grease inlet, degrease the tapped hole on the Si

grease inlet, and then reinstall the PT 1/8 socket head plug. Apply Three Bond
1211 on screwed parts.

5. Degrease the tapped hole on the So air flow, and then reinstall the hexagon socket

head plug. Apply Three Bond 1211 on screwed parts.

86 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Grease Replenishment for Axis 2 Speed Reducer

r

pp

6

ow

6

r

Lo: Air fl

Axis 2 speed reduce

Figure 9-5. Axis 2 Speed Reducer Diagram

NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are

inverted.

Hexagon socket head plug PT1/1

ove

i: Grease inlet

le A-PT1/1

G Ni

Maintenance Procedures

Replenish the grease according to the following procedure. Refer to Figure 9-5.

1. Remove the Axis 2 side cover.

2. Replace the PT 1/16 socket head plug (Li) with a A-PT 1/16 grease nipple.

3. Remove the Lo plug (hexagon socket head PT1/16).

NOTE: It is absolutely necessary that you remove the Lo plug. If grease is
added without removing it, the internal pressure will increase and this
may case damage to the seals.

4. Inject the grease into the Li grease inlet using a grease gun.

Grease type: Harmonic grease SK-1A

Amount of grease: 20cc

NOTE: Grease is not evacuated by the Lo exhaust port. Do not inject
excessive grease into the Li grease inlet.

5. Remove the G Nipple Li grease inlet, degrease the tapped hole on the Li grease
inlet, and then reinstall the PT 1/16 socket head plug. Apply Three Bond 1211 on
screwed parts.

6. Degrease the tapped hole on the Lo air flow, and then reinstall the hexagon socket
head plug. Apply Three Bond 1211 on screwed parts.

7. Reinstall the Axis 2 side cover.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 87

Chapter 9 - Maintenance and Inspection

Grease Replenishment for Axis 3 Speed Reducer

Uo:Air flow
Hexagon socket head plug PT1/16

Cover

Axis 3 speed reducer

Ui: Grease inlet
G Nipple A-PT/16

Figure 9-6. Axis 3 Speed Reducer Diagram

NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are

inverted.

Replenish the grease according to the following procedure. Refer to Figure 9-6.

1. Remove the Axis 3 side cover.

2. Replace the PT 1/16 socket head plug (Ui) with a A-PT 1/16 grease nipple

3. Remove the Uo plug (hexagon socket head PT 1/16).

NOTE: It is absolutely necessary that you remove the Uo plug. If grease is
added without removing it, the internal pressure will increase and this
may case damage to the seals.

4. Inject the grease into the Ui grease inlet using a grease gun.

NOTE: Grease is not evacuated by the Uo exhaust port. Do not inject
excessive grease into the Ui grease inlet.

Grease type: Harmonic grease SK-1A

Amount of grease: 8 cc

5. Remove the G Nipple from the Ui grease inlet, degrease the tapped hole on the Ui
grease inlet, and then reinstall the PT1/16 socket head plug. Apply Three Bond
1211 on screwed parts.

6. Degrease the tapped hole on the Uo air flow, and then reinstall the PT 1/16 socket
head plug. Apply Three Bond 1211 on screwed parts.

7. Reinstall the Axis 3 side cover.

88 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Maintenance Procedures

Grease Replenishment for Axis 4 and Axis 5 Speed Reducers

Axis 4 speed reducer

Axis 5 speed reducer

Cover

Ro: Air flow
Hexagon socket head plug PT1/16

Ri: Grease inlet
G Nipple A-PT1/16

Bo: Air flow
Hexagon socket head plug PT1/16

Bi: Grease inlet
G Nipple A-PT1/16

Figure 9-7. Axis 4 and Axis 5 Speed Reducers Diagram

Replenish the grease according to the following procedure. Refer to Figure 9-7.

1. Remove the Joint 5 access cover.

2. Remove the Ro and Bo plugs (hexagon socket head PT1/16).

NOTE: It is absolutely necessary that you remove the Ro and Bo plugs. If
grease is added without removing the plugs, the internal pressure will
increase and may cause damage.

3. Replace the PT 1/16 socket head plugs (Ri and Bi) with A-PT 1/16 grease nipples.

4. Inject the grease into the Ri and Bi grease inlets using a grease gun.

Grease type: Harmonic grease SK-1A

Amount of grease: 4 cc

NOTE: The grease is not exhausted from the Ro and Bo air flows. Do not
inject excessive grease.

5. Remove the G Nipples from the Ri and Bi grease inlets, degrease the tapped holes
on the Ri and Bi grease inlets, and then reinstall the PT 1/16 socket head plugs.
Apply Three Bond 1211 on screwed parts.

6. Degrease the tapped holes on the Ro and Bo air flows, and then reinstall the
hexagon socket head plugs. Apply Three Bond 1211 on screwed parts.

7. Reinstall the Joint 5 access cover.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 89

Chapter 9 - Maintenance and Inspection

Grease Replenishment for Axis 6 Speed Reducer

Ti: Grease Inlet
G Nipple A-PT1/16

Axis 6 speed reducer

Figure 9-8. Axis 6 Speed Reducer Diagram

Replenish the grease according to the following procedure. Refer to Figure 9-8.

1. Remove the Ti plug (PT 1/16 Allen head plug).

2. Replace the PT 1/16 Allen head plug (Ti) with the A-PT 1/16 grease nipple.

3. Inject the grease into the Ti grease inlet using a grease gun.

4. Remove the A-PT 1/16 grease nipple from the Ti grease inlet.

Grease type: Harmonic grease SK-1A

Amount of grease: 4 cc

NOTE: Do not inject excessive grease into the Ti grease inlet. If excessive
grease is added, the internal pressure will increase and may cause
damage.

5. Degrease the tapped hole on the Ti grease inlet, and then reinstall the hexagon
socket head plug. Apply Three Bond 1211 on screwed parts.

90 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Maintenance Procedures

Notes for Maintenance

Connect the battery unit with reference to the following figure before removing the
encoder connector (the connector with a WARNING label).

Encoder

Motor

Motor Cable, etc.

a: Insertion-type pin terminal (male)

Internal
Wire

Power Connector

Connect battery to encoder

to save the data before

removing conector.

WARNING

Encoder connector

b: Insertion-type pin terminal (female)

b

a

0BT

b

BAT

0BT4

a

BAT4

Battery Unit

WARNING label

WARNING

Connect battery to encoder
to save the data before
removing conector.

Figure 9-9. Encoder Connector Diagram

Connection Diagram

a

0BT

b

BAT

b

0BT4

a

BAT4

Battery Unit Type:
60660-00020

AdeptSix 300CR Robot Instruction Handbook, Rev. A 91

Chapter 9 - Maintenance and Inspection

Installing and Using Brake Release Box

The manual brake release box can be used to release the brakes on a specific axis of the
robot. This procedure describes how to install and use this device. See Figure 9-10.

WARNI NG: Secure the robot prior to releasing the brakes

on axes 2 and 3, to prevent injury to personnel or
equipment damage.

1. Make sure that high power is disabled (off).

2. Connect the 15-pin male D-sub connector into the 15-pin female D-sub connector
marked Brake on the MAI-2 board.

3. Press one of the E-Stops (MCP, CIP/Front Panel, or external).

NOTE: An E-Stop must be activated in order for the brake release box to
work.

4. Using the axis selector switch, select the axis that you want to release the brake.

5. Depress the brake release pushbutton, to release the brake.

6. Repeat steps 4 and 5 above for releasing the brakes on another axis.

NOTE: When the Status LED (Green) is on, it indicates that the circuit is
enabled, when the brake release pushbutton is pressed.

3

Axis selector switch

2

4

1

5

6

OFF

BRAKE

RELEASE

Status LED

Brake Release
Pushbutton

15-pin male
D-Sub connector

Figure 9-10. Manual Brake Release Box

92 AdeptSix 300CR Robot Instruction Handbook, Rev. A

9.3 Spare Parts

Go to the Adept web site for complete information on spare parts for your system.

http://www.adept.com/main/services/PartsCat/index.html

Spare Parts

AdeptSix 300CR Robot Instruction Handbook, Rev. A 93

Chapter 9 - Maintenance and Inspection

94 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Technical Specifications 10

10.1 Technical Specifications

Table 10-1. Technical Specifications

Operation Mode

Degrees of Freedom

Payload

Repetitive Positioning Accuracy

Axis 1 (turning) ±170°
Axis 2 (lower arm) +60°, -135°

Motion

Range

Maximum

Speed

Allowable

Moment

Allowable

Inertia

2

(GD

/4)

Mass

Ambient

Conditions

Axis 3 (upper arm) +250°, -10°

Axis 4 (wrist roll)
Axis 5 (wrist

pitch/yaw)

Axis 6 (wrist twist) ±350°
Axis 1 3.66 rad/s, 210° /s
Axis 2 2.79 rad/s, 170° /s
Axis 3 3.93 rad/s, 225° /s
Axis 4 5.23 rad/s, 300° /s
Axis 5 5.23 rad/s, 300° /s
Axis 6 7.33 rad/s, 420° /s

Axis 4 5.39N•m (0.55 kgf•m)
Axis 5 5.39N•m (0.55 kgf•m)

d

Axis 6 2.94N•m (0.3 kgf•m)
Axis 4 0.1 kg•m
Axis 5 0.1 kg•m
Axis 6 0.03 kg•m

Tempe rat ure 0 ° to 45° C

Humidity 20 to 80% RH (non-condensing)

Vibration Less than 0.5° G

Others Free from corrosive gases and

Power Capacity

a

Vertically Articulated

6

3 kg

±0.03 mm

b

c

±165°
±135°

2

2

2

39 kg

liquids, as well as explosive gases
Clean and dry
Free from excessive electrical noise
(plasma)

1 kVA

AdeptSix 300CR Robot Instruction Handbook, Rev. A 95

Chapter 10 - Technical Specifications

a

SI units are primarily used in this table. However, gravitational units are
used for values that appear in parentheses ( ).

b

Conforms to ISO9283.

c

The Axis 4 Working range is affected by the working range of Axis 2 and
Axis 3. See text and Figure 10-5 on page 100 for details.

d

Refer to “Allowable Wrist Load” on page 51 for details on the permissible
moment of inertia.

10.2 Robot Cleanroom Specifications

The AdeptSix 300CR has the FEDERAL STANDARD 209E Cleanliness Class 1.

a

Under the condition that the manipulator is in the downflow of 0.4 m/s or more in
a vertically rectified state and 150 liters/min. or more are taken in.

10.3 Part Names and Working Axes

J4-

J4+

J3+

J2+

Lower Arm

Rotary Head

J3-

J2-

J1+

J1-

J5-

J5+

Upper
Arm

Wrist

J6+

J6-

a

Wrist Flange

Base

Figure 10-1. Part Names and Working Axes

96 AdeptSix 300CR Robot Instruction Handbook, Rev. A

10.4 Baseplate Dimensions

Baseplate Dimensions

12

A

160

180

113 ± 0.1

77 ± 0.1

50

195

220

View A

0.1
±

97

+0.012

Ø 6 Reference Hole

0

50

195

220

Ø11 Mounting Holes (4 holes)

Dimensions in mm

Figure 10-2. Baseplate Dimensions (mm)

0.1
±

113

AdeptSix 300CR Robot Instruction Handbook, Rev. A 97

Chapter 10 - Technical Specifications

10.5 Dimensions and Working Range

170˚

R246

R312

R694

697

67

70

260

300

170˚

318

237

142

0

1

114

150

90˚

45˚

229

230

12

245

150˚

250

312
275

70˚

90

Point P

694

Point P working
envelope

Figure 10-3. Dimensions and Working Range

Dimensions in mm

844

680
600

590
484

431

346

286

159

0

156
168

209

82

142

74

Ø220

Ø246

119

44

49

54

98 AdeptSix 300CR Robot Instruction Handbook, Rev. A

10.6 Axis 5 Working Range

The working range of Axis 5, maintaining a constant angle to the center of Axis 4
(forearm), is shown in Figure 10-4.

Axis 3 rotation center

Axis 2 rotation center

135

135

Axis 5 Working Range

Axis 5 rotation center

°

Wrist axis

°

Axis 1 rotation center

Note: Prevent the wrist from touching the main body of the robot by depending
on the posture of Axes 1,2 and 3 for the base axes.

Figure 10-4. Axis 5 Working Range

NOTE: In certain configurations, it is possible for the robot body to come

in contact with itself.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 99

Chapter 10 - Technical Specifications

10.7 Axis 2 and 3 Effect on Axis 4 Working Range

When the working envelope of the Axis 2 is -15° or more and the working envelope of the
Axis 3 is +185° or more, the working envelope of the Axis 4 is -67° to +165°.

When the working envelope of the Axis 2 is +70° or more and the working envelope of the
Axis 3 is -51° or more, the working envelope of the Axis 4 is -68.5°to +165°.

185˚ (Axis 3)

-15˚ (Axis 2)

+70˚ (Axis 2)

Figure 10-5. Axis 2 and Axis 3 Rotation

-51˚ (Axis 3)

100 AdeptSix 300CR Robot Instruction Handbook, Rev. A