Nortech Systems Adept XUSR, Adept XSYS, RS-232-TERM, RS-422-485 User Manual

Adept SmartController

User’s Guide

Covers the SmartController CS, SmartController CX, and sDIO Module

OK

SF

1 2 3

OK

LANHPE

SF ES HD

123

RS-422/485

*S/N 1000-XXXXX*

XDC1 XDC2

24V 5A

SmartController CS

R

LANHPE

HDES

1 2 3 4

SmartServo

SW1

XDIO

1.2

1.1

ON

OFF

XUSR

Device Net

Eth 10/100

XSYS

RS-232/TERM

XFP

XMCP

- + - +

RS-422/485

RS-232-2

*S/N 3562-XXXXX*

XDC1 XDC2

24V 5A

-+ -+

SmartController CX

Eth 10/100

XSYS

CAMERA

BELT ENCODER

RS-232/TERM

RS-232-1

XFP

XMCP

R

1.1 1.2 2.1 2.2

SW1

1 2 3 4

ON

OFF

XDIO

SmartServo IEEE-1394

Device Net

XUSR

Adept SmartController

User’s Guide

Covers the SmartController CS, SmartContoller CX, and sDIO Module

OK

SF

1 2 3

OK
SF ES HD

123

RS-422/485

*S/N 1000-XXXXX*

XDC1 XDC2

24V 5A

SmartController CS

R

LANHPE

HDES

1 2 3 4

SmartServo

SW1

ON

XDIO

1.2

1.1

OFF

XUSR

Device Net

Eth 10/100

XSYS

RS-232/TERM

XFP

XMCP

- + - +

RS-422/485

RS-232-2

*S/N 3562-XXXXX*

XDC1 XDC2

24V 5A

-+ -+

SmartController CX

Eth 10/100

XSYS

CAMERA

BELT ENCODER

RS-232/TERM

RS-232-1

XFP

XMCP

R

LANHPE

1.1 1.2 2.1 2.2

SW1

1 2 3 4

ON
OFF

XDIO

SmartServo IEEE-1394

Device Net

XUSR

P/N: 00356-00100, Rev. E

May 2003

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

2003 by Adept Technology, Inc. All rights reserved.

The Adept logo, CHAD, the CHAD logo, and Soft Machines

are registered trademarks of Adept Technology, Inc.

ActiveV, Adept, Adept 1060, Adept 1060+, Adept 1850, Adept 1850 XP, Adept 540, Adept 560, Adept C40,

Adept C60, Adept CC, Adept CHADIQ, Adept CHADIQh, Adept CHADIQt, Adept Cobra 550, Adept

Cobra 550 CleanRoom, Adept Cobra 600, Adept Cobra 800, Adept DeskTop, Adept Digital Workcell, Adept

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Any trademarks from other companies used in this publication

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Printed in the United States of America

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Adept SmartController CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Adept SmartController CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

sDIO Expansion Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

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

Adept Document Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3 Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reading and Training for Users and Operators . . . . . . . . . . . . . . . . . . . . . . 17

System Safeguards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety Features on the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . 18

Computer Controlled Robots and Motion Devices . . . . . . . . . . . . 18

Manually Controlled Robots and Motion Devices . . . . . . . . . . . . . 19

Other Computer-Controlled Devices . . . . . . . . . . . . . . . . . . . . . . . . 19

Program Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Inappropriate Uses of the Adept SmartController . . . . . . . . . . . . . . . . . . . . 20

1.5 Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.6 CAT-3 Version of SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Functionality Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

MCP Enable Switch Not Functional in Auto Mode . . . . . . . . . . . . 21

High Power Indication on XDIO Connector. . . . . . . . . . . . . . . . . . . 21

E-Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operational Change in SmartModule Systems . . . . . . . . . . . . . . . . . . . . . . 22

2 SmartController Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.1 Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Before Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Upon Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Repacking for Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Space Around the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Rack Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . . 25

Panel Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . 26

Table Mounting the SmartController. . . . . . . . . . . . . . . . . . . . . . . . . 27

Stacking Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

CompactFlash Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adept SmartController User’s Guide, Rev. E 5

Table of Contents

Installing CompactFlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

24VDC Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

24VDC Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Daisy-Chaining Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installing 24VDC Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

IEEE 1394 Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.2 System Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3 SmartController Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.1 SmartController CS Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.2 SmartController CX Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.3 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4 Configuring the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DIP-Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

AdeptWindows PC Graphical User Interface. . . . . . . . . . . . . . . . . . 43

ASCII Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

AUTO Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.5 SmartController Serial I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

RS-232 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

RS-422/485 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.6 Installing the User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Graphical Interface Using AdeptWindows . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Text Interface Using a PC with HyperTerminal Software. . . . . . . . . . . . . . . . 47

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Text Interface Using a Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Recommended Terminal for Text-Based Systems . . . . . . . . . . . . . . 48

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.7 Connecting Customer-Supplied Safety and Power Control Equipment . . . . . 49

Connecting Equipment to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Emergency Stop Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

User E-Stop Indication - Remote Sensing of E-Stop . . . . . . . . . . . . . 55

Line E-Stop Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Muted Safety Gate E-Stop Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remote Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

User Manual/Auto Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

User High Power On Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Remote High Power On/Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

High Power On/Off Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remote Front Panel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remote MCP Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.8 Connecting Customer-Supplied Digital I/O Equipment. . . . . . . . . . . . . . . . . . . 58

6 Adept SmartController User’s Guide, Rev. E

Table of Contents

XDIO Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Input Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

REACT Input Signals 1001 to 1012 . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Fast Input Signals 1001 to 1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Digital I/O Connector Ordering Details (Third-Party Sources). . . . . . . . . . . 64

AMP Part Numbers for 50-Pin Male D-Sub . . . . . . . . . . . . . . . . . . . . 64

Thomas and Betts Part Numbers for 50-Pin Male D-Sub . . . . . . . . . 64

Screw-Terminal Field-Wiring Adapter Blocks . . . . . . . . . . . . . . . . . . . . . . . . . 64

Phoenix Contact Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Weidmüller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.9 Belt Encoder Interface on SmartController CX. . . . . . . . . . . . . . . . . . . . . . . . . . 65

4 AdeptVision sAVI Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

sAVI Board Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

sAVI Board System Requirements and Restrictions. . . . . . . . . . . . . . . . . . . . 67

Pixel Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

AdeptVision sAVI Inspection System Limitations . . . . . . . . . . . . . . . . . . . . . 68

4.2 Camera Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Guidelines for Cameras. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Cameras Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Standard Resolution Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

High Resolution Cameras. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Downloading Camera Information . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.3 Camera Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Two-Camera Breakout Cable for RS-170 Cameras . . . . . . . . . . . . . . . . . . . 70

Four-Camera Breakout Cable for RS-170 Cameras . . . . . . . . . . . . . . . . . . . 71

10-Meter Camera Extension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.4 Installing Camera Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Connecting the Cables to the RS-170 Standard Camera . . . . . . . . . . . . . 72

4.5 Camera Cable Pin and Signal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.6 sAVI Board Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5 SmartController Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.1 Changing the Lamp in the High Power Indicator. . . . . . . . . . . . . . . . . . . . . . . . 85

6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6.1 SmartController Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6.2 sDIO Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

6.3 Adept Front Panel Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

6.4 Adept MCP Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Adept SmartController User’s Guide, Rev. E 7

Table of Contents

A sDIO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

A.1 Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Rack Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Panel Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Table Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Stack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

A.2 Installing the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

A.3 Configuring a Single sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Default sDIO I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Modifying the Default sDIO Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Assigning sDIO Signal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Assigning I/O Signal Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

sDIO Signal Mapping Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

sDIO Signal Mapping Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

A.4 Using Multiple sDIO Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Configuring a System with an sDIO and a RIO . . . . . . . . . . . . . . . . . . . . . . 103

A.5 sDIO Module Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

A.6 sDIO Digital I/O Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

sDIO Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

sDIO Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Testing sDIO Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

sDIO LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

sDIO Output Power Supply Current Selection . . . . . . . . . . . . . . . . 107

Optional DIO Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Labeling Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Input and Output Cable Wiring Information . . . . . . . . . . . . . . . . . 111

B Adept DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

B.1 DeviceNet Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Volume 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Volume 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

B.2 Limitations of the Adept DeviceNet Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . 116

B.3 Adept Supplied DeviceNet Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Connecting DeviceNet Hardware to the Adept DeviceNet Scanner. . . 117

B.4 DeviceNet Physical Layer and Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

DeviceNet Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Termination of the DeviceNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Power Supply and the DeviceNet Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Power Capabilities of a DeviceNet Cable System . . . . . . . . . . . . 122

8 Adept SmartController User’s Guide, Rev. E

Table of Contents

C Using the Manual Control Pendant (MCP) . . . . . . . . . . . . . . . . . . . . . 125

C.1 Manual Control Pendant Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

MCP Enable Switch Function on CAT-3 SmartController . . . . . . . . . . . . . . 125

MCP III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

MCP-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

3-Position Enable Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

MCP-4 Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Connecting the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

MCP Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Soft Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Data Entry Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Mode Control and Joint/Axis Control Buttons . . . . . . . . . . . . . . . . 131

Speed Bars and Slow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Emergency Stop From the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Re-Enabling Power After Enable Switch Released. . . . . . . . . . . . . . . . . . . 132

In Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

In Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Background Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

C.2 MCP Predefined Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Predefined Function Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

The Edit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

The Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

The Clear Error Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

The CMD Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Prog Set Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

C.3 Moving a Robot or Motion Device With the MCP . . . . . . . . . . . . . . . . . . . . . . 140

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Mode Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

COMP/PWR Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

MAN/HALT Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

DIS PWR Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

RUN/HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Joint/Axis Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

STEP Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Speed Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

In World, Tool, and Joint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

In Comp Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Slow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Robot States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

World State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Tool State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Joint State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Free State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Adept SmartController User’s Guide, Rev. E 9

Table of Contents

Controlling More Than One Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Robots With Fewer Than Six Joints . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Robots With More Than Six Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

10 Adept SmartController User’s Guide, Rev. E

List of Figures

Figure 2-1. Rack Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 2-2. Panel Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 2-3. Table Mounting the SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 2-4. Stack Mounting the SmartController and sDIO . . . . . . . . . . . . . . . . . . . . . . . 28

Figure 2-5. CompactFlash Memory Card Compartment . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 2-6. User Supplied Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 2-7. Chassis Grounding Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 2-8. 24V Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 2-9. System Cable Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 3-1. SmartController CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 3-2. SmartController CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 3-3. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 3-4. CAT-3 E-Stop Circuit on XUSR and XFP Connectors . . . . . . . . . . . . . . . . . . . 52

Figure 3-5. Non-CAT-3 E-Stop Circuit on XUSR and XFP Connectors . . . . . . . . . . . . . . . 53

Figure 3-6. Front Panel Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Figure 3-7. Digital Input Wiring Examples (XDIO Connector) . . . . . . . . . . . . . . . . . . . . . 60

Figure 3-8. Digital Output Wiring for XDIO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Figure 3-9. Belt Encoder Typical Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Figure 4-1. Two-Camera Breakout Cable for RS-170 Cameras . . . . . . . . . . . . . . . . . . . . 70

Figure 4-2. Four-Camera Breakout Cable For RS-170 Cameras . . . . . . . . . . . . . . . . . . . 71

Figure 4-3. Camera Cable Installation Drawing (RS-170) . . . . . . . . . . . . . . . . . . . . . . . . 73

Figure 4-4. Pin Locations for Camera Cable Connector (12-Pin Hirose Male) . . . . . . . 77

Figure 5-1. Lamp Body Contact Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Figure 6-1. SmartController Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Figure 6-2. sDIO Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Figure 6-3. Adept Front Panel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Figure 6-4. Adept Front Panel Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Figure 6-5. MCP Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Figure 6-6. MCP Cradle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Figure A-1. sDIO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Figure A-2. Rack Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Figure A-3. Panel Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Figure A-4. Table Mounting the sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Figure A-5. Using Multiple sDIO Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Figure A-6. sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Figure A-7. Typical sDIO Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure A-8. Typical sDIO Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Figure B-1. Trunklines and Droplines Made of Thick and Thin Cable . . . . . . . . . . . . . . 118

Figure B-2. DeviceNet Thick Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Adept SmartController User’s Guide, Rev. E 11

List of Figures

Figure B-3. DeviceNet Thin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Figure B-4. DeviceNet Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Figure B-5. Example of a Terminating Resistor Installation on a DeviceNet Bus . . . . . 122

Figure B-6. DeviceNet Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Figure C-1. 3-Position Enable Switch on MCP-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Figure C-2. Holding the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Figure C-3. Cradling the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Figure C-4. MCP Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Figure C-5. Data Entry Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Figure C-6. MCP Predefined Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Figure C-7. EDIT Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Figure C-8. DISPLAY Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Figure C-9. CLEAR ERROR Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Figure C-10. Command (CMD) Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Figure C-11. Program Set Function Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Figure C-12. Mode Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Figure C-13. Speed Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Figure C-14. WORLD State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Figure C-15. TOOL State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Figure C-16. TOOL State (Six-Axis Robot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Figure C-17. JOINT State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Figure C-18. JOINT State (Six-Axis Robot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Figure C-19. FREE State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Adept SmartController User’s Guide, Rev. E 12

List of Tables

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

Table 2-1. Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Table 2-2. Specifications for 24VDC User-Supplied Power Supply. . . . . . . . . . . . . . . . . . .30

Table 3-1. SmartController LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Table 3-2. LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Table 3-3. SW1 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Table 3-4. RS-232 Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Table 3-5. Serial Connectors and V

Table 3-6. RS-422/485 Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Table 3-7. Contacts Provided by the XUSR Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 3-8. Contacts Provided by the XFP Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Table 3-9. Remote MCP Connections on the XMCP Connector . . . . . . . . . . . . . . . . . . .51

Table 3-10. DIO Input Circuit Specifications (XDIO connector). . . . . . . . . . . . . . . . . . . . . .59

Table 3-11. DIO Output Specifications (XDIO connector) . . . . . . . . . . . . . . . . . . . . . . . . . .61

Table 3-12. XDIO Digital I/O Connector Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table 3-13. Belt Encoder Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Table 4-1. Breakout Cable Camera Connector Pin Assignments (RS-170) . . . . . . . . . . .75

Table 4-2. Standard Breakout Cable Strobe and Power Connector Pin Assignments . .76

Table 4-3. Adept 10-Meter Camera Cable Pin Assignments . . . . . . . . . . . . . . . . . . . . . . .77

Table 4-4. Two-Camera Breakout Cable Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . .78

Table 4-5. Four-Camera Breakout Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . .79

Table 4-6. Four-Camera Breakout Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . .81

Table 4-7. Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Table A-1. Default I/O Configuration for sDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Table A-2. sDIO Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Table A-3. sDIO Chassis LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Table A-4. sDIO Output Circuit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Table A-5. X3 Input Cable Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Table A-6. X4 Input Cable Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Table A-7. X1 Output Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Table A-8. X2 Output Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Table B-1. DeviceNet Signal to Pin Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Table B-2. Features of a DeviceNet Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Table B-3. DeviceNet Data Rates Relative to Cable Type and Length . . . . . . . . . . . . .119

Table B-4. DeviceNet Connector Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Table B-5. Maximum Current on a Dropline Relative to its Length . . . . . . . . . . . . . . . . .123

Table C-1. MCP-4 Compatibility Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

+

Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Adept SmartController User’s Guide, Rev. E 13

List of Tables

Table C-2. Controlling More Than One Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Table C-3. Robots With More Than 6 Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Adept SmartController User’s Guide, Rev. E 14

1.1 Product Description

The Adept SmartController is a member of Adept’s family of high-performance
distributed motion and vision controllers. The Adept SmartController is designed for use
with Adept SmartModules, the AdeptSix line of robots, and the Adept sMI6 Module for
the SmartMotion product. All Adept SmartControllers offer known scalability and
support for IEEE 1394-based digital I/O and general motion expansion modules.

Adept SmartController CS

The IEEE 1394 interface is the foundation of Adept SmartServo, Adept's new distributed
controls architecture supporting the new family of Adept products, including Adept
SmartModules, AdeptSix robots, Adept Cobra s600 and s800 robots, and the Adept
SmartMotion product.

The Adept SmartController CS is configured for standard applications that do not require
vision or conveyor belt tracking. The controller features several high-speed
communication interfaces, including Fast Ethernet, IEEE 1394, and DeviceNet. The
SmartController offers known scalability and support for Adept’s IEEE 1394-based digital
I/O and general motion expansion modules.

Introduction 1

Adept SmartController CX

The Adept SmartController CX is a high performance motion and vision controller. It has
the same capability as the SmartController CS, plus additional support for an integrated
vision option, a conveyor tracking option, a more powerful processor, an additional pair
of serial ports, and a second pair of IEEE 1394 network ports.

NOTE: The information in this manual applies to both the CS and CX
models, except where differences are specifically noted.

sDIO Expansion Module

The sDIO expansion module provides 32 optical isolated digital inputs and 32 optical
isolated outputs and also includes an IEEE 1394 interface.

Customers can access I/O signals from the following points using these products:

• the XDIO connector on a SmartController

• the DeviceNet connector on a SmartController

• the DIO X1-X4 connectors on an sDIO

• a Remote I/O (RIO) device on a SmartModule

Adept SmartController User’s Guide, Re v. E 15

Chapter 1 - Introduction

1.2 How Can I Get Help?

Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on
getting assistance with your Adept software and hardware.

Additionally, you can access information sources on Adept’s corporate web
site:

http://www.adept.com

Related Manuals

This manual covers the installation and maintenance of an Adept SmartController system,
including the sDIO. There are additional manuals that cover programming the system,
reconfiguring installed components, and adding other optional components. The
following manuals (available on the Adept Document Library CD-ROM provided with
each system) provide information on advanced configurations and system specifications.

Table 1-1. Related Manuals

Manual Title Description

AdeptWindows Installation
Guide and AdeptWindows

Online Help

Instructions for Adept
Utility Programs

V+ Operating System User’s
Guide

V+ Language User’s Guide Describes the V

Describes complex network installations, installation and use of
NFS server software, the AdeptWindows 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

Adept Document Library

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

To access the Adept Document Library, type the following URL into your browser:

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

or, select the Document Library link on the Home page of the Adept web site.

NOTE: The Adept Document Library was formerly known as the
Knowledge Express.

16 Adept SmartController User’s Guide, Rev. E

1.3 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.

WARNING: This indicates a potentially hazardous

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

Warnings, Cautions, and Notes

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.

1.4 Safety

Reading and Training for Users and Operators

Adept systems can include computer-controlled mechanisms that are capable of moving
at high speeds and exerting considerable force. Like all robot and motion systems, and
most industrial equipment, they must be treated with respect by the user and the operator.

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

We recommend you read the American National Standard for Industrial Robot Systems - Safety
Requirements, published by the Robotic Industries Association (RIA) in conjunction with
the American National Standards Institute. The publication, ANSI/RIA R15.06, contains
guidelines for robot system installation, safeguarding, maintenance, testing, startup, and
operator training.

Adept SmartController User’s Guide, Rev. E 17

Chapter 1 - Introduction

We also recommend you read the International Standard IEC 204 or the European
Standard EN 60204, Safety of Machinery – Electrical Equipment of Machines, and ISO 10218
(EN 775), Manipulating Industrial Robots – Safety, particularly if the country of use requires
a CE-certified installation.

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

There are several warnings in this manual that say only skilled or instructed persons
should attempt certain procedures. The qualifications are as follows.

• Skilled persons have technical knowledge or sufficient experience to enable them
to avoid the dangers which electricity may create (engineers and technicians).

• Instructed persons are adequately advised or supervised by skilled persons to
enable them to avoid the dangers which electricity may create (operating and
maintenance staff).

System Safeguards

Safeguards must be an integral part of robot or motion workcell design, installation,
operator training, and operating procedures.

Adept systems have various communication features to aid in constructing system
safeguards. These include the emergency stop circuitry and digital input and output lines.
These features are described in Chapter 3 of this user’s guide.

Safety Features on the Front Panel

The optional external Front Panel has three important safety features, the
indicator, the

MANUAL/AUTOMATIC switch, and the EMERGENCY STOP switch. If you

HIGH POWER

choose not to use the Front Panel, you should provide similar safety features in the
system. See Chapter 3 for more information, or call Adept Customer Service.

Computer Controlled Robots and Motion Devices

DANGER: Entering the workcell when the

HIGH POWER

light is on can result in severe injury.

Adept systems are computer controlled, and the program that is currently running the
robot or motion device may cause it to move at times or along paths you may not
anticipate. When the

HIGH POWER light on the optional Front Panel is illuminated, do not

enter the workcell because the robot or motion device might move unexpectedly. If this
bulb fails, you will not be able to enable High Power. See Chapter 5 for details on
replacing the bulb.

18 Adept SmartController User’s Guide, Rev. E

Manually Controlled Robots and Motion Devices

Safety

Adept robots and other motion devices can also be controlled manually when the

POWER

light on the Front Panel is illuminated. When this light is lit, motion can be
initiated from the system keyboard or from the optional Manual Control Pendant (MCP).
If you have to enter the workcell when this light is lit, press the

MAN/HALT button on the

MCP. This will prevent anyone else from initiating unexpected motion from the system
keyboard.

Other Computer-Controlled Devices

In addition, Adept systems can be programmed to control equipment or devices other
than the robot or main motion device. The program controlling these other devices may
cause them to operate unexpectedly. Make sure that safeguards are in place to prevent
personnel from entering the workcell when a program is running.

Adept Technology highly recommends the use of additional safety features such as light
curtains, safety gates, or safety floor mats to prevent entry to the workcell while

POWER

is enabled. These devices can be connected using the emergency stop circuitry.

Program Security

Programs and data stored in memory can be changed by trained personnel using the V+
commands and instructions documented in the V
alteration of programs, you should restrict access to the keyboard. This can be done by
placing the keyboard in a locked cabinet. Alternatively, the V
instructions can be used in your programs to restrict access to the V

+

manuals. To prevent unauthorized

+

ATTAC H a nd FSET

+

command prompt.

HIGH

HIGH

Adept SmartController User’s Guide, Rev. E 19

Chapter 1 - Introduction

Inappropriate Uses of the Adept SmartController

The Adept SmartController is intended for use as a component subassembly of a complete
industrial automation system. The SmartController subassembly must be installed inside
a suitable enclosure. Installation and usage must comply with all safety instructions and
warnings in this manual. Installation and usage must also comply with all applicable local
or national statutory requirements and safety standards. The SmartController
subassembly 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 SmartController subassembly may come into contact with
liquids.

• In situations where the SmartController subassembly will be subject to extremes of
heat or humidity. See specifications for allowable temperature and humidity
ranges.

1.5 Standards Compliance

The Adept SmartController is intended for use with other equipment and is considered a
subassembly rather than a complete piece of equipment on its own. The SmartController
meets the requirements of these standards:

EN 61000-4-2

EN 61000-4-3

EN 61000-4-4

EN 61000-4-5

EN 61000-4-6

EN 50081-2

To maintain compliance with the above standards, the SmartController must be installed
and used properly with any additional equipment, in accordance with all regulations of
the standards. You must also carefully follow all installation instructions in this user’s
guide.

20 Adept SmartController User’s Guide, Rev. E

1.6 CAT-3 Version of SmartController

Identification

The Adept SmartController has been modified to be compatible with Category 3 safety
requirements. The CAT-3 version of both the CS and CX models of the SmartController
can be identified by the serial number on the front of the controller.

CAT-3 Version of SmartController

Original SmartController CS

Original SmartController CX

CAT-3 SmartController CS

CAT-3 SmartController CX

Serial Number: 3561-xxxxx

Serial Number: 3562-xxxxx

Serial Number: 1000-xxxxx

Serial Number: 2000-xxxxx

Functionality Changes

MCP Enable Switch Not Functional in Auto Mode

The CAT-3 version of the SmartController has a significant functional difference from the
original SmartController. When a CAT-3 SmartController system is operating in Auto
Mode, the Enable Switch on the MCP has no effect on the operation. This means in the
Auto mode, the Enable switch does not have to be pressed to enable High Power, and
releasing the Enable switch while running will not turn off High Power. This is true for
both the MCP-3 and MCP-4 models.

CAUTION: The new functionality of the MCP Enable

switch in Auto Mode must be recognized by persons
familiar with Adept systems, and working patterns and
habits adjusted accordingly.

High Power Indication on XDIO Connector

In the CAT-3 SmartController, a V
connector (pins 45 and 46), will close when High Power has been enabled. The user can
use this feature to power an indicator lamp, or other device, that signals High Power is
On.

+

controlled, normally open relay contact, on the XDIO

E-Stop Circuit

The CAT-3 SmartController modification is shown in the E-Stop diagram in Figure 3-4 on

page 52. The change from the original SmartController circuit is evident in the center area

of the drawing at the MCP-4 Enable switch.

Adept SmartController User’s Guide, Rev. E 21

Chapter 1 - Introduction

Operational Change in SmartModule Systems

When a CAT-3 SmartController is used in an Adept SmartModules system, or an Adept
Servo Kit system, that includes a PDU-2, there is a minor change in operation compared to
the original SmartController. The sequence would be:

1. In a SmartModule system with a CAT-3 SmartController, while operating in

Manual Mode, power is turned off by releasing the Enable switch on the MCP.

2. To re-enable power, the user must press and hold the Enable switch.

3. Next the user must press the Cmp/Pwr button on the MCP.

4. Then the user must press the High Power button on the Front Panel to turn on

High Power to the robot. The LCD display on the MCP will instruct the user to
press the button. The button will be blinking, and must be pressed within 10
seconds. (Ten seconds is the default timeout for the High Power button to be
pressed. This timeout can be changed using the CONFIG_C utility.)

22 Adept SmartController User’s Guide, Rev. E

SmartController Installation 2

2.1 Controller Installation

This equipment must be shipped and stored in a temperature-controlled environment. See

Table 2-1. It should be shipped and stored in the Adept-supplied packaging, which is

designed to prevent damage from normal shock and vibration. You should protect the
package from shock and vibration.

Table 2-1. Environmental Specifications

Ambient temperature 5°C to 40°C

Storage and shipment temperature –25°C to +55°C

Humidity range 5 to 90%, nonconducting

Altitude up to 2000 m (6500 feet)

Free space around controller (for proper
cooling)

Chassis protection class IP20 (NEMA Type 1)

Recommendations for customer-supplied
enclosure for Adept controller.
(Mandatory for installations in EU or EEA
countries.)

10 mm at back, 13 mm on sides

Enclosure must meet EN 60204 (IEC 204)
requirements and be rated at IP54.

Before Unpacking

Carefully inspect all shipping crates for evidence of damage during transit. Pay special
attention to tilt and shock indication labels on the exteriors of the containers. If any
damage is indicated, request that the carrier’s agent be present at the time the container is
unpacked.

Upon Unpacking

Compare the actual items received (not just the packing slip) with your equipment
purchase order, and verify that all items are present and that the shipment is correct.
Inspect each item for external damage as it is removed from its container. Contact Adept
immediately if any damage is evident. See “How Can I Get Help?” on page 16.

Retain all containers and packaging materials. These items may be needed in the future to
settle a damage claim or to transport the equipment to a new location.

Adept SmartController User’s Guide, Re v. E 23

Chapter 2 - SmartC on tr olle r Ins ta llat ion

Perform the steps below to unpack the Adept SmartController, and optional Adept sDIO
Expansion Module, optional Front Panel, and optional Manual Control Pendant (MCP).
Then, see the later sections for information on mounting the equipment.

1. Remove the Adept SmartController and any optional sDIO from their boxes.

Place them near the robot, or mount them in a rack. See “Mounting the

SmartController” on page 24.

2. Remove the optional Front Panel from its box and set it on a flat surface near the

Adept SmartController.

3. Remove the optional MCP from its box and place it on a flat surface near the Front

Panel.

Repacking for Relocation

If the controller needs to be relocated, reverse the steps in the installation procedure.
Reuse all original packing containers and materials and follow all safety notes used for
installation. Improper packaging for shipment will void your warranty.

Space Around the Chassis

When the SmartController and/or sDIO is installed, you must allow 10 mm at the back of
the unit and 13 mm on the sides of the unit for proper air cooling. To facilitate installation,
make sure that the factory installed CompactFlash Memory Card is in place within the
SmartController prior to mounting it. This is crucial if you plan to mount it in a way that
restricts access to the side of the unit, and thus to the CompactFlash Memory
compartment (see the “CompactFlash Memory Card” section on page 28 for
information).

Mounting the SmartController

The following mounting options are available for the SmartController:

• Rack

•Panel

•Table

In addition, the SmartController and sDIO can be stack mounted (one unit placed on top
of another). See the sections below for information on mounting the SmartController;

page 93 for information on mounting the sDIO.

NOTE: To maintain compliance with EN 60204 in European installations,
the mounting of the controller and all terminations at the controller must
be performed in accordance with this standard.

24 Adept SmartController User’s Guide, Rev. E

190.0

Controller Installation

Rack Mounting the SmartController

To rack mount the SmartController in a standard 19-inch equipment rack, install the
optional mounting brackets on the side of the controller, as shown in Figure 2-1. These
brackets must be ordered separately, they do not come with the SmartController.

88.1

3.6
TYP.

44.4

21.8

R 3.6

2X 40356-00004

462.0

482.8

Figure 2-1. Rack Mounting the SmartController

3X M3 x 6MM
BOTH SIDES

3.8

2X 25.0

19.1

14.2

Adept SmartController User’s Guide, Rev. E 25

Chapter 2 - SmartC on tr olle r Ins ta llat ion

Panel Mounting the SmartController

To panel mount the SmartController, install two brackets on each side at the rear of the
unit, as shown in Figure 2-2. Use the screws from the accessories kit.

200.5

14.0

8.1

44.9

6.6

27.4

16.0

8X M3 x 6MM

4X 40356-00000

R3.6 TYP.

16.1

44.9

346.6

273.9

359.8

Figure 2-2. Panel Mounting the SmartController

26 Adept SmartController User’s Guide, Rev. E

Controller Installation

Table Mounting the SmartController

To table mount the SmartController, install two brackets on each side near the bottom of
the unit, as shown in Figure 2-3. Use the screws from the accessories kit.

29.5

120.9

4X 40356-00001

24.9

R 3.6

12.1

24.1

378.6

391.8

4X M3 x 6MM
BOTH SIDES

16.2

Figure 2-3. Table Mounting the SmartController

120.9

16.0

21.6

Adept SmartController User’s Guide, Rev. E 27

Chapter 2 - SmartC on tr olle r Ins ta llat ion

Stacking Components

To stack mount the SmartController and an sDIO or sMI6 module, install two brackets on
each side of the units, as shown in Figure 2-4. These brackets are supplied with the sDIO
and sMI6 modules.

28.1

30.7

76.5

16.0

120.9

2X 40356-00002
BOTH SIDES

8X M3 x 6MM
BOTH SIDES

133.0

OK
SF

1 2 3

328.9

IEEE-1394

1.1 1.2

R

LINK

OK

SF

R

HPE

LAN

SW1

ES

HD

1 2 3 4

ON
OFF

XDIO

IEEE-1394

1.1 1.2

X1

XUSR

Device Net

Eth 10/100

X2

XSYS

X3

RS-232/TERM

XFP

186.5

Figure 2-4. Stack Mounting the SmartController and sDIO

CompactFlash Memory Card

The SmartController is equipped with a CompactFlash™ (CF). The SmartController
system uses a CF in place of a traditional hard disk drive. In fact, it is often referred to as a
“solid state hard drive”. The CF is about half the size of a credit card and twice as thick. It
has no moving parts and is therefore reliable and durable. It is also removable and can be
moved to another SmartController for replacement or testing.

The CF capacity shipped with all systems is currently 30 MB and is factory configured by
Adept. The CF stores the V
programs, data files and Adept licenses.

+

operating system, optional AIM software, application

*S/N 3563-XXXXX*

X4

XDC1 XDC2

24V 0.5A

SC-DIO

-+ -+

*S/N 3561-XXXXX*

RS-422/485

XMCP

XDC1 XDC2

SmartController CS

24V 5A

-+ -+

NOTE: Adept reserves the right to increase the size of the CF without
notice.

28 Adept SmartController User’s Guide, Rev. E

Controller Installation

Not all types of CompactFlash are compatible with the SmartController. Adept requires
the use of the CF supplied by Adept at the time of controller purchase and that all
replacement CF cards be purchased from Adept.

NOTE: With an AdeptWindowsPC ethernet connection you can also use
the supplied NFS software to remotely mount hard disk drives and
directories located on a Personal Computer (PC). See the AdeptWindows

User’s Guide for further details.

CAUTION: Use suitable measures for eliminating

electrostatic discharge during removal and installation of
the CompactFlash. This includes, but is not limited to, the
use of a grounded wrist strap while performing this
operation.

CAUTION: Do not remove the CompactFlash when power

is connected to the SmartController.

Installing CompactFlash

To install a CompactFlash (CF) into a SmartController:

1. Make sure that the SmartController is disconnected from its power source.

2. Locate the CF compartment (see Figure 2-5).

Eject Button

CompactFlash
Compartment

Figure 2-5. CompactFlash Memory Card Compartment

Adept SmartController User’s Guide, Rev. E 29

Chapter 2 - SmartC on tr olle r Ins ta llat ion

NOTE: If you are replacing an existing CF, the original must be sent to
Adept for replacement. Press the button inside the CF compartment to
eject the original card, remove it, and return it to Adept. Contact Adept
Customer Service for assistance.

3. Carefully remove the CF from the READ ME FIRST box or shipping container.

Locate the CF slot and position the card so its connector is facing towards the
SmartController and the label is facing up.

4. Insert the CF into the SmartController.

NOTE: Your licenses were installed onto the CF at the factory when it was
initialized. Your licenses must be reinstalled onto a new CF by using the
provided passwords and the V
passwords are provided in a box or folder labeled READ ME FIRST.

Once installed, Adept recommends that you do not repeatedly remove and insert the CF.

Connecting Power

The SmartController and sDIO require filtered 24VDC power.

+

INSTALL monitor command. These

NOTE: Users must provide their own power supply. Make sure the power
cables and power supply conform to the specifications below.

24VDC Power Specifications

Table 2-2. Specifications for 24VDC User-Supplied Power Supply

Customer-Supplied Power
Supply

Circuit Protection Not more than 8A (below the

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

Shield Termination Braided shield connected to “-”

NOTE: The power requirements for the user-supplied power supply will
vary depending on the configuration of the SmartController and
connected devices. A minimum configuration of the controller, front
panel and MCP will require 1A at 24VDC. However, a 24V, 5A power
supply is recommended to allow for additional current draw from
connected devices, such as external IEEE 1394 devices and digital I/O
loads.

24VDC, 120W (5A).

amperage rating of the cable used).

maximum length 10 meters

terminal at the appropriate XDC
connector.

30 Adept SmartController User’s Guide, Rev. E