Omron Adept Hornet 565 User Manual

Adept Hornet 565

Robot User’s Guide

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

Adept Technology, Inc., assumes no responsibility for any errors or omissions in the documentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us in preparation of future documentation. Please submit your comments to: techpubs@adept.com.

Adept, the Adept logo, the Adept Technology logo, AdeptVision, AIM, Blox, Bloxview, FireBlox, Fireview,

Meta Controls, MetaControls, Metawire, Motivity, Soft Machines, and Visual Machines are registered

trademarks of Adept Technology, Inc.

Brain on Board is a registered trademark of Adept Technology, Inc. in Germany.

Adept ACE, Adept ePLC Connect, Adept Hornet 565, Adept SmartController EX, Adept SmartVision MX,

Adept T20, eAIB, IO Blox, and eV+ are trademarks of Adept Technology, Inc.

Any trademarks from other companies used in this publication

are the property of those respective companies.

Created in the United States of America

Table of Contents

Chapter 1: Introduction 11

1.1 Adept Hornet 565 Robots, Product Description

Adept eAIB Amplifier 12 Adept Hornet 565 Robot Base 12 Inner Arms 13 Ball Joints, Outer Arms 13 Platforms 13 Adept SmartController™ EX 15

1.2 Warnings, Cautions, and Notes in Manual

1.3 Safety Precautions

1.4 What to Do in an Emergency

1.5 Additional Safety Information

1.6 Intended Use of the Robots

1.7 Installation Overview

1.8 Manufacturer’s Declaration

1.9 How Can I Get Help?

Related Manuals 18 Adept Document Library 19

Chapter 2: Robot Installation 21

2.1 Transport and Storage

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking 21 Upon Unpacking 21 Unpacking 21

2.3 Repacking for Relocation

2.4 Environmental and Facility Requirements

2.5 Mounting Frame

Robot-to-Frame Considerations 24 Mounting 24

2.6 Mounting the Robot Base

Robot Orientation 25 Mounting Surfaces 25 Mounting Procedure 25 Install Mounting Hardware 26

2.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft

Aligning the Platform with the Base 27

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Table of Contents

Attaching the Outer Arms 28 Attaching the Theta Drive Shaft 31

2.8 End-Effectors

Attaching an End-Effector 33 Aligning an End-Effector 33 Grounding 33 Accessing Vacuum 33 Routing End-effector Lines 34

Chapter 3: System Installation 35

3.1 System Cables, eAIB Only (no SmartController EX)

List of Cables and Parts 36 Cable Installation Overview 37 Optional Cables 38

3.2 System Cables, with SmartController EX

Installing a SmartController EX Motion Controller 39 List of Cables and Parts 40 Cable Installation Overview 41 Less Common Cables 41

3.3 System Cables for Systems with Belt Encoders

List of Cables and Parts 43 Cable Installation Overview 43

3.4 Adept ACE Software

User-supplied PC 44 Installing Adept ACESoftware 44

3.5 Robot Interface Panel

3.6 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Robot and Controller Power 46 Details for 24 VDC Mating Connector 47 Procedure for Creating 24 VDC Cable 47 Installing 24 VDC Robot Cable 48

3.7 Connecting 200-240 VAC Power to Robot

Specifications for AC Power 49 Details for AC Mating Connector 51 Procedure for Creating 200-240 VAC Cable 51 Installing AC Power Cable to Robot 52

3.8 Grounding the Adept Robot System

Grounding Robot-Mounted Equipment 52 Grounding Robot Base to Frame 53

3.9 Installing User-Supplied Safety Equipment

Emergency Stop Circuits 58 Remote Manual Mode 60 User Manual/Auto Indication 60 User High Power On Indication 60

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Table of Contents

Remote High Power On/Off Control 60 High Power On/Off Lamp 61 Remote Front Panel or User-Supplied Control Panel Usage 61 Remote Pendant Usage 62

Chapter 4: System Operation 63

4.1 Robot Status Display Panel

4.2 Status Panel Fault Codes

4.3 Using the Brake-Release Button

Robot Brakes 64 Brake-Release Button 65

4.4 Optional Adept Front Panel

4.5 Connecting Digital I/O to the System

I/O on the eAIB: 67 I/O with an Optional SmartController EX: 67

4.6 Using Digital I/O on eAIB XIO Connector

Optional I/O Products 70 XIO Input Signals 70 XIO Output Signals 72 XIO Breakout Cable 74

4.7 Starting the System for the First Time

Verifying Installation 76 Turning on Power and Starting Adept ACE 77 Enabling High Power 78 Verifying E-Stop Functions 78 Aligning the Platform and J4 Motor 78 Verify Robot Motions 79

4.8 Robot Motions

Straight-line Motion 79 Containment Obstacles 79

4.9 Learning to Program the Adept Hornet 565 Robot

Chapter 5: Options 81

5.1 Tall Frame Adapters

5.2 ePLC Connect

Configuration 82 Setting the Robot IP Address 82 Setting the Robot IP Address on the PLC 84 Using the PLC to Enable High Power 84

5.3 SmartVision MX Industrial PC

5.4 SmartController EX Motion Controller

5.5 sDIO Module

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Table of Contents

5.6 IOBlox I/ODevice

5.7 eAIB XBELT IOAdapter Cable

5.8 Cable Inlet Box

Overview 86 Installation Procedure 87

5.9 Intelligent Force Sensor

5.10 Ball Stud Locks

Installing a Ball Stud Lock 93 Removing a Ball Stud Lock 94

Chapter 6: Maintenance 95

6.1 Cleaning

Water Shedding 95 Wash-Down 95 Chemical Compatibility 96

6.2 Periodic Inspection

Checking Safety Systems 98 Checking Robot Mounting Bolts 98 Checking Robot Gear Drives 98 Checking Fan Operation 99

6.3 Periodic Maintenance

Replacing the Theta Drive Shaft 101 Replacing the Encoder Battery Pack 103

6.4 Non-Periodic Maintenance

Changing the Lamp in the Optional Adept Front Panel High-Power Indicator 106 Replacing a Platform 107 Replacing a Ball Joint Insert 108 Replacing Outer Arm Spring Assemblies 108 Replacing the eAIB Chassis 112

6.5 Commissioning a System with an eAIB

Safety Commissioning Utilities 117 E-Stop Configuration Utility 118 E-Stop Verification Utility 119 Teach Restrict Configuration Utility 119 Teach Restrict Verification Utility 120

100

106

116

121

Chapter 7: Technical Specifications 123

7.1 Dimension Drawings

7.2 Robot Specifications

7.3 Environmental Specifications

Operating 127 Shipping and Storage 127

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123

126

127

Table of Contents

7.4 Payload Specifications

Payload 127 Torque 127

7.5 Performance

Cycle Times 128 Power Consumption 128 Payload Mass vs. Acceleration 129 Payload Inertia vs. Acceleration 129

7.6 Robot Mounting Frame

127

128

129

Chapter 8: Environmental Concerns 137

8.1 Ambient Environment

8.2 Cleanroom Classification

8.3 Design Factors

Robot Base and Components 138 Inner Arms 138 Ball Joints 138 Outer Arms 138 Spring Assemblies 139 Platforms 139

137

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Chapter 1: Introduction

Joint 3

eAIB

Robot Base

Tool Flange

Platform and Ball

Joints

Theta

Drive Shaft

Ball Joints,

Joint 1

Outer Arms

Status Display Panel

Joint 4

Cover

Robot Base

Cover

Inner Arm

Motor Plug

Mounting Pad

Joint 2

Inner Arm

(Spring Assemblies

not shown)

1.1 Adept Hornet 565 Robots, Product Description

The Adept Hornet 565™ robot is a three-axis parallel robot. The three identical axis motors control movement of the robot tool in X, Y, and Z directions. On the four-motor model, a fourth motor on the robot base turns a telescoping drive shaft, which provides theta rotation of the tool flange through a geared platform.

The Hornet 565 robot is available in two models. One has a J4 platform, a theta motor and theta drive shaft. This provides ±360° of rotation at the tool flange. The other model has a fixed platform with no tool flange rotation.

Figure 1-1. Major Robot Components

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Chapter 1: Introduction

Adept eAIB Amplifier

The Adept Hornet 565 robot uses an Adept eAIB™ amplifier. The robot is powered and controlled using the eAIB. The amplifiers and full servo control for the Adept Hornet 565 robot are contained in the eAIB, which is embedded in the base of the robot. The eAIB also provides the platform for running Adept’s eV+ OS and language.

The Adept eAIB features:

On-board digital I/O: 12 inputs, 8 outputs

Low EMI for use with noise-sensitive equipment

No external fan for quiet operation

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

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

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

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

Hardware-based E-Stop and Teach Restrict controls

For improved safety relative to European standards implemented in 2012.

Figure 1-2. Adept eAIB

Adept Hornet 565 Robot Base

The Adept Hornet 565 robot base is an aluminum casting that houses the four or three drive motors, and supports the eAIB. It provides three mounting pads for attaching the base to a rigid support frame. The Status Display panel is mounted on the side of the robot base.

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Chapter 1: Introduction

Inner Arm

Ball Joint Socket

Ball Joint Socket Insert

Outer Arm Springs

Spring Horseshoe

Pressed Pin

Ball Joint Stud

Outer Arms

Inner Arms

Three robot motors attach directly to the inner arms through high-performance gear reducers. If the robot has a theta rotation motor, it is mounted at the top of the robot base. The following figure shows an inner arm from a Hornet 565 robot. RIA-compliant hard stops limit the inner arm motion to -53° and +114.6°.

Ball Joints, Outer Arms

The inner arm motion is transmitted to the platform through the outer arms, which are connected between the inner arms and platform with precision ball joints. The outer arms are carbon fiber epoxied assemblies with identical ball joint sockets at each end. A bearing insert in each socket accepts the ball joint studs on the inner arms and platform, and allows for approximately ± 60° of relative motion. No ball joint lubrication is required.

Figure 1-3. Ball Joint Assembly

Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints. The outer arms can be installed and removed without tools.

Platforms

The platform converts the motion of the Hornet 565 robot motors into Cartesian motion, and, for the four-motor version, theta rotation of the robot tool flange.

The fixed platform, with no theta rotation, is stainless steel.

The J4 platform has a fourth motor, theta drive shaft, and geared J4 platform that can rotate its tool flange ±360°. The platform is electroless-nickel-plated aluminum.

Both platforms have a 38 mm hole through their center, for users to route air lines or electric cables to the tool flange.

For the J4 version of the Hornet 565 robot, a stainless steel theta drive shaft attaches to a Ujoint at both the platform and the J4 motor on the robot.

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Chapter 1: Introduction

Figure 1-4. J4 Platform (Electroless Nickel-plated Aluminum)

Figure 1-5. Fixed Platform (Stainless Steel)

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Chapter 1: Introduction

Platform Clocking

The J4 platform, which is rotational, is constructed such that the clocking, or rotational alignment, of the platform relative to the robot base is critical. This is detailed in Aligning the Platform with the Base on page 27.

Platform Shipping

The platform, outer arms, and theta drive shaft are removed.

The platform is shipped assembled as a unit. You will need to connect the outer arms between the inner arms and the platform to reassemble the robot. The outer-arm assemblies are interchangeable.

For the Hornet 565 robot with the J4 platform, you will also have to connect the telescoping drive shaft that connects the platform to the fourth motor on the robot base.

Any end-effectors and their air lines and wiring are user-supplied.

Adept SmartController™ EX

The optional SmartController EXmotion controller supports tracking more conveyors, as well as other options. Like the eAIB, the SmartController EX uses the eV+ operating system. It offers scalability and support for IEEE 1394-based digital I/O and general motion expansion modules. The SmartController EX also includes Fast Ethernet and DeviceNet.

Figure 1-6. Adept SmartController EX

Refer to the Adept SmartController EX User’s Guide for SmartController specifications.

1.2 Warnings, Cautions, and Notes in Manual

There are five levels of special alert notation used in Adept manuals. In descending order of importance, they are:

DANGER:This indicates an imminently hazardous electrical situation which, if not avoided, will result in death or serious injury.

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Chapter 1: Introduction

DANGER:This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:This indicates a potentially hazardous electrical situation which, if not avoided, could result in injury or major damage to the equipment.

WARNING:This indicates a potentially hazardous situation which, if not avoided, could result in injury or major damage to the equipment.

CAUTION:This indicates a situation which, if not avoided, could result in damage to the equipment.

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

1.3 Safety Precautions

l All personnel who install, operate, teach, program, or maintain the system must read

this guide, read the Adept Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot.

l All personnel who design the robot system must read this guide, read the Adept Robot

Safety Guide, and must comply with all local and national safety regulations for the

location in which the robot is installed.

l The robot system must not be used for purposes other than described in Intended Use of

the Robots on page 17. Contact Adept if you are not sure of the suitability for your application.

l The user is responsible for providing safety barriers around the robot to prevent anyone

from accidentally coming into contact with the robot when it is in motion.

DANGER:An Adept Hornet robot can cause serious injury or death, or damage to itself and other equipment, if the following safety precautions are not observed:

l Power to the robot and its power supply must be locked out and tagged out before any

maintenance is performed.

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Chapter 1: Introduction

1.4 What to Do in an Emergency

Press any E-Stop button (a red push-button on a yellow background) and then follow the internal procedures of your company or organization for an emergency situation. If a fire occurs, use CO2to extinguish the fire.

1.5 Additional Safety Information

Adept provides other sources for more safety information.

The Manufacturer’s Declaration of Conformity (MDOC) lists all standards with which each robot complies. See Manufacturer’s Declaration on page 18.

The Adept Robot Safety Guide provides detailed information on safety for Adept robots. It also gives resources for more information on relevant standards. It ships with each robot manual, and is also available from the Adept Document Library. For details, see Adept Document Library on page 19.

1.6 Intended Use of the Robots

The Adept Hornet 565 robot is intended for use in parts assembly and material handling for payloads up to 3 kg (6.6 lb).

See Robot Specifications on page 126 for complete information on the robot specifications. Refer to the Adept Robot Safety Guide for details on the intended use of Adept robots.

1.7 Installation Overview

The system installation process is summarized in the following table. Also, refer to System Installation on page 35.

NOTE:For dual-robot installations, see the Adept Dual-Robot Configuration Procedure, which is available in the Adept Document Library.

Task to be Performed Reference Location

If purchased, mount the optional cable box. Options on page 81.

Mount the robot to a level, stable mounting frame. Mounting on page 24.

Attach the robot outer arms and platform. Attaching the Outer Arms on page

Attach the theta drive shaft, for the J4 platform. Attaching the Theta Drive Shaft on

Install the Front Panel and Pendant, if purchased, and Adept ACE software.

Table 1-1. Installation Overview

28.

page 31.

System Cables, eAIB Only (no SmartController EX) on page 35 and Adept ACE Software on page 44.

Create a 24 VDC cable and connect it between the robot and the user-supplied 24 VDC power supply.

Create a 200-240 VAC cable and connect it between Connecting 200-240 VAC Power to

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Procedure for Creating 24 VDC Cable on page 47.

Chapter 1: Introduction

Task to be Performed Reference Location

the robot and the facility AC power source. Robot on page 49.

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

Equipment on page 53.

Connect digital I/O through the robot XIO connector. Using Digital I/O on eAIB XIO

Connector on page 69.

Start the system, including system operation testing. Starting the System for the First Time

on page 76.

Install optional equipment, including end-effectors, user air and electrical lines, external equipment, etc.

1.8 Manufacturer’s Declaration

The Manufacturer’s Declaration of Incorporation and Conformity for Adept robot systems can be found on the Adept website, in the Download Center of the Support section.

http://www.adept.com/support/downloads/file-search

NOTE:The Download Center requires that you are logged in for access. If you are not logged in, you will be redirected to the Adept website Login page.

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

From the Product drop-down list, select Adept Hornet Robots category.

Click Begin Search. The list of available documents is shown in the Search Results area, which opens at the bottom of the page. You may need to scroll down to see it.

Use the Description column to locate the document for the language you want, and then click the corresponding Download ID number to access the Download Details page.

On the Download Details page, click Download to open or save the file.

Options on page 81.

1.9 How Can I Get Help?

Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on getting assistance with your Adept software and hardware. Additionally, you can access information sources on Adept’s corporate website:

http://www.adept.com

Related Manuals

This manual covers the installation, operation, and maintenance of an Adept Hornet 565 robot system. There are additional manuals that cover programming the system and adding optional components. See the following table. These manuals are available on the Adept software media shipped with each system.

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Chapter 1: Introduction

Table 1-2. Related Manuals

Manual Title Description

Adept Robot Safety Guide Contains safety information for Adept robots.

Adept ACE User’s Guide Describes the installation and use of Adept ACE.

Adept T20 Pendant User's Guide

Adept SmartController EX User’s Guide

Describes the use of the optional Adept T20 manual control pendant.

Contains complete information on the installation and operation of the optional Adept SmartController EX and sDIO products.

Adept SmartVision MX User's Guide

Adept ePLC Connect 3 User’s Guide

Instructions for use of the optional Adept SmartVision MX industrial PC.

Describes the installation and use of the Adept ePLC Connect 3 software, for using a user-supplied PLC as controller.

Adept IO Blox User’s Guide Describes the IOBlox product.

Adept Dual-Robot Configuration Procedure

Contains cable diagrams and configuration procedures for a dual-robot system.

Adept Document Library

The Adept Document Library (ADL) contains documentation for Adept products. You can access the ADL from the Adept website. Select:

Support > Document Library

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

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

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

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Chapter 2: Robot Installation

2.1 Transport and Storage

This equipment must be shipped and stored within the range –10 to +60° C (14 to 140° F). Humidity should be less than 75%, non-condensing. The robot should be shipped and stored in the Adept-supplied crate, which is designed to prevent damage from normal shock and vibration. You should protect the crate from excessive shock and vibration.

Use a forklift, pallet jack, or similar device to transport the packaged equipment.

The robot must always be stored and shipped in an upright position. Do not lay the crate on its side or any other non-upright position. This could damage the robot.

The Adept Hornet 565 robot J4 model weighs 52 kg (115 lb) with no options installed.

The fixed model weighs 48.6 kg (107 lb) with no options installed.

The crate weighs 68 kg (150 lb).

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking

Carefully inspect all shipping crates for evidence of damage during transit. If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked.

Upon Unpacking

Before signing the carrier’s delivery sheet, compare the actual items received (not just the packing slip) with your equipment purchase order. Verify that all items are present and that the shipment is correct and free of visible damage.

If the items received do not match the packing slip, or are damaged, do not sign the receipt. Contact Adept as soon as possible (see How Can I Get Help? on page 18).

If the items received do not match your order, please contact Adept immediately.

Retain all containers and packaging materials. These items may be necessary to settle claims or, at a later date, to relocate the equipment.

Unpacking

The Hornet 565 robot is shipped in a crate that holds the robot base, outer arms, platform, theta drive shaft, and any accessories ordered. The crate is made of wood.

The top of the crate should be removed first.

Remove the Klimp®fasteners holding the top to the rest of the crate. See the following figure.

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Chapter 2: Robot Installation

Figure 2-1. Klimp Fastener on Crate

The robot base is shipped with the inner arms attached. The outer arms are in a cardboard box, assembled in pairs. The platform is shipped fully assembled, but separate from the robot base and outer arms. The theta drive shaft is shipped with Ujoints attached, but separate from the robot and platform.

Lift the top off of the crate sides, and set it aside.

Figure 2-2. Crate, with Top Removed

Remove all cardboard boxes from inside the crate.

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Chapter 2: Robot Installation

These will include the outer arms, theta drive shaft, and platform.

Remove all fasteners (Klimp and lag)holding the crate sides to the base, and lift off the crate sides.

The four sides will come off as a single piece, so this requires two people lifting from opposite sides of the crate.

You will be left with the robot base, with eAIB and inner arms, attached to the pallet.

The robot base is held to the pallet with tie-downs.

Remove the tie-downs.

NOTE:The pallet will not fit inside most frames, so the robot will need to be manually moved to the inside of the frame for mounting.

2.3 Repacking for Relocation

If the robot or other equipment needs to be relocated, reverse the steps in the installation procedures in this chapter. Reuse all original packing containers and materials and follow all safety notes used for installation. Improper packaging for shipment will void your warranty.

CAUTION:The robot must always be shipped in an upright orientation.

2.4 Environmental and Facility Requirements

The Hornet 565 robot system installation must meet the operating environment requirements shown in the following table.

Table 2-1. Robot System Operating Environment Requirements

Ambient temperature 1 to 40° C (34 to 104° F)

Humidity 5 to 90%, non-condensing

Altitude up to 2000 m (6500 ft)

NOTE: For robot dimensions, see Dimension Drawings on page 123.

NOTE: For power requirements, see Specifications for 24 VDC Robot and Controller Power

on page 46 and Specifications for AC Power on page 49.

NOTE: For chemical cleaning information, refer to Chemical Compatibility on page 96.

2.5 Mounting Frame

The design of the robot mounting frame is the user’s responsibility.

The flatness of the frame mounting tabs is critical. See Robot-to-Frame Considerations (following) and Mounting Surfaces on page 25.

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Chapter 2: Robot Installation

The frame must be stiff enough to prevent excessive vibration.

The eAIB must be removable from the robot without removing the robot from the frame. This is needed for maintenance and inspection of the robot.

The Hornet 565 robot is designed to be mounted above the work area suspended on a usersupplied frame. The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace.

While Adept does not offer robot frames for purchase, and the frame design is the responsibility of the user, we provide some general guidelines as a service to our users.

Any robot’s ability to settle to a fixed point in space is governed by the forces, masses, and accelerations of the robot. Since “every action has an equal and opposite reaction”, these forces are transmitted to the robot frame and cause the frame and base of the robot to move and possibly vibrate in space. As the robot system works to position the tool flange relative to the base of the robot, any frame or base motion will be “unobservable” to the robot system, and will be transmitted to the tool flange. This transmitted base motion will result in inertial movement of the tool flange mass, and will cause disturbance forces to be introduced into the robot control system. These disturbance forces cause “work” to be done by the robot servo control system which may result in longer settling times for robot operations.

It is important to note that, even after the system reports the robot to be fully settled, the tool flange will still be moving by any amount of motion that the suspended base of the robot may be experiencing.

Robot-to-Frame Considerations

The Hornet 565 robot has a moderately-complex mounting requirement due to the nature of the parallel-arm kinematics and the need to minimize the robot size and mass. Arm Travel Volume on page 125 shows the inner arm travel and how it may encroach on the robot mounting points. As a starting point, for a frame that is 1440 mm in the X and Ydirections, (allowing use of the full range of the robots), you should attempt to attain a frame frequency of 25 Hz.

For specialized applications, such as heavy payloads and/or aggressive moves, you may want to attain a frame frequency of 40 Hz.

In general, a smaller frame will yield a higher frequency. If you aren’t going to use the entire work envelope, you can increase the frequency simply by using a smaller frame.

A lower frequency frame, more aggressive robot moves, and heavier payloads will all contribute to longer settling times.

Mounting

Dimension Drawings on page 123 shows the mounting hole pattern for the Hornet 565 robot. Note the hole location and mounting pad tolerances for position and flatness.

Deviation from this flatness specification will, over time, cause a possible loss of robot calibration.

NOTE:Adept suggests welding the robot mounting tabs as a last step in the frame fabrication, using a flat surface as a datum surface during the tack welding operation.

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Chapter 2: Robot Installation

2.6 Mounting the Robot Base

Robot Orientation

Adept recommends mounting the Hornet 565 robot so that the Status Display Panel faces away from the conveyor belt. Although the work envelope of the robot is symmetrical, this orientation gives better access to the status display. It also orients the arm loading for aggressive moves across the belt.

This orientation places the robot World Y-axis along the conveyor belt, and the X-axis across the belt. See Mounting Dimensions on page 123.

Mounting Surfaces

Mounting surfaces for the robot mounting tabs must be within 0.75 mm of a flat plane.

CAUTION:Failure to mount the Hornet 565 robot within

0.75mm of a flat plane will result in inconsistent robot locations.

NOTE:The base casting of the robot is aluminum and can be dented if bumped against a harder surface.

CAUTION:Do not attempt to lift the robot from any points other than with slings as described here.

Mounting Procedure

The Hornet 565 robot has three mounting pads. Each pad has one hole with an M12 x 1.75 spring-lock Heli-Coil®.

Position the robot directly under the mounting frame.

NOTE:The pallet will not fit inside most frames, so the robot will need to be manually moved to the inside of the frame.

Put nylon straps through the six slots near the three mounting pads.

The following figure shows two of these slots.

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Chapter 2: Robot Installation

Mounting Pad

Lifting Slots

Figure 2-3. Two of Six Lifting Slots

Take up any slack in the straps.

The mechanism you use for lifting the straps will be dependent on the frame design, so it is not specified here.

Slowly lift the robot base up, keeping the holes in the robot base pads and the frame pads aligned, until the top surfaces of the robot base pads are touching the bottom surfaces of the frame mounting pads.

Follow the instructions in Install Mounting Hardware that follow.

Install Mounting Hardware

Because of the possible variability of the mounting frames, mounting hardware is usersupplied. The bolts need to be M12-1.75, either stainless steel or zinc-plated steel. The threads must engage 24 mm (0.94 in.) of the robot base threads (Heli-Coil), for sufficient support.

When mounting the robot, note the following:

Verify that the robot is mounted squarely before tightening the mounting bolts.

Insert the bolts through the holes in the frame and into the threaded holes in the robot base mounting pads.

Ground the robot base to the mounting frame.

Refer to Grounding Robot Base to Frame on page 53.

Tighten the bolts to 61 N·m (45 ft-lb).

NOTE:The robot base-mounting tabs have spring-lock Heli-Coils in the M12 holes, so lock washers are not needed on the M12 mounting bolts.

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Chapter 2: Robot Installation

Joint 3

eAIB

Robot Base

Tool Flange

Platform and Ball

Joints

Theta

Drive Shaft

Ball Joints,

Joint 1

Outer Arms

Status Display Panel

Joint 4

Cover

Robot Base

Cover

Inner Arm

Motor Plug

Mounting Pad

Joint 2

Inner Arm

(Spring Assemblies

not shown)

NOTE: Check the tightness of the mounting bolts one week after initial installation, and then recheck every 3 months. See Checking Robot Mounting Bolts on page 98.

2.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft

Figure 2-4. Major Robot Components

The Adept Hornet 565 robot platform is attached to the inner arms by the outer arms.

NOTE:Except for attaching the outer arms and theta drive shaft, the platform is shipped fully-assembled.

Aligning the Platform with the Base

NOTE:The fixed platform is symmetrical, and can be mounted in any rotational position. The tool flange must be down, away from the robot body.

This section only applies to the J4 platform.

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Chapter 2: Robot Installation

Theta Drive Shaft Attachment

Joint 1

Joint 3 Joint 2

Tool

Flange

X+

Y+

The rotational alignment of the platform with the base is critical to the correct operation of the robot.

CAUTION:Incorrect alignment of the platform will result in incorrect robot performance.

Both the theta drive shaft attachment on the robot base and the platform are offset by about 2 in. from the centers of the robot base and tool flange. The platform should be attached so that the shaft aligns with the J4 motor, between Joint 1 and Joint 3 on the robot base. Joint 1 in the preceding figure should connect to motor 1, which is immediately to the right of the Status Display panel on the robot base.

Attaching the Outer Arms

One pair of outer arms attaches between each inner arm and the platform. No tools are needed.

Each outer arm has a ball joint socket at each end.

The inner arms and the platform have corresponding pairs of ball studs.

Figure 2-5. J4 Platform Orientation, Top View

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Chapter 2: Robot Installation

Inner Arm

Ball Joint Socket

Ball Joint Socket Insert

Outer Arm Springs

Spring Horseshoe

Pressed Pin

Ball Joint Stud

Outer Arms

Figure 2-6. Inner Arm Ball Studs

WARNING:Pinch hazard. Ball joints are spring-loaded. Be careful not to pinch your fingers.

Outer arm pairs are shipped assembled. Each pair has two springs and two horseshoes at each end. See the following figure.

Adept Hornet 565 Robot User's Guide, User’s Guide, Rev A

Figure 2-7. Ball Joint Assembly

CAUTION:Ensure that the bearing insert is in place in the end of each outer arm.

Page 29 of 142

Chapter 2: Robot Installation

NOTE:In the following steps, take care not to trap debris between the ball studs and their sockets.

NOTE: The procedure for attaching outer arms is the same for both platforms.

Attach one pair of outer arms to each inner arm.

As illustrated in the following figure, the outer arm assembly is most easily achieved by pivoting the two arms away from each other lengthwise. This requires the least stretching of the spring to attach the ball joints.

Slip one ball joint socket over the corresponding ball stud.

Swing the bottom end of the outer arm pair sideways as you slip the other ball joint socket over the corresponding ball stud.

CAUTION:Do not overstretch the outer arm springs. Separate the ball joint sockets only enough to fit them over the ball studs.

Figure 2-8. Installing Ball Joints

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Chapter 2: Robot Installation

Attach one pair of outer arms to each of the three pairs of ball studs on the platform.

Swing the bottom end of the outer arm pair to the right, as far as possible.

Slip the right ball joint socket over the right ball stud. (Move the platform as needed to do this.)

Move the platform and outer arm pair to the left as you slip the left ball joint socket over the corresponding ball stud.

Ensure that all spring hooks are fully-seated in the grooves of the horseshoes, as shown in the following figure:

Figure 2-9. Horseshoe and Spring Assembly

Attaching the Theta Drive Shaft

NOTE:The fixed platform does not use a theta drive shaft, so this section does not apply to systems with a fixed platform.

Each U-joint has two identical ends. When the theta drive shaft is shipped, it will have one end of a U-joint attached to each end. One connects to the J4 motor drive, the other connects to a shaft on the top of the J4 platform.

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Chapter 2: Robot Installation

Top U-Joint at J4 Motor

Upper Section of Drive Shaft

Lower Section of Drive Shaft

Bottom U-Joint at J4 Platform

Theta Drive Shaft

Set

Screw

U-Joint

J4 Shaft (Motor or Platform)

Connect the top U-joint to the drive shaft of the J4 motor.

The top (J4 motor)end of the drive shaft is labeled with a temporary label, indicating Top. Remove the label before use.

Connect the bottom U-joint to the shaft on top of the J4 platform.

NOTE:The drive shaft is not symmetrical. There is a top and a bottom. Installing the drive shaft upside-down will degrade system performance. Note the orientation label on the drive shaft. Look for a “Top” label on the drive shaft.

To attach the free end of the U-joints:

Slide the end of the U-joint over the shaft (platform or J4 motor).

The fit will be fairly tight.

The hole in the side of the U-joint needs to line up with the hole in the shaft.

Figure 2-10. U-Joint

Screw an M6 x 20 dog point set screw (included) through the shaft, going through the hole in the side of the U-joint, and into the blind hole on the opposite side of the U-joint. The U-joint is not threaded.

Use Loctite 242.

Tighten to 5 N-m (3.7 ft-lbf)of torque. The head of the set screw should be flush with the outer surface of the U-joint.

For the top U-joint, use a 3 mm hex key, with a 10 - 15 mm short leg. There is not enough room at the J4 motor shaft to use a standard hex key.

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10 - 15 mm

3 mm

NOTE:The platform and the J4 motor will have to be aligned after the ACE software is installed and the robot is power-on. See Aligning the Platform and J4 Motor on page 78.

2.8 End-Effectors

You are responsible for providing and installing any end-effector or other tooling, as well as vacuum lines and wiring to the end-effector.

See the drawing Tool Flange Dimensions, Both Platforms on page 124 for dimensions of the tool flange.

Chapter 2: Robot Installation

Figure 2-11. Short 3 mm Hex Key

Attaching an End-Effector

You can attach end-effectors to the tool flange using either four M6 x 1.0 screws, or a ring clamp. Hardware for both methods is supplied in the accessories kit.

NOTE:The combined weight of the end-effector and the payload must not exceed the maximum rated payload.

Aligning an End-Effector

A 6 mm diameter x 12 mm dowel pin (user-supplied) fits in a hole in the tool flange and can be used as a keying or anti-rotation device in a user-designed end-effector.

Grounding

If hazardous voltages are present at the end-effector, you must install a ground connection to the end-effector. See Grounding Robot-Mounted Equipment on page 52.

Accessing Vacuum

The hole through the center of the tool flange has been made as large as possible to allow vacuum and/or electric lines to pass through.

WARNING:Do not tap the tool flange, as this would weaken it.

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Chapter 2: Robot Installation

Routing End-effector Lines

End-effector lines (either vacuum/air lines or electrical wires) can be routed to the platform by:

Attaching them to the inner and outer arms, and then to the platform.

Routing them from the robot support frame to the outer arms.

Routing them from the robot base directly to the platform.

If end-effector lines are attached to the outer arms to reach the end-effector, either directly from the frame, or along the inner arms:

Make every attempt to keep the load on the outer arms as evenly-balanced as possible. The added weight should be attached symmetrically about the platform center.

Verify that the arms can be fully-extended without interference from the lines. Ensure that there is enough line to reach the end-effector at all platform locations.

Verify that the platform can be fully-rotated at all positions without affecting or being affected by the lines.

Verify that any service loop or excess line does not hang down below the end-effector at any platform position.

Verify that excess line cannot become tangled in the outer arms or platform.

If end-effector lines are attached directly to the bottom of the robot base to reach the endeffector:

Lines attached to the robot base need some form of retraction mechanism or service loop to take up the slack when the platform is near the robot base.

Ensure that the lines (and retraction mechanism) do not apply significant force, in any direction, to the platform.

Ensure that lines going to the robot base do not block your view of the status LED.

Ensure that lines going to the robot base do not interfere with the inner arm movement.

User-added end-effector lines:

Should be checked for the entire work envelope being utilized. They must reach without being pulled, and without impeding arm or platform movement.

Cannot pull against the platform with significant force. Robot performance will be affected.

Must be considered as part of the payload, if they add weight to the platform or outer arms.

Are the user’s responsibility for maintenance. They are not covered in the Maintenance section of this manual.

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Chapter 3: System Installation

24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Adept

Hornet 565

Robot

24 VDC, 6 A

Power Supply

200-240 VAC

10 A

single-phase

AC Power Cable

DC Power

Cable

Front Panel Cable

Front Panel (option)

User-Supplied PC

running Adept ACE Software

T20 Adapter Cable

XMCP Jumper Plug

XMCP

XFP

XUSR

XUSR Jumper Plug

eAIB XSYSTEM Cable

Robot Interface

Panel

XUSR for:

- User E-Stop/Safety Gate

- Muted Safety Gate

The Jumper Plug is required if neither of these is used

Ethernet from PC

T20 Bypass Plug

User-Supplied Ground Wire

T20 Pendant (option)

Either T20 Pendant,T20 Bypass Plug, or XMCP Jumper Plug must be used

85 - 264 VAC Universal Input

24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Ethernet to eAIB

FP Jumper Plug

Either Front Panel or FP plug must be used

Ethernet from eAIB to SmartVision MX

User-supplied

Switch

User-supplied

PLC Option

Adept SmartVision MX (option)

DC Power Cable

Camera (option)

3.1 System Cables, eAIB Only (no SmartController EX)

See System Installation on page 35 for additional information on system grounding.

Figure 3-1. System Cable Diagram, eAIB Only

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Chapter 3: System Installation

List of Cables and Parts

Open the Accessory box and locate the eAIB XSYSTEM cable. Connect the cables and peripherals as shown in the preceding figure. Parts and steps are covered in the following two tables.

Part Cable and Parts List Part # Part of: Notes

A eAIB XSYSTEM Cable Assembly 13323-000 standard, eAIB

B User E-Stop, Safety Gate n/a n/a user-supplied

C XUSR Jumper Plug 04736-000 13323-000 standard, eAIB

D Front Panel (option) 90356-10358 or user-supplied

E Front Panel Cable 10356-10500 90356-10358 or user-supplied

F Front Panel Jumper Plug 10053-000 13323-000 standard, eAIB

G XMCP Jumper Plug 04737-000 13323-000 standard, eAIB

H T20 Bypass Plug 10048-000 10055-000 standard, T20

J T20 Adapter Cable 10051-003 10055-000 standard, T20

K T20 Pendant (option) 10055-000 option

L AC Power Cable (option) 04118-000 90565-010 or user-supplied

M 24 VDC Power Cable (option) 04120-000 90565-010 or user-supplied

N 24 VDC, 6 A Power Supply

04536-000 90565-010 or user-supplied

(option)

P Ethernet Cable - PC -> PLC

n/a n/a user-supplied

(Only while programming PLC)

Q Ethernet Cable - switch -> eAIB n/a n/a user-supplied

R Ethernet Cable - switch ->

n/a n/a user-supplied

SmartVisionMX

S Ethernet switch, cable for

SmartVision MX.

n/a n/a option,

user-supplied

T Camera and cable n/a n/a option

The XUSR, XMCP, and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup.

WARNING:Under no circumstances should you run an Adept system, in production mode, with all three jumpers installed. This would leave the system with no E-Stops.

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Chapter 3: System Installation

Cable Installation Overview

Power requirements for the SmartVision MX industrial PC are covered in that user guide. For 24 VDC, both the Hornet 565 robot and a SmartVision MX can usually be powered by the same power supply.

Step Connection Part

1 Connect eAIB XSYSTEM cable to XSYSTEM on eAIB. A

2 Connect a user E-Stop or Muted Safety Gate to the eAIB XSYSTEM cable XUSR

connector or

2a verify XUSR jumper plug is installed in eAIB XSYSTEM cable XUSR connector. C

3 Connect Front Panel cable to optional Front Panel and eAIB XSYSTEM cable

D, E

XFP connector or

3a if using user-supplied Front Panel, connect Front Panel to eAIB XSYSTEM cable

A, E

XFP. See warning after table.

4 Connect T20 adapter cable to eAIB XSYSTEM cable XMCP connector or J, K

4a if no T20, install XMCP jumper

or T20 Adapter Cable with T20 bypass plug.

5 Connect user-supplied ground to robot. See Grounding the Adept Robot System

G or H

n/a

on page 52.

6 Connect 200-240 VAC to AC Input on eAIB Interface Panel; secure with clamp. L

7 Connect 24 VDC to DC Input on Interface Panel. N,

7a Connect 24 VDC and shield ground to SmartVision MX, if used. See

SmartVision MX user's guide for location.

N, M

8 Connect Ethernet cable from PC to PLC, if a PLC is used. P

9 Connect Ethernet cable from PLC to switch, if a PLC is used. S

9a Connect Ethernet cable from switch to eAIB. Q, S

9b Connect Ethernet cable from SmartVision MX, if used, to switch. R, S

10 Connect optional camera and cable to SmartVision MX, if used. T

NOTE:A front panel can be purchased with each Hornet 565 robot system, but you can choose to replace its functionality with equivalent circuits. That is beyond the scope of this guide.

WARNING:A front panel must be installed to provide an EStop button and to enable power to the robot. To operate without the Adept Front Panel, the user must supply equivalent circuits.

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Page 37 of 142

Optional Cables

NOTE:The following cables are not covered in the steps in the preceding table.

Part Description Notes

Chapter 3: System Installation

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

eAIB XBELT IO Adapter Cable Available as option

The XIO Breakout cable is for using the I/O on the eAIB. See XIO Breakout Cable on page 74.

Cables for adding belt encoders are covered in System Cables for Systems with Belt Encoders on page 42.

Available as option

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Chapter 3: System Installation

Adept SmartController EX (option)

T20 Adapter

Cable

XMCP Jumper Plug

T20 Bypass Plug

T20 Pendant (option)

Either T20 Pendant, T20 Bypass Plug, or XMCP J

umper Plug

must be used

Adept SmartVision MX (option)

Front Panel

Cable

Front Panel (option)

FP Jumper Plug

Either Front Panel or FP plug must be used

Adept Hornet

565 Robot

24 VDC, 6 A Power Supply

200-240 VAC 10 A single-phase

AC Power Cable

DC Power

Cable

DC Power

Cable

User-Supplied PC running PLC or ACE Programming Software

eAIB XSYS Cable

Ethernet from PC to PLC, Switch, or SmartController EX

User-Supplied Ground Wire

85 - 264 VAC Univ

ersal

Input

24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Ethernet to

SmartController EX

User-supplied Camera (option)

User-Supplied Ground Wire

Robot Interface Panel

from Controller XSYS Port

IEEE 1394

XUSR Jumper Plug

XUSR for:

- User E-Stop/Safety Gate

- Muted Safety Gate

- Jumper plug required when not used

User-supplied switch (option)

Optional User-supplied PLC

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

3.2 System Cables, with SmartController EX

When the optional SmartController EX is included in the system, the Pendant, Front Panel, and XUSR connections, if used, must connect to the SmartController EX.

Installing a SmartController EX Motion Controller

Refer to the Adept SmartController EX User’s Guide for complete information on installing the optional Adept SmartController EX. This list summarizes the main steps.

Mount the SmartController EX and optional front panel.

Connect the optional front panel to the SmartController EX.

Figure 3-2. System Cable Diagram with SmartController EX

Adept Hornet 565 Robot User's Guide, User’s Guide, Rev A

Page 39 of 142

Connect the optional pendant to the SmartController EX.

Connect user-supplied 24 VDC power to the controller.

Instructions for creating the 24 VDC cable, and power specification, are covered in the

Adept SmartController EX User’s Guide.

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

List of Cables and Parts

Part Cable and Parts List Notes

A eAIB XSYS Cable standard, eAIB

B User E-Stop, Safety Gate user-supplied

C XUSR Jumper Plug standard,

D Front Panel (option) or user-supplied

E Front Panel Cable or user-supplied

F Front Panel Jumper Plug standard,

Chapter 3: System Installation

SmartController EX

G XMCP Jumper Plug standard,

SmartController EX

H T20 Bypass Plug standard, T20

J T20 Adapter Cable standard, T20

K T20 Pendant (option) option

The following three items are available, as an option, in the Adept power supply/cable kit 90565-010

L AC Power Cable user-supplied/option

M 24 VDC Power Cable user-supplied/option

N 24 VDC, 6 A Power Supply user-supplied/option

P Ethernet Cable, PC -

user-supplied

SmartController

Q Ethernet Cable, PC -

user-supplied, option

SmartVisionMX

R IEEE 1394 cable standard

S Camera and cable user-supplied, option

The XUSR, XMCP, and XFP jumpers intentionally bypass safety connections so you can test the system functionality during setup.

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Chapter 3: System Installation

WARNING:Under no circumstances should you run an Adept system, in production mode, with all three jumpers installed. This would leave the system with no E-Stops.

Cable Installation Overview

Step Connection Part

1 Connect eAIB XSYS cable to XSYSTEM on eAIB A

2 Connect a user E-Stop or Muted Safety Gate to the XUSR connector or B

2a verify XUSR jumper plug is installed in XUSR connector. C

3 Connect Front Panel cable to optional Front Panel and XFP connector or D, E

3a if using user-supplied Front Panel, connect Front Panel to eAIB XSYSTEM cable

A, E

XFP. See warning after table.

4 Connect Pendant adapter cable to XMCP connector or J, K

4a if no Pendant, install XMCP jumper or bypass plug. G or

5 Connect user-supplied ground to robot. See robot user's guide for location. n/a

5a Connect user-supplied ground to SmartController EX. See SmartController

n/a

EXuser's guide for location.

5b Connect user-supplied ground to SmartVision MX, if used. See SmartVision

n/a

MX user's guide for location.

6 Connect 200-240 VAC to AC Input on eAIB; secure with clamp. L

7 Connect 24 VDC to DC Input on eAIB and SmartController EX. N,M

7a Connect 24 VDC to SmartVision MX, if used. N,M

8 Connect Ethernet cable from PC to SmartController EX. P

9a Connect Ethernet cable to SmartVision MX, if used. Q

10 Connnect IEEE1394 cable between SmartController EXand eAIB SmartServo R

11 Connect optional camera and cable to SmartVision MX, if used. S

Less Common Cables

NOTE:The following cables are not covered in the steps in the preceding table.

Adept Hornet 565 Robot User's Guide, User’s Guide, Rev A

WARNING:A front panel must be installed to provide an EStop button and to enable power to the robot. To operate without the Adept Front Panel, the user must supply equivalent circuits.

Page 41 of 142

Chapter 3: System Installation

24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

XBELT IO

13463-000

HDB26

FEMALE

BELT

ENCODER

FORCE/

EXPIO

RS232

BELT ENC.

09443-000

DB15

FEMALE

RS-232

Force/EXPIO

Adept

Hornet

Robot

24 VDC, 6 A

Power Supply

200-240 VAC

10 A

single-phase

AC Power Cable

DC Power

Cable

Front Panel Cable

Front Panel

User-Supplied PC running Adept ACE Software

T20 Adapter Cable

XMCP Jumper Plug

XMCP

XFP

XUSR

XUSR Jumper Plug

eAIB XSYSTEM Cable

Robot Interface

Panel

XUSR for:

- User E-Stop/Safety Gate

- Muted Safety Gate

The Jumper Plug is required if neither of these is used

Ethernet from PC

T20 Bypass Plug

User-Supplied Ground Wire

T20 Pendant (option)

Either T20 Pendant,T20 Bypass Plug, or XMCP Jumper Plug must be used

85 - 264 VAC Universal Input

24V

GND

200 240V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Ethernet to eAIB

FP Jumper Plug

Either Front Panel or FP plug must be used

XBELTIO - Belt/Force/RS232

Belt Y-Splitter

to Belt Encoder 1

to Belt Encoder 2

Belt

Part Description Notes

XIO Breakout Cable, 12 inputs/

Available as option

8 outputs, 5 M

Y Cable, for XSYS cable connections to dual robots

Available as option with SmartController EX

eAIB XBELT IO Adapter Cable Available as option

The XIO Breakout cable is for using the I/O on the eAIB. See XIO Breakout Cable on page 74.

The Y cable attaches at the SmartController EX XSYS connector, and splits it into two XSYS connectors. This is part number 00411-000. See the Dual Robot Configuration Guide.

3.3 System Cables for Systems with Belt Encoders

Figure 3-3. System Cable Diagram with Belt Encoder Cables

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Chapter 3: System Installation

List of Cables and Parts

Open the Accessory box and locate the eAIB XSYSTEM cable. Connect the cables and peripherals as shown in the preceding figure. Parts and steps are covered in the following two tables.

The optional eAIBXBELT IO Adapter cable splits the eAIB XBELTIO port into a belt encoder lead, an Intelligent Force Sensor or IOBlox lead, and an RS-232 lead.

Part Cable and Parts List Part # Part of: Notes

A eAIB XSYSTEM Cable Assembly 13323-000 standard, eAIB

B User E-Stop, Safety Gate n/a n/a user-supplied

C XUSR Jumper Plug 04736-000 13323-000 standard, eAIB

D Front Panel (option) 90356-10358 or user-supplied

E Front Panel Cable 10356-10500 90356-10358 or user-supplied

F Front Panel Jumper Plug 10053-000 13323-000 standard, eAIB

G XMCP Jumper Plug 04737-000 13323-000 standard, eAIB

H T20 Bypass Plug 10048-000 10055-000 standard, T20

J T20 Adapter Cable 10051-003 10055-000 standard, T20

K T20 Pendant (option) 10055-000 option

L AC Power Cable (option) 04118-000 90565-010 or user-supplied

M 24 VDC Power Cable (option) 04120-000 90565-010 or user-supplied

N 24 VDC, 6 A Power Supply

04536-000 90565-010 or user-supplied

(option)

Q Ethernet Cable -> eAIB n/a n/a user-supplied

U eAIB XBELTIO cable 13463-000 option

V Y-adapter cable 09443-000 option

Cable Installation Overview

Step Connection Part

1 Connect eAIB XSYSTEM cable to XSYSTEM on eAIB. A

2 Connect a user E-Stop or Muted Safety Gate to the eAIB XSYSTEM cable XUSR

connector or

2a verify XUSR jumper plug is installed in eAIB XSYSTEM cable XUSR connector. C

3 Connect Front Panel cable to optional Front Panel and eAIB XSYSTEM cable

XFP connector or

3a if using user-supplied Front Panel, connect Front Panel to eAIB XSYSTEM cable

XFP. See warning after table.

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Page 43 of 142

D, E

A, E

Chapter 3: System Installation

Step Connection Part

4 Connect T20 adapter cable to eAIB XSYSTEM cable XMCP connector or J, K

4a if no T20, install XMCP jumper

or T20 Adapter Cable with T20 bypass plug.

5 Connect user-supplied ground to robot. See Grounding the Adept Robot System

on page 52.

6 Connect 200-240 VAC to AC Input on eAIB Interface Panel; secure with clamp. L

7 Connect 24 VDC to DC Input on Interface Panel. N,

8 Connect Ethernet cable from PC to eAIB. P

10 Connect optional eAIB XBELTIO cable to the XBELTIO port on eAIB. U

11 Connect the Y-adapter cable to the eAIB XBELTIO cable, Belt branch V

3.4 Adept ACE Software

User-supplied PC

The user loads the Adept ACE software onto the PC and connects it to the eAIB via an Ethernet cable. Depending on the other equipment in the system, there may be an Ethernet switch between the two.

G or H

n/a

Installing Adept ACESoftware

The Adept ACE disk will display a ReadMe file when inserted in your PC. This contains hardware and software requirements for running Adept ACE software.

You install Adept ACE from the Adept Software disk. Adept ACE needs Microsoft .NET Framework. The Adept ACE Setup Wizard scans your PC for .NET, and installs it automatically if it is not already installed.

Insert the disk into the disk drive of your PC.

If Autoplay is enabled, the Adept software disk menu is displayed. If Autoplay is disabled, you will need to manually start the disk.

NOTE:The online document that describes the installation process opens in the background when you select one of software installation steps below.

Especially if you are upgrading your Adept ACE software installation: from the Adept ACE software disk menu, click Read Important Information.

From the Adept ACE software disk menu, select:

Install the Adept ACE Software

The Adept ACE Setup wizard opens.

Follow the online instructions as you step through the installation process.

When the installation is complete, click Finish.

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Page 44 of 142

After closing the Adept ACE Setup wizard, click Exit on the disk menu to close the menu.

NOTE:You will have to restart the PC after installing Adept ACE software.

3.5 Robot Interface Panel

Chapter 3: System Installation

Figure 3-4. Robot Interface Panel

24 VDC—for connecting user-supplied 24 VDC power to the robot. The mating connector is provided.

Ground Point—for connecting cable shield from user-supplied 24 VDC cable.

200-240 VAC—for connecting 200-240 VAC, single-phase, input power to the robot. The

mating connector is provided.

XIO (DB26, high density, female) — for user I/O signals for peripheral devices. This connector provides 8 outputs and 12 inputs. For connector pin allocations for inputs and outputs, see Using Digital I/O on eAIB XIO Connector on page 69. That section also contains details on how to access these I/O signals via eV+.

XBELTIO — adds a belt encoder, EXPIO, (which supports either IOBLOX or an Intelligent Force sensor), and an RS-232 interface. Requires optional eAIB XBELT IO Adapter cable. The belt encoder can be split for two belts with a Y-adapter.

SmartServo x2 (IEEE 1394) — for connecting the IEEE 1394 cable from the robot to a controller. The other robot connector can be used to connect to a second robot or another 1394-based motion axis.

XSYSTEM — This requires either the eAIB XSYSTEM (three-headed)cable (XFP, XMCP, and XUSR), or an eAIB XSYS cable, if connecting to a SmartController EX.

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Chapter 3: System Installation

ENET - Two Ethernet ports are available. One will be needed to connect to a PC running Adept ACE software.

3.6 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Robot and Controller Power

Table 3-1. VDC User-Supplied Power Supply

User-Supplied Power Supply 24 VDC (± 10%), 150 W (6 A)

Circuit Protection

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

Shield Termination Braided shield connected to ground at

User-supplied 24 VDC power supply must incorporate overload protection to limit peak power to less than 300 W, or an 8 A in-line fuse must be added to the 24 VDC power source. (In case of multiple robots on a common 24 VDC supply, each robot must be fused individually.)

(21.6 V< Vin< 26.4 V)

Output must be < 300 W peak, or 8 Amp in-line fuse

both ends of cable. See User-Supplied 24 VDC Cable on page 48.

NOTE:Fuse information is located on the eAIB electronics.

The requirements for the user-supplied power supply will vary depending on the configuration of the robot and connected devices. Adept recommends a 24 VDC, 6 A power supply to allow for startup current draw and load from connected user devices, such as solenoids and digital I/O loads. If multiple robots are to be sourced from a common 24 VDC power supply, increase the supply capacity by 3 A for each additional robot.

CAUTION:Make sure you select a 24 VDC power supply that meets the specifications in the preceding table. Using an underrated supply can cause system problems and prevent your equipment from operating correctly. See the following table for recommended power supplies.

Table 3-2. Recommended 24 VDC Power Supplies

Vendor Name Model Ratings

XP Power JPM160PS24 24 VDC, 6.7 A, 160 W

Mean Well SP-150-24 24 VDC, 6.3 A, 150 W

Astrodyne ASM150-24 24 VDC, 6.66 A, 150 W

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Chapter 3: System Installation

Details for 24 VDC Mating Connector

The 24 VDC mating connector and two pins are supplied with each system. They are shipped in the cable/accessories box.

Table 3-3. 24 VDC Mating Connector Specs

Connector Details Connector receptacle, 2 position, type:

Molex Saber, 18 A, 2-Pin

Molex P/N 44441-2002

Digi-Key P/N WM18463-ND

Pin Details Molex connector crimp terminal,

female, 14-18 AWG

Molex P/N 43375-0001

Digi-Key P/N WM18493-ND

Recommended crimping tools: Molex P/N 63811-7200

Digi-Key P/N WM1618-ND

Procedure for Creating 24 VDC Cable

NOTE:The 24 VDC cable is not supplied with the system, but is available in the

optional Power Cable kit. See List of Cables and Parts on page 36.

Locate the connector and pins shown in the preceding table.

Use 14-16 AWG wire to create the 24 VDC cable. Select the wire length to safely reach from the user-supplied 24 VDC power supply to the robot base.

NOTE:A separate 24 VDC cable is required for the optional SmartController EX.

That cable uses a different style of connector. See the Adept SmartController EX User’s

Guide.

Crimp the pins onto the wires using the crimping tool.

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

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

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Chapter 3: System Installation

–

24 V, 6 A

Frame Ground

24 V, 5 A

–

User-Supplied

Power Supply

24 VDC

Adept Hornet

565 Robot

User-Supplied Shielded Power Cable

SmartController EX

(Option)

User-Supplied Shielded Power Cable

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

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

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

–

GND

Installing 24 VDC Robot Cable

Connect one end of the shielded 24 VDC cable to the user-supplied 24 VDC power supply. See the following figure.

The cable shield should be connected to frame ground on the power supply.

Do not turn on the 24 VDC power until instructed to do so in System Operation on page 63.

Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the interface panel on the top of the robot.

Connect the cable shield to the ground point on the interface panel.

Figure 3-5. User-Supplied 24 VDC Cable

NOTE:Adept recommends that DC power be delivered over a shielded cable, with

the shield connected to ground at both ends of the cable.

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Chapter 3: System Installation

3.7 Connecting 200-240 VAC Power to Robot

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

Ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system.

Specifications for AC Power

Table 3-4. Specifications for 200-240 VAC User-Supplied Power Supply

Auto-Ranging Nominal Voltage

200 to 240 V 180 V 264 V 50/60 Hz

Minimum Operating Voltage

Maximum Operating Voltage

Frequency/ Phasing

External Circuit Breaker, User-Supplied

10 Amps

1-phase

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

robot performance.

NOTE:The Adept robot system is intended to be installed as a piece of equipment

in a permanently-installed system.

NOTE: If a three-phase power source is used, it must be symmetrically-earthed

(with grounded neutral). Connections called out as single-phase can be wired Line-

to-Neutral or Line-to-Line.

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

DANGER:AC power installation must be performed by a skilled and instructed person - see the Adept Robot Safety Guide. During installation, unauthorized third parties must be prevented, through the use of fail-safe lockout measures, from turning on power.

Facility Overvoltage Protection

The robot must be protected from excessive overvoltages and voltage spikes. If the country of installation requires a CE-certified installation or compliance with IEC1131-2, the following information may be helpful. IEC 1131-2 requires that the installation must ensure that

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Chapter 3: System Installation

EENNL

F1 10 A

Adept Hornet

565 Robot

1Ø 200–240 VAC

User-Supplied AC Power Cable

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

1Ø 200–240 VAC 20 A

L = Line N = Neutral E = Earth Ground

EENL3L

F5 10 A

F4 10 A

Adept Hornet

565 Robot

1Ø 200–240 VAC

User-Supplied AC Power Cable

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

3Ø 200–240 VAC

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

200–240 VAC

CategoryII overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltage CategoryII, i.e., not higher than the impulse voltage corresponding to the rated voltage for the basic insulation. The user-supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient.

In the industrial environment, non-periodic overvoltage peaks may appear on mains power supply lines as a result of power interruptions to high-energy equipment (such as a blown fuse on one branch in a 3-phase system). This will cause high current pulses at relatively low voltage levels. Take the necessary steps to prevent damage to the robot system (for example, by interposing a transformer). See IEC 1131-4 for additional information.

AC Power Diagrams

Figure 3-6. Typical AC Power Installation with Single-Phase Supply

Figure 3-7. Single-Phase Load across L1 and L2 of a Three-Phase Supply

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Details for AC Mating Connector

The AC mating connector is supplied with each system. It is shipped in the Robot Accessory Kit. The plug is internally labeled for the AC power connections (L, E, N).

Table 3-5. AC Mating Connector Details

AC Connector details AC in-line power plug,

straight, female, screw terminal, 10 A, 250 VAC

Qualtek P/N 709-00/00

Digi-Key P/N Q217-ND

NOTE:The AC power cable is not supplied with the system. However, it is

available in the optional Power Cable kit. See List of Cables and Parts on page 36.

Procedure for Creating 200-240 VAC Cable

Locate the AC mating connector shown in AC Mating Connector Details on page 51.

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

Loosen the two screws on the cable clamp. See AC Power Mating Connector on page 52.

Use 18 AWG wire to create the AC power cable. Select the wire length to safely reach from the user-supplied AC power source to the robot base.

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

Insert the wires into the connector through the removable bushing.

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

Tighten the screws on the cable clamp.

Reinstall the cover and tighten the screw to secure the connector.

10.

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

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Chapter 3: System Installation

Figure 3-8. AC Power Mating Connector

Installing AC Power Cable to Robot

Connect the AC power cable to your facility AC power source.

Do not turn on AC power at this time.

See Typical AC Power Installation with Single-Phase Supply on page 50 and SinglePhase Load across L1 and L2 of a Three-Phase Supply on page 50.

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

Secure the AC connector with the locking latch.

3.8 Grounding the Adept Robot System

Proper grounding is essential for safe and reliable robot operation.

Grounding Robot-Mounted Equipment

DANGER:Failing to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end-effector when an electrical fault condition exists.

If hazardous voltages are present at any user-supplied robot-mounted equipment or tooling, you must install a ground connection for that equipment or tooling. Hazardous voltages can be considered anything in excess of 30 VAC (42.4 VAC peak) or 60VDC.

If there will be hazardous voltages present at the tool flange or end-effector, you must:

Connect the mounting frame to protective earth ground.

Ground the robot base to the mounting frame.

The eAIB is grounded to the robot base through a conductive gasket.

Ground the end-effector to the robot base.

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Chapter 3: System Installation

Frame

If frame is painted under screw head. Use ring terminal and run the other end to an unpainted part of the frame.

If frame is unpainted under screw head. Use star washer, but not ring terminal.

Both screws and star washers must be electrically conductive (stainless or zincplated steel)

M12 Screw

External-tooth star washer

Robot Base

NOTE:A ground strap from the end-effector to the base mounting pad must

include a service loop that allows full rotation and movement of the tool flange.

Grounding Robot Base to Frame

NOTE:You must ground the robot to the frame for all installations.

Use any of the three M12 mounting screws for this connection.

Screws must be stainless or zinc-plated steel.

Use an external-tooth star washer, touching the mounting screw head.

Washers must be stainless or zinc-plated steel.

If the frame is painted where the M12 screw makes contact with it, use a ring terminal under the star washer, and connect the other end of the wire from the terminal to a suitable grounding surface on the frame.

If the frame is not painted where the M12 screw makes contact with it, you do not need to use a ring terminal, just put an external-tooth star washer under the mounting screw head.

3.9 Installing User-Supplied Safety Equipment

Figure 3-9. Any of the Three M12 Mounting Screws can be used for Grounding.

The user is responsible for installing safety barriers to protect personnel from coming in contact with the robot unintentionally. Depending on the design of the workcell, safety gates, light curtains, and emergency stop devices can be used to create a safe environment. Read the

Adept Robot Safety Guide for a discussion of safety issues.

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Chapter 3: System Installation

Refer to the Adept SmartController EX User's Guide for information on connecting safety equipment into the system through the XUSR connector on the optional SmartController. There is a detailed section on Emergency Stop Circuits and diagrams on recommended E-Stop configurations.

The user-supplied safety and power-control equipment connects to the system through the XUSR and XFP connectors, either on the eAIB XSYSTEM cable or the optional SmartController EX. The XUSR connector (25-pin) and XFP (15-pin) connector are both female D-sub connectors. Refer to the following table for the XUSR pin-out descriptions. See Table 3-7. for the XFP pin-out descriptions. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 57 for the XUSR wiring diagram.

Table 3-6. Contacts Provided by the XUSR Connector

Pin Pairs

Description Comments

Voltage-Free Contacts Provided by Customer

1, 14 User E-Stop CH 1 (mushroom push-

N/C contacts, Shorted if NOT Used

button, safety gates, etc.)

2, 15 User E-Stop CH 2 (same as pins

N/C contacts, Shorted if NOT Used

1, 14)

3, 16 Line E-Stop (used for other robot or

N/C contacts, Shorted if NOT Used assembly line E-Stop interconnection. Does not affect E-Stop indication (pins 7, 20)

4, 17 Line E-Stop (same as pins 3, 16) N/C contacts, Shorted if NOT Used

5, 18 Muted safety gate CH 1 (causes E-

N/C contacts, Shorted if NOT Used Stop in Automatic mode only)

6, 19 Muted Safety Gate CH 2 (same as

N/C contacts, Shorted if NOT Used pins 5, 18)

Voltage-Free Contacts provided by Adept

7, 20 E-Stop indication CH 1 Contacts are closed when Front Panel,

pendant, and customer E-Stops are not

tripped

8, 21 E-Stop indication CH 2 (same as pins

7, 20)

Contacts are closed when Front Panel,

pendant, and customer E-Stops are not

tripped

9, 22 Manual/Automatic indication CH 1 Contacts are closed in Automatic mode

10, 23 Manual/Automatic indication CH 2 Contacts are closed in Automatic mode

11, 12,

No connection

13, 24, 25

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Chapter 3: System Installation

Pin 1

Pin 8

Pin 9

Pin 15

XFP

Table 3-7. Contacts Provided by the XFP Connector

Pin Pairs

Description Requirements for User-Supplied

Front Panel

Voltage-Free Contacts Provided by Customer

1, 9 Front Panel E-Stop CH 1 User must supply N/C contacts

2, 10 Front Panel E-Stop CH 2 User must supply N/C contacts

3, 11 Remote Manual/Automatic switch CH

Optional - jumper closed for Auto Mode-only operation

Manual = Open Automatic = Closed

4, 12 Remote Manual/Automatic switch CH

Optional - jumper closed for Auto Mode-only operation

Manual = Open Automatic = Closed

6, 14 Remote High Power on/off momentary

push-button

User must supply momentary pushbutton to enable High Power to system

Non-voltage-Free Contacts

5, 13 Adept Supplied 5 VDC and GND for

High Power On/Off Switch Lamp

User must supply lamp, or use 1 W, 47 ohm resistor - system will not operate if not present

7, 15

Controller system 5 V power on LED, 5

Optional - indicator only

V, 20mA

8 No connection

See the figure Front Panel Schematic on page 58 for a schematic diagram of the Adept Front Panel.

Users must exercise caution to avoid inadvertently connecting 24 V signals to these pins,

because this will damage the electronics.

NOTE:The system was evaluated by Underwriters Laboratory with an Adept Front Panel. If you provide a substitute front panel, this could void UL compliance.

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Chapter 3: System Installation

Table 3-8. Remote Pendant Connections on the XMCP Connector

Pin XMCP (15-Pin D-Sub)

Description

1, 9 Pendant E-Stop Push-button CH 1

2, 10 Pendant E-Stop Push-button CH 2

3, 11 Pendant Enable CH 1 (Hold-to-run)

4, 12 Pendant Enable CH 2 (Hold-to-run)

13 Serial GND/Logic GND

7 Pendant TXD: eV+to Pendant TXD

8 Pendant RXD: eV+to Pendant RXD

14 No connection

15 No connection

Shield Shield GND

6 24 V

5 No connection

The following figure shows an E-Stop diagram for the system. See System Installation on page 35 for a description of the functionality of this circuit.

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Chapter 3: System Installation

ES1

ES2

ESTOP 24 V

Source

XSYSTEM-31

(XFP-1)

XSYSTEM-20

(XFP-9)

(XPND-7)

XSYSTEM-24

(XPND-24)

(XUSR-1)

(XUSR-14)

XSYSTEM-13

(XUSR-3)

(XPND-9)

T20 Pendant

Enable

XSYSTEM-8

(XPND-26)

Manual Mode Path

Force-Guided Relay

Cyclic Check

Control Circuit

Single-Phase AC Input 200-240 VAC

Front Panel ESTOP Pushbutton

T20 ESTOP Pushbutton

User E-Stop and Gate Interlock (Jumper closed when not used, MUST open both channels independently if used.)

LINE E-Stop (External User E-Stop System)

Muted Safety Gate Active in Auto mode only (Jumper closed when not used)

Front Panel Auto/Manual Keyswitch

High Power to Amplifiers (Internal Connections)

Front Panel High Power ON/OFF

Auto/Manual

Output

User ESTOP

Output

XSYSTEM-32 (XFP-2)

ESTOP Ground

(XFP-10)

(XPND-6)

(XPND-23)

(XUSR-2)

(XUSR-15)

XSYSTEM-43 (XUSR-4)

XSYSTEM-39 (XUSR-17)

XSYSTEM-9 (XUSR-16)

(XPND-8)

XSYSTEM-38 (XPND-25)

XSYSTEM-29 (XUSR-18)

XSYSTEM-44 (XUSR-19)

ES1

ES2

SR1 SR2

AM2

AM1

XSYSTEM-14

(XUSR-5)

XSYSTEM-30 (XUSR-6)

Auto Mode

Path

XSYSTEM-33 (XFP-13)

6 V, 1.2 W

Bulb

XSYSTEM-3 (XFP-5)

XSYSTEM-31 (XFP-6)

XSYSTEM-34 (XFP-14)

ESTOP 24 V

Source

XSYSTEM-5

(XFP-4)(XFP-3)

XSYSTEM-19 (XFP-12)

XSYSTEM-4

(XFP-11)

AM2

Coil

AM1 Coil

XSYSTEM-12 (XUSR-9)

XSYSTEM-28 (XUSR-10)

AM2

AM1

XSYSTEM-42 (XUSR-23)

XSYSTEM-27 (XUSR-22)

XSYSTEM-26 (XUSR-8)

XSYSTEM-10 (XUSR-7)

XSYSTEM-25 (XUSR-20)

XSYSTEM-40 (XUSR-21)

Figure 3-10. E-Stop Circuit on XUSR and XFP Connectors

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Chapter 3: System Installation

ESTOPSRC

24 VS

5 VD

SYSPWRLT 7

2 3

11 12 13 14 15

XFP

15PDSUBM

MANUALSRC1

HIPWRREQ

MANUALRLY2

MANUALRLY1

HIPWRLT

ESTOPFP2

ESTOPFP1

HPLT5V

MANUALSRC2

"MANUAL/AUTO""System Power LED"

MANUALSRC1

SW1

MANUALRLY2 MANUALRLY1

MANUALSRC2

24 VS

"HIGH POWER ON/OFF"

SWL1

HIPWRREQ

HPLT5 V

HIPWRLT

ESTOPSRC

"EMERGENCY STOP"

SW2

ESTOPFP2 ESTOPFP1

5 VD

2-PIN_MINI

SYSPWRLT

Adept Front Panel Schematic

Figure 3-11. Front Panel Schematic

Emergency Stop Circuits

The eAIB XSYSTEM cable provides connections for Emergency Stop (E-Stop) circuits on the XUSR and XFP connectors. This gives the controller system the ability to duplicate E-Stop functionality from a remote location using voltage-free contacts. See Figure 3-10.

The XUSR connector provides external two-channel E-Stop input on pin pairs 1, 14 and 2, 15. The XFP connector provides two-channel E-Stop input on pin pairs 1, 9 and 2, 10.

NOTE:These pins must be shorted if not used. Both channels must open independently if used. Although an Emergency Stop will occur, the controller will flag an error state if one channel is jumpered closed and the other channel is opened. It will also flag an error state if the channels are shorted together.

User E-Stop Indication Contacts - Remote Sensing of E-Stop

These contacts provide a method to indicate the status of the ESTOP chain, inclusive of the Front Panel Emergency Stop push-button, the pendant Emergency Stop push-button, and the User Emergency Stop Contacts.

NOTE:These contacts do not indicate the status of any connections below the User E-Stop contacts. Thus, they will NOT indicate the status of the Line E-Stop, MCP

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Chapter 3: System Installation

ENABLE, or the Muted Safety gate. If you have a specific need in this area, contact Adept Customer Service for information on alternate indicating modes.

Two pairs of pins on the XUSR connector (pins 7, 20 and 8, 21) provide voltage-free contacts, one for each channel, to indicate whether the E-Stop chain, as described above, on that channel is closed. Both switches are closed on each of the redundant circuits in normal operation (no E-Stop). The user may use these contacts to generate an E-Stop for other equipment in the workcell. The load on the contacts must not exceed 40 VDC or 30VAC at a maximum of 1 A.

These voltage-free contacts are provided by a redundant, cyclically-checked, positive-drive, safety relay circuit for Category 3 PL-d per ENISO 13849 operation (see Figure 3-10. and the table System Installation on page 35 for the customer E-Stop circuitry).

Line E-Stop Input

The XUSR connector on the controller contains a two-channel Line E-Stop input for workcell or other equipment emergency-stop inputs. Generally, the customer E-Stop Indication contact outputs are used to generate an emergency stop in such external equipment. Thus, if one were to wire the same equipment’s outputs into the customer E-Stop input (that is, in series with the local robot’s E-Stop push-buttons), a lock-up situation could occur.

The Line E-Stop input comes into the circuit at a point where it cannot affect the customer EStop indication relays and will not cause such a lock-up situation. For any situation where two systems should be cross-coupled, for example, the customer E-Stop indication of one controller is to be connected to the input of another controller, the Line E-Stop input is the point to bring in the other controller’s output contacts. See the figure E-Stop Circuit on XUSR and XFP Connectors on page 57 for more information.

Do not use the Line E-Stop for such devices as local E-Stop push-buttons, since their status should be reported to the outside on the local user E-Stop indication output contact while the Line E-Stop inputs will not.

Muted Safety Gate E-Stop Circuitry

Two pairs of pins on the XUSR connector (pins 5, 18 and 6, 19) provide connections for a safety gate designed to yield an E-Stop allowing access to the workspace of the robot in Manual mode only, not in Automatic mode. It is up to the customer to determine if teaching the robot in Manual Mode, by a skilled programmer (See Qualification of Personnel in the

Adept Robot Safety Guide), wearing safety equipment and carrying an Adept pendant, is

allowable under local regulations. The E-Stop is said to be “muted” in Manual mode (for the customer E-Stop circuitry, see the figures and tables at the beginning of the section System Installation on page 35).

The muted capability is useful for a situation where a shutdown must occur if the cell gate is opened in Automatic mode, but you need to open the gate in Manual mode. If the mute gate is opened in Automatic mode, the robot defaults to Manual mode operation when power is reenabled. In muted mode, the gate can be left open for personnel to work in the robot cell. However, safety is maintained because of the speed restriction.

CAUTION:If you want the cell gate to always cause a robot shutdown, wire the gate switch contacts in series with the user E-Stop inputs. Do not wire the gate switch into the muted safety gate inputs.

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Chapter 3: System Installation

Remote Manual Mode

The optional Adept Front Panel provides for a Manual Mode circuit. See Remote High Power On/Off Control on page 60 for further details about the customer Remote Manual Mode circuitry.

The Adept Front Panel, or a user-supplied panel, must be incorporated into the robot workcell to provide a “Single Point of Control” (the pendant) when the controller is placed in Manual mode. Certain workcell devices, such as PLCs or conveyors, may need to be turned off when the operating mode switch is set to Manual mode. This is to ensure that the robot controller does not receive commands from devices other than from the pendant, the single point of control.

If the user needs to control the Manual/Automatic mode selection from other control equipment, then a custom splitter cable or complete replacement of the Adept Front Panel may be required. See Front Panel Schematic on page 58. In this situation, a pair of contacts should be wired in series with the Adept Front Panel Manual/Automatic mode contacts. Thus, both the AdeptFront Panel, or the user-supplied panel, and the customer contacts need to be closed to allow Automatic mode.

WARNING:Do not wire user-supplied Manual/Automatic contacts in parallel with the Adept Front Panel, or the user-supplied panel, switch contact. This would violate the “Single Point of Control” principle and might allow Automatic (high-speed) mode to be selected while an operator is in the cell.

User Manual/Auto Indication

Two pairs of pins on the XUSR connector (pins 9, 22 and 10, 23) provide a voltage-free contact to indicate whether the Front Panel and/or remote Manual/Automatic switches are closed. The user may use these contacts to control other mechanisms (for example, conveyor, linear modules, etc.) when Manual mode is selected. The load on the contacts should not exceed 40 VDC or 30 VAC at a maximum of 1 A.

User High Power On Indication

In the optional SmartController EX, eV+ controls a normally-open relay contact on the XDIO connector (pins 45, 46, see the table System Installation on page 35), that 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. The limit on these contacts is 1 A at 30 VDC or 30 VAC.

Remote High Power On/Off Control

The easiest and most effective way to provide the high power on/off control in a remote location is to mount an optional Adept Front Panel in the desired location with an extension cable.

However, if the user needs to control high power on/off from other control equipment or from a location other than the front panel, then a custom splitter cable will be required. See the Front Panel schematic (Front Panel Schematic on page 58) for details of the Adept Front Panel’s wiring. In this situation, a second momentary contact for high power on/off would be placed in

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Chapter 3: System Installation

parallel with the panel push-button contact. This second contact should be suppressed when in

Manual mode (see the note on “Single Point of Control” below).

This method allows relocating the push-button switch to a more convenient location. Implementation of this method must conform to EN standard recommendations.

NOTE:European standards require that the remote High Power push-button be located outside of the workspace of the robot.

Pins 6, 14 and 5, 13 of the XFP connector provide this remote capability. Pins 5, 13 provide power for the lamp, +5 VDC and ground, respectively. Pins 6, 14 are inputs for voltage-free normally-open contacts from a user-supplied momentary push-button switch.

WARNING:To fulfill the “Single Point of Control” requirement, do not place the Manual/Automatic and High Power On controls in multiple locations. After putting the robot into Manual mode, the operator should remove the key for safety purposes. The system should not be wired so that a PLC or another operator can put the system back into Automatic mode.

High Power On/Off Lamp

The Adept Front Panel High Power On/Off Lamp (P/N: 27400-29006) will cause an error, from eV+, if the lamp burns out. This error prevents High Power from being turned on. This safety feature prevents a user from not realizing that High Power is enabled because the High Power indicator is burned out. See Changing the Lamp in the Optional Adept Front Panel HighPower Indicator on page 106 for information on changing this lamp.

Remote Front Panel or User-Supplied Control Panel Usage

Users can mount the optional Front Panel remotely by using an extension cable or by wiring a user-supplied Front Panel (control panel) to the controller using the 15-pin XFP connector. The Front Panel contains no active components, only switches and lights. Customers should be able to adapt the Front Panel’s functionality into their own Front Panel design. To automatically control the Front Panel’s signals, use relay contacts instead of switches. See the figure Front Panel Schematic on page 58 for a schematic drawing of the Front Panel, and see the table System Installation on page 35 for a summary of connections and pin numbers.

NOTE:The system was evaluated by Underwriters Laboratory with an Adept Front Panel. If you provide a substitute front panel, the system may no longer be UL compliant.

Customers can build an extension cable to place the optional Adept Front Panel in a remote location. The extension cable must conform to the following specifications:

Wire Size: must be larger than 26 AWG.

Connectors: must be 15-pin, standard D-sub male and female.

Maximum cable length is 10 meters.

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NOTE: The XMCP and XFP connectors can be interchanged without electrical damage. However, neither the Front Panel nor the pendant will work properly unless they are plugged into the correct connector.

Remote Pendant Usage

Customers can build an extension cable to place the pendant in a remote location. The extension cable must conform to the following specifications:

Wire Size: must be larger than 26 AWG.

Connectors: must be 15-pin, standard D-sub male and female.

Maximum cable length is 10 meters.

CAUTION:Do not modify the cable that is attached to the pendant. This could cause unpredictable behavior from the robot system.

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4.1 Robot Status Display Panel

The robot Status Display panel is located on the side of the robot base.

The combined status LED/high-power lamp and the brake-release button are on the underside of the robot base.

The Status Display and LED blinking pattern indicate the status of the robot.

Figure 4-1. Robot Status Display Panel

Table 4-1. Robot Status LED Definition

LED Status

Off No display 24 VDC not present

Off OK High Power Disabled

Amber, Solid ON High Power Enabled

Amber, Solid Fault Code(s) Fault, see Status Display

Amber, Slow Blink OK Selected Configuration Node

Amber, Fast Blink Fault Code(s) Fault, see Status Display

See Status Panel Fault Codes on page 64.

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Description

Chapter 4: System Operation

4.2 Status Panel Fault Codes

The Status Display, shown in Robot Status Display Panel on page 63, displays alpha-numeric codes that indicate the operating status of the robot, including fault codes. The following table gives definitions of the fault codes. These codes provide details for quickly isolating problems during troubleshooting.

The displayed fault code will continue to be displayed even after the fault is corrected or additional faults are recorded. All displayed faults are cleared from the display, and reset to a no-fault condition, upon successfully enabling high power to the robot, or power cycling the 24 V supply to the robot.

LED Status Code LED Status Code

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

ON High Power ON Status hV High Voltage Bus Fault

MA Manual Mode I# Initialization Stage (Step #)

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

Table 4-2. Status Panel Codes

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

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

BA Backup Battery Low Voltage PR Processor Overloaded

AC AC Power Fault RC RSC Fault

D# Duty Cycle Exceeded (Joint #) S# Safety System Fault (Code #)

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

ES E-Stop SW Watchdog Timeout

F# External Sensor Stop T# Safety System Fault (Code 10 + #)

FM Firmware Mismatch TR Teach Restrict Fault

FW IEEE 1394 Fault V# Hard Envelope Error (Joint #)

h# h# High Temp Amp (Joint #)

For more information on status codes, go to the Adept Document Library on the Adept website, and in the Procedures, FAQs, and Troubleshooting section, look for the Adept Status Code Summary document.

See Major Robot Components on page 11 for Joint # locations.

4.3 Using the Brake-Release Button

Robot Brakes

The robot has a braking system which decelerates the robot in an emergency condition, such as when the emergency stop circuit is open or a robot joint passes its softstop.

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Chapter 4: System Operation

BrakeRelease Button

Status Display Panel

Joint 1

Joint 2

Joint 3

Status LED/

High-power

Lamp

This braking system does not prevent you from moving the robot manually, once the robot has stopped (and high power has been disabled).

In addition, the three inner-arm motors have electromechanical brakes, which are released when high power is enabled. When high power is disabled, the brakes engage and hold the position of the platform fixed.

Brake-Release Button

Under some circumstances, you may want to manually position the platform without enabling high power. For such instances, a Brake-Release button is located on the underside of the robot base. When system power is ON, pressing this button releases the brakes, which allows movement of the arms and platform.

Figure 4-2. Brake Release and LED Light

If this button is pressed while high power is ON, high power automatically shuts down.

NOTE:24 Volt robot power must be ON to release the brakes.

CAUTION:When the Brake-Release button is pressed, the

platform and end-effector may drop to the bottom of its travel. To prevent possible damage to the equipment, make sure that the platform is supported when releasing the brakes and verify that the end-effector or other installed tooling is clear of all obstructions.

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Auto Mode

Manual Mode

Remote Brake Release Feature

You can also configure the XIO Input 6.2 (pin 18) to act as an alternate hardware brake release input. The setting is available on the Robot page in the Adept ACE software. The parameter is Remote Brake Release Input. When enabled (True), activating XIO Input 6.2 is identical to pressing the physical brake release button on the robot base. The input status will still reflect in the IO register.

4.4 Optional Adept Front Panel

Figure 4-3. Adept Front Panel

XFP cable

With a SmartController EX:Connects to the XFP connector on the SmartController.

Without a SmartController EX, connects to the XFP branch of the eAIBXSYSTEM cable.

System 5 V Power-On LED

Indicates whether or not power is connected to the robot.

Manual/Automatic Mode Switch

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

High Power On/Off Switch and Lamp

Controls high power, which is the flow of current to the robot motors. Enabling high power is a two-step process. An “Enable Power” request must be sent from the usersupplied PC, an executing program, or the optional pendant. Once this request has been made and the High Power On/Off lamp/button is blinking, the operator must press and release this button, and high power will be enabled.

NOTE:The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step.

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NOTE:If enabled, the Front Panel button must be pressed while blinking (default time-out is 10 seconds). If the button stops blinking, you must enable power again.

Emergency Stop Switch

The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements. Pressing this button turns off high power to the robot motors.

NOTE:A Front Panel or equivalent circuits must be installed to be able to Enable Power to the robot. To operate without the Adept Front Panel, the user must supply the equivalent circuits.

4.5 Connecting Digital I/O to the System

You can connect digital I/O to the system in several different ways. See the following table and figure.

I/O on the eAIB:

Table 4-3. Digital I/O Connection Options

Product I/O Capacity For more details

XIO Connector on eAIB 12 inputs

8 outputs

IOBlox, using optional eAIB XBELT IO Adapter Cable

12 inputs 8 outputs

see Using Digital I/O on eAIB XIO Connector on page 69

Adept IO Blox User’s Guide

I/O with an Optional SmartController EX:

Table 4-4. More Digital I/O Connection Options

Product I/O Capacity For more details

XDIO Connector on optional SmartController EX

Optional sDIO Module, connects to SmartController EX

12 inputs 8 outputs

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

see the Adept SmartController

EX User’s Guide

see the Adept SmartController

EX User’s Guide

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Chapter 4: System Operation

Optional

IO Blo

Device

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

eAIB XBELTIO Adapter Cable

RS-232

XBEL

EXPIO

IEEE-1394

SC-DIO

LINK

*S/N 3563-XXXXX*

24V 0.5A

+ - +

1.1

1.2 XDC1 XDC2

24 V

GND

200 -

240 V

XBELTIO

XIO

Servo

ENETENET

XSYSTEM

Optional sDIO #1

Optional SmartController EX

Hornet 565 Robot

XIO Connector 12 Input signals: 1097 to 1105 8 Output signals: 0097 to 0104

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

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

For Dual Robot systems, see the Adept Dual-Robot Configuration Procedure.

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

Table 4-5. Default Digital I/O Signal Configuration, Single Robot System

Location Type Signal Range

Controller XDIO connector Inputs 1001 - 1012

Outputs 0001 - 0008

sDIO Module Inputs 1033 - 1064

Outputs 0033 - 0064

sDIO Module 2 Inputs 1065 - 1096

Robot 1 XIO connector Inputs 1097 - 1108

Outputs 0065 - 0096

Outputs 0097 - 0104

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Pin 1

Pin 9

Pin 10

Pin 18

Pin 26

Pin 19

4.6 Using Digital I/O on eAIB XIO Connector

The XIO connector on the robot interface panel offers access to digital I/O, 12 inputs and 8 outputs. These signals can be used by eV+ to perform various functions in the workcell.

See the following table for the XIO signal designations.

12 Inputs, signals 1097 to 1108

8 Outputs, signals 0097 to 0104

Brake Release and LED Light

Table 4-6. XIO Signal Designations, Inputs

Pin No.

Designation

Signal Bank

eV+ Signal Number

1 GND

2 24 VDC

3 Common 1 1

4 Input 1.1 1 1097

5 Input 2.1 1 1098

6 Input 3.1 1 1099

7 Input 4.1 1 1100

8 Input 5.1 1 1101

9 Input 6.1 1 1102

10 GND

11 24 VDC

12 Common 2 2

13 Input 1.2 2 1103

Pin Locations

14 Input 2.2 2 1104

15 Input 3.2 2 1105

16 Input 4.2 2 1106

17 Input 5.2 2 1107

18 Input 6.2 2 1108

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XIO 26-pin female connector on Robot Interface Panel

Chapter 4: System Operation

Table 4-7. XIO Signal Designations, Outputs

Pin No. Designation

Signal Bank

eV+ Signal Number

19 Output 1 0097

20 Output 2 0098

21 Output 3 0099

22 Output 4 0100

23 Output 5 0101

24 Output 6 0102

25 Output 7 0103

26 Output 8 0104

Optional I/O Products

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

XIO Breakout Cable, 5 meters long, with flying leads on user’s end. See XIO Breakout Cable on page 74 for information. This cable is not compatible with the XIO Termination Block.

Pin Locations

XIO Termination Block, with terminals for user wiring, plus input and output status LEDs. Connects to the XIO connector with 6-foot cable. See the Adept XIO Termination

Block Installation Guide for details.

XIO Input Signals

The 12 input channels are arranged in two banks of 6. Each bank is electrically isolated from the other bank and is optically isolated from the robot’s ground. The 6 inputs within each bank share a common source/sink line.

The inputs are accessed through direct connection to the XIO connector (see Table 4-6. ), or through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.

The XIO inputs cannot be used for REACTI programming, high-speed interrupts, or vision triggers. See the eV+ Language User’s Guide for information on digital I/O programming.

XIO Input Specifications

Table 4-8. XIO Input Specifications

Operational voltage range 0 to 30 VDC

OFF state voltage range 0 to 3 VDC

ON state voltage range 10 to 30 VDC

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Chapter 4: System Operation

Typical threshold voltage Vin= 8 VDC

Operational current range 0 to 7.5 mA

OFF state current range 0 to 0.5 mA

ON state current range 2.5 to 7.5 mA

Typical threshold current 2.0 mA

Impedance (Vin/Iin) 3.9 KΩ minimum

Current at Vin= +24 VDC Iin≤ 6 mA

Turn-on response time (hardware)

Software scan rate/response time

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

Turn-off response time (hardware)

Software scan rate/response time

5 µsec maximum

16 ms scan cycle/ 32 ms max response time

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

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Typical Input Wiring Example

Adept-Supplied Equipment

User-Supplied Equipment

Signal 1097

Part Present Sensor

Signal 1098

Feeder Empty Sensor

Signal 1099

Part Jammed Sensor

Signal 1100

Sealant Ready Sensor

Signal 1101

Signal 1102

+24V

GND

Bank 1

Common

Bank 2

Common

Signal 1103

Signal 1104

Signal 1105

Signal 1106

Signal 1107

Signal 1108

GND

+24V

Wiring Terminal Block

Typical User Input Signals

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

Bank 1 configured for

Sinking (NPN) Inputs

Bank 2 configured for

Sourcing (PNP) Inputs

Input Bank 2 Input Bank 1

XIO Connector – 26-Pin Female D-Sub

(equivalent circuit)

Chapter 4: System Operation

XIO Output Signals

The eight digital outputs share a common, high side (sourcing) driver IC. The driver is designed to supply any kind of load with one side connected to ground. It is designed for a range of user-provided voltages, from 10 to 24 VDC, and each channel is capable of up to 0.7 A of current. This driver has overtemperature protection, current limiting, and shorted-load protection. In the event of an output short or other overcurrent situation, the affected output of

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

NOTE:The OFF state current range exceeds the leakage current of XIO outputs. This guarantees that the inputs will not be turned on by the leakage current from the outputs. This is useful in situations where the outputs are looped-back to the inputs for monitoring purposes.

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Chapter 4: System Operation

the driver IC turns off and back on automatically to reduce the temperature of the IC. The driver draws power from the primary 24 VDC input to the robot through a self-resetting polyfuse.

The outputs are accessed through a direct connection to the XIO connector (see XIO Signal Designations, Inputs on page 69), or through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.

XIO Output Specifications

Table 4-9. XIO Output Circuit Specifications

Parameter Value

Power supply voltage range See System Installation on page 35.

Operational current range, per channel

Total Current Limitation, all channels on

ON-state resistance (I

= 0.5 A) Ron≤ 0.32 Ω @ 85° C

out

Output leakage current I

≤ 700 mA

out

≤ 1.0 A @ 40° C ambient

total

≤ 1.5 A @ 25° C ambient

total

≤ 25 µA

out

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

(hardware only)

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

(hardware only)

Output voltage at inductive load turnoff (I Load = 1 mH)

DC short circuit current limit 0.7 A ≤ I

Peak short circuit current I

out

= 0.5 A,

(+V - 65) ≤V

LIM

≤ 4 A

ovpk

demag

≤ 2.5 A

≤ (+V - 45)

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Chapter 4: System Operation

Adept-Supplied Equipment User-Supplied Equipment

Outputs 1-8

Typical User Loads

XIO Connector – 26-Pin Female D-Sub

+24 VDC

Signal 0097

Signal 0098

Signal 0099

Signal 0100

Signal 0101

Signal 0102

Signal 0103

Signal 0104

GND

Load

Customer AC Power Supply

Load

(equivalent circuit)

Wiring Terminal Block

Typical Output Wiring Example

Figure 4-6. Typical User Wiring for XIO Output Signals

XIO Breakout Cable

The XIO Breakout cable is available as an option—see the following figure. This cable connects to the XIO connector on the eAIB, and provides flying leads on the user’s end, for connecting input and output signals in the workcell. The cable length is 5 M (16.4 ft).

See the following table for the cable wire chart.

NOTE:This cable is not compatible with the XIO Termination Block.

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Figure 4-7. Optional XIO Breakout Cable

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Chapter 4: System Operation

Pin 9

Pin 1

Pin 18

Pin 10

Pin 19

Pin 26

Table 4-10. XIO Breakout Cable Wire Chart

Signal

Pin No.

Designation Wire Color Pin Locations

1 GND White

2 24 VDC White/Black

3 Common 1 Red

4 Input 1.1 Red/Black

5 Input 2.1 Yellow

6 Input 3.1 Yellow/Black

7 Input 4.1 Green

8 Input 5.1 Green/Black

9 Input 6.1 Blue

10 GND Blue/White

11 24 VDC Brown

12 Common 2 Brown/White

13 Input 1.2 Orange

14 Input 2.2 Orange/Black

15 Input 3.2 Grey

16 Input 4.2 Grey/Black

17 Input 5.2 Violet

18 Input 6.2 Violet/White

19 Output 1 Pink

20 Output 2 Pink/Black

21 Output 3 Light Blue

22 Output 4 Light Blue/Black

23 Output 5 Light Green

24 Output 6 Light Green/Black

25 Output 7 White/Red

26-pin male connector on XIO Breakout Cable

26 Output 8 White/Blue

Shell Shield

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Chapter 4: System Operation

4.7 Starting the System for the First Time

Follow the steps in this section to safely bring up your robot system. The tasks include:

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

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

Verifying that all E-Stops in the system function correctly

Moving the robot with the pendant (if purchased), to confirm that each joint moves correctly

Verifying Installation

Verifying that the system is correctly installed and that all safety equipment is working correctly is an important process. Before using the robot, perform the following checks to ensure that the robot and controller have been properly installed.

DANGER:After installing the robot, you must test it before you use it for the first time. Failure to do this could cause death, serious injury, or equipment damage.

Mechanical Checks

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

Verify that any platform tooling is properly installed.

Verify that the platform has been aligned with the J4 motor (J4 version only).

Verify that all peripheral equipment is properly installed such that it is safe to turn on power to the robot system.

System Cable Checks

Verify the following connections:

NOTE:The first three connections are made via the eAIB XSYSTEM cable if you are not using an optional SmartController EX.

Front Panel to the XSYSTEM on the eAIB, or

XFP port on a SmartController EX.

Pendant to the XSYSTEM on the eAIB, or

XMCP port on a SmartController EX, or a loop-back dongle installed.

XUSR to the XSYSTEM on the eAIB, or

XUSR port on a SmartController EX,

or XUSR jumper installed.

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

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

Ethernet cable from PLC (if used) to eAIB or SmartController EX (if used)

If you are using an optional SmartController EX:

User-supplied 24 VDC power connected to the SmartController.

User-supplied ground wire installed between the SmartController and ground.

One end of the IEEE 1394 cable installed into a SmartServo port on the SmartController EX, and the other end installed into a SmartServo port on the robot interface panel.

eAIB XSYS (eAIB) cable between the robot interface panel XSYSTEM connector and XSYS connector on the SmartController EX, and the latching screws tightened.

See System Installation on page 35.

Ethernet cable from PLC (if used) to SmartController EX.

User-Supplied Safety Equipment Checks

Verify that all user-supplied safety equipment and E-Stop circuits are installed correctly.

Turning on Power and Starting Adept ACE

After the system installation has been verified, you are ready to turn on AC and DC power to the system and start up Adept ACE.

Turn on the 200-240 VAC power. See System Installation on page 35.

WARNING:Make sure personnel are skilled and instructed—refer to the Adept Robot Safety Guide.

Turn on the 24 VDC power to the robot. See System Installation on page 35. The Status Panel displays OK. The Robot Status LED will be off.

If you have an Adept Front Panel, verify the Auto/Manual switch on the Front Panel is set to Auto Mode.

Turn on the user-supplied PC and start Adept ACE.

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

From the Windows Start menu bar, select:

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

On the Adept ACE Getting Started screen:

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

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Chapter 4: System Operation

Select the IP address of the controller you wish to connect to, or manually type in the IP address.

Click OK. You will see the message “Working, please wait”.

Enabling High Power

NOTE:If you are controlling the robot with a PLC, see Using the PLC to Enable High Power on page 84.

After you have started the Adept ACE software and connected to the controller, enable high power to the robot motors:

1. From the Adept ACE main menu, click the Enable High Power icon:

If the High Power button on the Front Panel is blinking, press and release it.

The optional Adept Front Panel is shown in Optional Adept Front Panel on page 66. (If the button stops blinking, you must Enable Power again.)

NOTE:The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step.

This step turns on high power to the robot motors and calibrates the robot.

The Robot Status LED glows amber.

The code on the Robot Diagnostic Panel displays ON (see Robot Status Display Panel on page 63).

Verifying E-Stop Functions

Verify that all E-Stop devices are functional (pendant, Front Panel, and user-supplied). Test each mushroom button, safety gate, light curtain, etc., by enabling high power and then opening the safety device. The High Power push button/light on the Front Panel should go out for each.

Aligning the Platform and J4 Motor

It is possible for either the motor shaft or the platform shaft to be turned, manually, before the theta drive shaft is connected to both. If not detected, the software may assume the robot’s tool flange is at a different angle than it really is. To ensure that the software knows the actual rotation of the tool flange with respect to the J4 motor, you need to use the ACE software to establish this alignment.

Within the ACE software, open the Hornet565 robot object.

In the Configure tab, click Adjust J4 Zero.

This will launch a utility for aligning the theta drive shaft.

Follow the instructions in the utility.

Contact Adept Service for more information on this procedure. Refer to the How to Get Help

Resource Guide (Adept P/N 00961-00700) for details on getting assistance.

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NOTE:Once the theta drive shaft is installed, the J4 motor and the tool flange will always rotate together, so the software will know the orientation of the tool flange.

Verify Robot Motions

Use the pendant (if purchased) to verify that the robot moves correctly. Refer to the Adept T20

Pendant User’s Guide for complete instructions on using the pendant.

The Hornet 565 robot is a parallel-arm robot and, as such, individual joint motions are not allowed. If you attempt to move a joint in Joint mode, you will get an error message:

JOINT <n> OUT OF RANGE

where <n> is the joint that you attempted to move. Joints are identified in Major Robot Components on page 11.

If one joint must be moved separately, release the brakes (while supporting the platform) and move the joint manually.

If the optional pendant is not installed in the system, you can move the robot using the

Robot Jog Control in the Adept ACE software. For details, see the Adept ACE User’s

Guide.

4.8 Robot Motions

Straight-line Motion

Joint-interpolated motion is not possible with the Hornet 565 robot, because the positions of all the joints must always be coordinated in order to maintain the connections to the moving platform. Therefore, for the Hornet 565 robot, the eV+ system automatically performs a straight-line motion when a joint-interpolated motion instruction is encountered.

Containment Obstacles

The work space of the robot is defined by an inclusion obstacle. This is done because, unlike other robots, joint limits are not meaningful in defining the work space. The eV+ software defines a cone-like shape as a containment obstacle. This is actually the work envelope. See Work Envelope, Side View on page 124 and Technical Specifications on page 123. Other obstacles can be defined within this obstacle.

4.9 Learning to Program the Adept Hornet 565 Robot

To learn how to use and program the robot, see the Adept ACE User’s Guide, which provides information on robot configuration, control and programming through the Adept ACE software “point and click” user interface.

For eV+ programming information, refer to the eV+ user and reference guides in the Adept Document Library (ADL) on the Adept website. For more details on the ADL, see Adept Document Library on page 19.

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Chapter 5: Options

This section covers options that are available to enhance the Hornet 565 robot. The options available are:

Tall Frame Mounting Adapters

For mounting the Hornet 565 robot in a taller (competitor’s) frame.

ePLC Connect

For using a user-supplied PLC to program the robot’s motions.

SmartVision MX industrial PC

To add vision-processing power and connectivity to the robot.

SmartController EX motion controller

To increase connectivity, I/O, conveyor tracking and general processing speed for the Hornet 565 robot.

sDIOModule

Add 32 inputs and 32 outputs, up to 4 sDIOmodules per system.

IOBlox I/ODevices

Add 8 inputs and 8 outputs, up to 4 IOBlox devices per system.

eAIBXBELTIOAdapter cable

Splits the EXPIO port into a belt encoder lead, a RS-232 lead, and a lead for either IOBlox or an Intelligent Force Sense System.

Inlet Cable Box

To increase the overall robot’s IP- rating to IP-65.

Intelligent Force Sense System

Allows quick detection of forces in six dimensions at the gripper.

Ball Stud Locks

To ensure that ball joints do not separate under extreme use.

5.1 Tall Frame Adapters

The Hornet 565 robot can be mounted in a tall frame, previously used for a competitive parallel robot, by installing a set of three frame adapters.

The frame adapters lower the height of the robot by 118 mm (4.65 in.).

The lengths of the three mounting bolts will need to be increased by 118 mm.

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5.2 ePLC Connect

The Hornet 565 robot can use a user-supplied PLC, with Adept’s ePLC Connect software, to control the robot motions.

Refer to Adept ePLC Connect 3 User’s Guide.

Hornet 565 robots that use a PLC, but do not use a SmartController EX, rely on the usersuppllied PLC for all digital I/O.

Configuration

The user-supplied PLC and Hornet 565 robot are connected either through a shared network or via a user-supplied Ethernet cable.

When the robot is powered on and waiting for a PLC connection, the robot status panel will display its IP address, two digits at a time.

The format will be:

IP xxx-xxx-xxx-xxx OK

NOTE: If you can use the robot’s default IP address, then you can skip the Adept ACE software installation completely.

Chapter 5: Options

Setting the Robot IP Address

Configure the IP address of the Hornet 565 robot using Adept ACE software.

Connect the PC and the robot, either through a shared network or with an Ethernet cable between them.

Start the Adept ACE software. Refer to Adept ACE Software on page 44.

Click the Detect and Configure button, circled in red in the following figure.

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Figure 5-1. Detect and Configure Button

The IP address detection and configuration window will open. The ACE software will show the IP address of any controllers it detects. See the following figure.

Figure 5-2. IP Addresses Detected

You can change the IP address and subnet mask in the Desired Address and Desired Subnet fields, if needed.

Click OK. The ACE software will ask you to wait for the controller to reboot.

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Setting the Robot IP Address on the PLC

Using your PLC software, set the IP address for the PLC to connect to on the robot.

Figure 5-3. Example: Setting an IP Address with RS Logix

The PLC should now be able to communicate with the robot.

Using the PLC to Enable High Power

The details of enabling high power to the robot will vary, depending on the software running on your PLC.

Figure 5-4. Example: Enabling High Power with RS Logix

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In the RS Logix example, double-clicking Controller Tags, and then setting the value of pv_rbt_ reset_fault to 1 will enable high power on the robot.

NOTE: pv_rbt_reset_fault is the name for a register which is fixed when downloading the PLC code example from the Adept Web site.

Once high power is enabled, the Robot Status Panel displays ON, and the amber Robot Status LED is on.

5.3 SmartVision MX Industrial PC

The Adept SmartVision MX™ is a Windows®7 Embedded industrial PC designed to run Adept’s ACE software. It is compatible with the Adept Hornet 565 robot, with or without the Adept SmartController EX motion controller.

For inspection applications, the Adept SmartVision MX industrial PC is designed to be a “plug-and-play” vision system. Using a USB or GigE camera, along with Adept’s PC-based vision software, the unit is a complete industrial vision solution, providing expanded vision processing power for vision-guided robotics or inspection.

Refer to Adept SmartVision MX User's Guide.

5.4 SmartController EX Motion Controller

The optional SmartController EXmotion controller supports tracking more conveyors than an eAIB alone, as well as other options. Like the eAIB, the SmartController EX uses the eV+ operating system. It offers scalability and support for IEEE 1394-based digital I/O and general motion expansion modules. The SmartController EX also includes Fast Ethernet and DeviceNet.

Refer to Adept SmartController EX User’s Guide.

5.5 sDIO Module

Adds 32 inputs and 32 outputs to the system. This requires the optional SmartController EX motion controller. Up to 4 sDIO modules can be added to a system.

5.6 IOBlox I/ODevice

Adds 8 inputs and 8 outputs per device. Up to 4 devices can be used. Requires the eAIB XBELT IO Adapter cable.

5.7 eAIB XBELT IOAdapter Cable

Splits the EXPIO port into a belt encoder lead, one RS-232 lead, and one lead for either IOBlox or Intelligent Force Sense System.

The belt encoder lead can be split into two belt encoder leads with the belt encoder Y-adapter. See System Cable Diagram with Belt Encoder Cables on page 42.

5.8 Cable Inlet Box

The addition of the cable inlet box raises the entire robot’s IP rating to IP-65.

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Chapter 5: Options

185

(Mounting Surface)

Cable Exit from Rear of Box

Figure 5-5. Cable Inlet Box Mounted on a Hornet 565 Robot

NOTE:The cable inlet box is not USDA compliant. Drainage of wash-down from the cable seal assembly does not comply with USDA requirements.

Overview

The cable seal assembly must be mounted on the top of the robot during the robot installation process. The cable seal assembly is an extra-cost option, and is shipped separately from the robot.

Components

Cable harness

eAIB Cable Seal Housing, 2 gaskets, 4 screws (Cable Seal Housing (left), Installed (right) on page 87)

Cable Entry Top Cover assembly, screw (Cable Entry Top Cover Assembly on page 88)

This includes the Roxtec CF 8 frame

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4 x 2-hole Roxtec modules

These are dense foam blocks surrounding pre-cut half-sleeves that can be peeled away to match the diameter of the cable to be sealed. See Adapting a Module to the Cable Size, Checking the Gap on page 89.

Roxtec grease, used to assemble and seal the modules (Greasing a Roxtec Module on page 89).

NOTE:The Roxtec CF 8 consists of a frame and integrated compression unit (a wedge and bolt that compress the modules once they are assembled inside the CF frame). See Cable Entry Top Cover Assembly on page 88.

Tasks

Measure and mark cables to establish service length.

Install eAIB cable inlet box.

Adapt Roxtec modules to fit cables.

Install cables through cable entry top cover assembly.

Attach cables to eAIB.

Attach cable entry top cover to eAIB cable inlet box.

Installation Procedure

Measure and mark all eAIB cables at 10 - 12 in. from the cable ends. This amount of slack is needed to install the seal assembly after the connections are made to the eAIB. See Cable Entry Assembly with Cables on page 90.

Install the cable seal housing on the top of the eAIB using four M4 x 50 screws, four M4 lock washers, and four M4 flat washers. Note that the centered M6-threaded hole must be toward the center of the robot base. See the following figure, right photograph. Ensure that the gasket is seated between the eAIB surface and the cable seal housing.

Figure 5-6. Cable Seal Housing (left), Installed (right)

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Figure 5-7. Cable Entry Top Cover Assembly

Figure 5-8. Bottom of Cable Entry Top Cover, CF Frame

Adapt Roxtec modules to fit the cables that will be used by peeling out half-circle strips from the modules. There should be a 0.1 to 1.0 mm gap between the halves of the modules for a proper seal. See the following figure.

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Figure 5-9. Adapting a Module to the Cable Size, Checking the Gap

Grease the Roxtec modules, using Roxtec grease. See the following figure.

Figure 5-10. Greasing a Roxtec Module

Grease the inside of the CF frame, where the modules will touch, using Roxtec grease.

Install each eAIB cable through its corresponding module, and insert the modules into the frame. See the following figure. Ensure that the terminated cable ends have 10 - 12 in. of slack. See Figure 5-13.

Figure 5-11. Installing Roxtec Modules into the Frame

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When all of the modules are in place, tighten the compression unit to 8 - 12 N-m (6-9 ft-lbf). See the following two figures. There should be no visible gaps between the modules or around the cables.

Figure 5-12. Tightening the Compression Unit

Figure 5-13. Cable Entry Assembly with Cables

Attach the ground lug to GND on the eAIB. The ground lug is for the cable shield of the user-supplied 24 VDC cable. See the following figure.

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Figure 5-14. Ground Lug Attachment

Hand-tighten all cables to the eAIB.

NOTE:All cables must be screwed into the eAIB.

10.

Attach the cable entry top cover, with Roxtec frame and modules, to the eAIB cable seal housing.

Slide the top cover over the seal housing lip, as shown in the following figure.

Ensure that the gasket between the top cover and the cable seal housing is seated, and that all cables are contained within the top cover.

Lower the top cover onto the seal housing, and secure with one screw.

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Figure 5-15. Installing Cable Entry Top Cover Assembly

5.9 Intelligent Force Sensor

The force sensor allows you to detect forces applied at the gripper, so you can stop the robot’s movement when a threshhold is passed. Requires the eAIB XBELT IO Adapter cable.

Refer to Adept Intelligent Force Sensing System User’s Guide.

5.10 Ball Stud Locks

Under abnormal or extreme loading conditions using very aggressive moves, or in the case of a collision, it is possible for the ball studs to separate from the ball joint sockets.

NOTE:In normal use, this will not happen.

If you are planning on extremely aggressive moves or extreme loading conditions, you may want to install ball stud locks. These attach to the ends of the outer arms, and trap the ball, to prevent the ball studs from separating from their sockets.

A ball stud lock kit (16 locks) is available from Adept as part number 09824-000.

The ball stud lock consists of slightly more than a half-circle of hard plastic that slides over the end of the ball joint socket. They can be installed and removed without tools. See the following figures.

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Figure 5-16. Ball Stud Locks

Figure 5-17. Ball Stud Lock on Ball Joint Socket

Installing a Ball Stud Lock

The ball stud lock has a groove that mates with a lip around the end of the ball joint socket.

To install a ball stud lock, line up the groove in the ball stud lock with the lip in the ball joint socket, and slide the lock on.

The lock is designed to be tight enough that it will not come off in use. No tools are needed.

Twist the ball stud lock back-and-forth slightly, after installation, to ensure that it is fully seated.

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Figure 5-18. Installing a Ball Stud Lock

Removing a Ball Stud Lock

To remove a ball stud lock, pull one end of the lock away from the ball joint socket. The lock will slide off (with resistance). No tools are needed.

Figure 5-19. Removing a Ball Stud Lock

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NOTE:Maintenance and cleaning of user-added optional equipment is the user’s responsibility. It is not covered in this manual.

NOTE:When performing maintenance on the robot, move any sub-assemblies away from any food processing area, to avoid any chance of contamination. Cover or protect the food processing area.

6.1 Cleaning

Water Shedding

Surfaces of the Hornet 565 robots have been designed to shed water. This increases the likelihood that contaminants or cleaning agents will drain with a wash-down procedure.

Wash-Down

Wash-down cleaning is appropriate for cleaning the Hornet 565 robot. Surfaces and joints have been designed with smooth internal radii for easy cleaning.

Chapter 6: Maintenance

Table 6-1. Typical Cleaning Schedule, Non-raw Food

Item Interval Suggested Cleaning Action

Outer Arms and Ball Studs

Platform 1 Week Clean with wipes, air, or water.

NOTE:The following cleaning actions and intervals are suggestions only. Refer to HACCP guidelines to determine what is required for your installation.

Item Interval Suggested Cleaning Action

Minimum: Entire robot

Optional: Platform Daily Clean Out of Place (dunk)

1 Week Clean with wipes or water.

Table 6-2. Typical Cleaning Schedule, Raw Food

Daily Clean In Place

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Chemical Compatibility

CAUTION:Not all materials used on the Adept Hornet 565 robot are compatible with all cleaning solutions available.

Caustic

The Hornet 565 robot is designed to be compatible with moderate cleaning agents commonly used in the cleaning of food-processing equipment, at room temperature. All robot components are designed to handle daily exposure to cleaning agents. Exposure may result in some discoloration of the materials, but no significant material removal.

NOTE: Anodized parts cannot be tank cleaned. Highly caustic cleaning agents are not suitable for Hornet 565 robots.

Acidic

In general, acidic cleaning solutions are incompatible with the Hornet 565 robot's materials. For acidic environments, contact Adept.

6.2 Periodic Inspection

Suggested Inspection Schedule on page 97 gives a summary of the inspection procedures and guidelines on frequency.

NOTE:The frequency of these procedures depends on the particular system, its operating environment, and amount of usage. Use the times in the tables as guidelines and modify the schedule as needed.

NOTE:The estimated times listed in the following table are for the inspection, not the repair.

WARNING:The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons, as defined in the Adept Robot Safety Guide.

The cover and the eAIB on the robot are not interlocked—turn off and disconnect power if these have to be removed. Lock out and tag out power before servicing.

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Table 6-3. Suggested Inspection Schedule

Item Sugg.

Freq.

User Cabling1Week

Outer Arm

1 Week

Inserts

Outer Arms

3 Mon

Platform 3

Mon

Robot

1 Year 60 Fans and Gear drives

Est. Time (Min)

Inspection Suggested

Remedy

Inspect for wear around robot joints and possible binding on robot.

Inspect inserts for excessive wear. Replace worn inserts.

Inspect outer arms for damage caused by possible accidental impact. Inspect springs and horseshoes for wear.

Inspect platform for damage caused by possible accidental impact.

Partially remove eAIB and Status Display to inspect fans for operation. Look for lubrication leaking from gear drives. See Checking Robot Gear Drives on page 98 and Checking Fan Operation on page 99.

Replace cabling if cracked or worn. Adjust cable position if binding.

Replace arms if damaged. Replace springs and horseshoes if worn or damaged.

Replace platform.

Diagnose and/or replace non-operational fans.

Replace gear drives.

Dynamic and Static seals

E-Stops 6

Robot Mounting bolts

Cable Inlet Box seals

eAIB seal 3

Cable Inlet Box gaskets

Status Display Panel

3 Mon

Mon

3 Mon

Mon

3 Mon

Inspect dynamic seals on inner arms and static seals for sanitizing wash-down environments. Check for good seal contact, inflexible, broken, seals.

Check functioning of E-Stops. See Checking Safety Systems on page 98.

Check tightness of bolts. See Checking Robot Mounting Bolts on page 98.

Check for good seal contact, inflexible, broken, seals.

Check for good seal contact, inflexible, broken, seal.

Check for good gasket contact, inflexible, broken gaskets.

Check for water inside the display. Check for good seal contact, inflexible, broken, seal.

Platforms: replace platform.

Inner arms: replace seals.

Replace Front Panel, or customer E-Stops.

Tighten bolts.

Replace seals.

Replace seal.

Replace gaskets.

Replace seal.

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NOTE:These lists are not necessarily complete.

Checking Safety Systems

These tests should be done every six months.

NOTE:Operating any of the following switches or buttons must disable high power. If any of the tests fail, repairs must be made before the robot is put back into operation.

Test operation of:

E-Stop button on front panel

E-Stop button on pendant

Auto/Manual switch on front panel

Enabling switch on pendant (Manual mode only)

Test operation of any user-supplied E-Stop buttons.

Test operation of barrier interlocks, etc.

Checking Robot Mounting Bolts

Check the tightness of the base mounting bolts after the first week, and then every 3 months. Refer to the following table for torque specifications.

Table 6-4. Mounting Bolt Torque Specifications

Standard Size Torque

Metric M12-1.75 61 N·m (45 ft-lb)

Checking Robot Gear Drives

NOTE:Gear drive inspection and fan operation inspection require removal of the same robot parts, and have the same schedules. You will probably want to perform these two inspections at the same time.

NOTE:The inner arm motor plugs are not used for this inspection because they cannot be removed without destroying them.

Adept Hornet 565 robots use gear drives, which use oil in their components for lubrication. Periodically inspect the robot for signs of oil on and around the gear drives.

To check the J1 and J2 gear drives:

Remove all power to the robot before starting this check.

Lock out and tag out AC power.

Wait for the motors to cool before performing this check.

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WARNING:Do not remove the encoder cable connectors from their sockets on the motors. If they are removed, the calibration data will be lost, requiring factory recalibration.

Remove the eAIB.

See Replacing the eAIB Chassis on page 112.

You do not need to disconnect the cables to the eAIB.

Check for oil inside the base of the robot.

Look through the venting slots under each motor for oil leakage.

Feel the bottom of the motors with your finger through the venting slots.

Check the outside of the motors and gear drives for any signs of oil.

Contact Adept if you find any signs of oil in these areas.

If you aren’t going to check the operation of the motor fans:

Re-install the eAIB.

See Installing a New eAIB Chassis on page 116.

To check the J3 gear drive:

Remove the four M4 hex-head bolts holding the Status Display panel.

Retain the bolts for re-installation.

These bolts were installed with Loctite 222.

Remove but do not disconnect the Status Display panel.

Retain the Status Display panel and gasket for re-installation.

Check the outside of the motor and gear drive for any sign of oil.

Re-install the Status Display panel with the four M4 bolts previously removed.

Apply Loctite 222 in each bolt hole, not on the bolts themselves.

Ensure that the Status Display panel gasket is in place between the panel and the robot body.

Torque the bolts to 1.1 N·m (10 in-lb).

Checking Fan Operation

The motor fans are PWM controlled. This check needs to be done with 24 VDC to the robot ON.

Verify that all fans operate:

Fans for J1 and J2 motors:

Remove the eAIB.

See Replacing the eAIB Chassis on page 112.

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You do not need to disconnect the cables to the eAIB.

Toggle power to the eAIB.

Motor fans run for about 1 minute before shutting off. (If the robot is hot, they will continue to run.)

Verify that J1 and J2 motor fans are running by looking through the eAIB opening.

Re-install the eAIB.

Installing a New eAIB Chassis on page 116.

Fan for J3 motor:(this cannot be seen through the eAIB opening)

Remove the four M4 hex-head bolts holding the Status Display panel.

Retain the bolts for re-installation.

These bolts were installed with Loctite 222.

Remove but do not disconnect the Status Display panel.

Retain the Status Display panel and gasket for re-installation.

Toggle power to the eAIB.

Motor fans run for about 1 minute before shutting off. (If the robot is hot, they will continue to run.)

Verify that the J3 motor fan is running by looking through the Status Display opening.

Re-install the Status Display panel with the four M4 bolts previously removed.

Apply Loctite 222 in each bolt hole, not on the bolts themselves.

Ensure that the Status Display panel gasket is in place between the panel and the robot body.

Torque the bolts to 1.1 N·m (10 in-lb).

6.3 Periodic Maintenance

Item Suggested

Interval

Maintenance

Theta Drive Shaft

Backup Encoder Battery Pack

1 Year or 5,000 hours

5 years to 10 years

30 Minutes Bushings in drive shaft are a normal wear item.

15 Minutes Replacement battery pack is inserted from the side

Table 6-5. Suggested Part Replacement

Estimated

Time of

The bushings are not field-replaceable, so the entire drive shaft must be replaced.

of the robot through the Status Display opening. See Maintenance on page 95

Description

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Theta Drive Shaft

Set

Screw

U-Joint

J4 Shaft (Motor or Platform)

10 - 15 mm

3 mm

Replacing the Theta Drive Shaft

NOTE:The fixed platform Hornet 565 robot does not use a theta drive shaft, so this procedure does not apply to those robots.

The bushings in the drive shaft are a normal wear item, and need to be replaced yearly or every 5,000 hours of use. Because the bushings are not field-replaceable, the procedure for this is to replace the entire drive shaft with a refurbished drive shaft, which will have new bushings. The worn drive shaft needs to be returned to Adept to be refurbished.

Removing the Theta Drive Shaft

The theta drive shaft has a U-joint on each of its ends. One connects to the J4 motor drive, the other connects to a shaft on the top of the J4 platform.

Disconnect the bottom U-joint from the shaft on top of the J4 platform.

Disconnect the top U-joint from the drive shaft of the J4 motor.

To remove a U-joint from a J4 motor or platform shaft:

Unscrew the M6 x 20 dog point set screw that goes through the U-joint and shaft.

For the top U-joint, use a 3 mm hex key, with a 10 - 15 mm short leg. There is not enough room at the J4 motor shaft to use a standard hex key.

The set screw was put in with Loctite 242.

Save the set screw for installing the replacement drive shaft.

Slide the end of the U-joint off of the J4 motor or platform shaft.

The fit will be fairly tight.

Installing a Drive Shaft

When the theta drive shaft is shipped, it will have one end of a U-joint attached to each end.

Figure 6-1. Short 3 mm Hex Key (Above), U-Joint (Right)

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Top U-Joint at J4 Motor

Upper Section of Drive Shaft

Lower Section of Drive Shaft

Bottom U-Joint at J4 Platform

NOTE:The drive shaft has a top and bottom. Installing it upside-down will degrade system performance. Look for a “Top” label on the drive shaft.

Attach the top U-joint to the drive shaft of the J4 motor.

The top (J4 motor)end of the drive shaft is labeled with a temporary label, indicating Top. Remove the label before use. See figure at right.

Attach the bottom U-joint to the shaft on top of the J4 platform.

To attach the free end of a U-joint:

Slide the free end of the U-joint over the J4 motor or platform shaft.

The fit will be fairly tight.

The hole in the side of the U-joint needs to line up with the hole in the shaft.

Insert one of the M6 x 20 dog point set screws previously removed through the hole in the side of the U-joint, screw it through the shaft, and into the blind hole on the opposite side of the U-joint. The shafts are threaded, the U-joints are not.

Use Loctite 242.

Tighten to 5 N-m (3.7 ft-lbf)of torque. The head of the set screw should be flush with the outer surface of the U-joint.

The old drive shaft, with U-Joints attached, needs to be returned to Adept so that it can be refurbished. Contact Adept field service for instructions. Refer to the How to Get Help Resource

Guide (Adept P/N 00961-00700) for details on getting assistance.

Aligning the Platform and J4 Motor

Within the ACE software, open the Hornet565 robot object.

In the Configure tab, click Adjust J4 Zero.

This will launch a utility for aligning the theta drive shaft.

Follow the instructions in the utility.

Contact Adept Service for more information on this procedure. Refer to the How to Get Help

Resource Guide (Adept P/N 00961-00700) for details on getting assistance.

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Chapter 6: Maintenance

NOTE:Once the theta drive shaft is installed, the J4 motor and the tool flange will always rotate together, so the software will know the orientation of the tool flange.

Replacing the Encoder Battery Pack

The data stored by the encoders is protected by a 3.6 V lithium backup battery pack located in the base of the robot.

CAUTION:Replace the battery pack only with a 3.6 V, 6.8 Ah lithium battery pack, Adept P/N 09977-000.

Battery Replacement Interval

If the robot is kept in storage and not in use, or if the robot is turned off (no 24 VDC supply) most of the time, then the battery pack should be replaced every 5 years.

If the robot is turned on, with 24 VDC supplied to the robot more than half the time, then you can increase the replacement interval to 10 years. If, for example, a robot is typically turned off only on weekends, the battery pack would need to be replaced every 10 years.

Battery Replacement Procedure

Obtain the replacement battery pack.

Switch off the optional SmartController EX, if one is being used.

Switch off the 24 VDC input supply to the robot.

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

Disconnect the 24 VDC supply cable from the robot +24 VDC input connector. See Robot Interface Panel on page 45 for locations of connectors.

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

Switch off and disconnect any other power supplies connected to the robot.

Remove the four M4 hex-head bolts holding the Status Display panel.

Retain the bolts for re-installation.

These bolts were installed with Loctite 222.

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Figure 6-2. Status Display Panel Face

Remove but do not disconnect the Status Display panel.

Retain the Status Display panel and gasket for re-installation.

NOTE:The battery pack is supported in a bracket that is attached to the back side of the Status Display panel with stand-offs. The battery pack is exposed when the Status Display panel is removed.

10.

The battery bracket assembly has two battery connectors. Locate the unused battery connector on the battery bracket. See the following figure.

CAUTION: If battery power is removed from the robot, factory calibration data may be lost, requiring robot recalibration by Adept personnel.

11.

Connect the new battery pack to the unused connector on the battery bracket, but do not disconnect the old battery pack yet. There is only one way to plug in the connector.

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Chapter 6: Maintenance

Cable Tie

Battery Pack

Diag Cable

Status Display Panel

Diag Cable Connector

Battery Bracket

Battery Cable

In-use Battery Connector

Unused Battery Connector

Figure 6-3. Battery Bracket on Status Display Panel

12.

Once the new battery pack is connected, you can disconnect and remove the old one. You will need to cut the cable tie holding the battery pack in the bracket.

NOTE:Dispose of the battery pack in accordance with all local and national environmental regulations regarding electronic components.

13.

Place the new battery pack in the battery bracket, and secure it and the “diag” cable, using a cable tie.

Fold any excess wiring (red and black) under the battery pack, so that it lies between the battery pack and the ‘V’ in the battery bracket.

The “diag” cable must be cable-tied to the bracket (and battery pack) to relieve strain on the Status Display connector.

NOTE:In the preceding figure, the diag cable has not yet been attached to the battery bracket.

14.

Re-install the Status Display panel with the four M4 bolts previously removed.

Apply Loctite 222 in each bolt hole, not on the bolts themselves.

Ensure that the Status Display panel gasket is in place between the panel and the robot body.

Torque the bolts to 1.1 N·m (10 in-lb).

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Omron Adept Hornet 565 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1: Introduction

1.1 Adept Hornet 565 Robots, Product Description

Adept eAIB Amplifier

Adept Hornet 565 Robot Base

Inner Arms

Ball Joints, Outer Arms

Platforms

Adept SmartController™ EX

1.2 Warnings, Cautions, and Notes in Manual

1.3 Safety Precautions

1.4 What to Do in an Emergency

1.5 Additional Safety Information

1.6 Intended Use of the Robots

1.7 Installation Overview

1.8 Manufacturer’s Declaration

1.9 How Can I Get Help?

Related Manuals

Adept Document Library

Chapter 2: Robot Installation

2.1 Transport and Storage

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking

Upon Unpacking

Unpacking

2.3 Repacking for Relocation

2.4 Environmental and Facility Requirements

2.5 Mounting Frame

Robot-to-Frame Considerations

Mounting

2.6 Mounting the Robot Base

Robot Orientation

Mounting Surfaces

Mounting Procedure

Install Mounting Hardware

2.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft

Aligning the Platform with the Base

Attaching the Outer Arms

Attaching the Theta Drive Shaft

2.8 End-Effectors

Attaching an End-Effector

Aligning an End-Effector

Grounding

Accessing Vacuum

Routing End-effector Lines

Chapter 3: System Installation

3.1 System Cables, eAIB Only (no SmartController EX)

List of Cables and Parts

Cable Installation Overview

Optional Cables

3.2 System Cables, with SmartController EX

Installing a SmartController EX Motion Controller

List of Cables and Parts

Cable Installation Overview

Less Common Cables

3.3 System Cables for Systems with Belt Encoders

List of Cables and Parts

Cable Installation Overview

3.4 Adept ACE Software

User-supplied PC

3.5 Robot Interface Panel

3.6 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Robot and Controller Power

Details for 24 VDC Mating Connector

Procedure for Creating 24 VDC Cable

Installing 24 VDC Robot Cable

3.7 Connecting 200-240 VAC Power to Robot

Specifications for AC Power

Details for AC Mating Connector

Procedure for Creating 200-240 VAC Cable

Installing AC Power Cable to Robot

3.8 Grounding the Adept Robot System

Grounding Robot-Mounted Equipment

Grounding Robot Base to Frame

3.9 Installing User-Supplied Safety Equipment

Emergency Stop Circuits

Remote Manual Mode