Page 1
Hornet 565 Robot
User’s Guide
I596-E-03
Page 2
Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, Inc., assumes no responsibility for any errors or omissions in the documentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us
in preparation of future documentation. Please submit your comments to: techpubs@adept.com.
Copyright 2015 - 2017 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America
Page 3
Revision History
Revision
code
01 June,
02 January,
03 July,
Date Revised Content
2016
2016
2017
Original release
Updated graphics with platform oriented correctly, showing current
drive shaft. Updated to OAT logo on status panel, front panel. Updated
safety chapter, minor changes to stopping distance graph section in
Technical Specifications. Fixed rotation of tool flange in Fig. 5-2, added
graphic for J4 alignment.
Updated drawing of tool flange to show 41.14 mm pilot bore that was
added since original release.
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Page 4
Page 5
Table of Contents
Chapter 1: Introduction 11
1.1 Hornet 565, Product Description
eAIB Amplifier 11
Hornet 565 Base 12
Inner Arms 12
Ball Joints, Outer Arms 13
Platforms 13
SmartController EX 15
1.2 Installation Overview
1.3 How Can I Get Help?
Corporate Addresses 17
Related Manuals 17
11
16
17
Chapter 2: Safety 19
2.1 Warnings, Cautions, and Precautions
2.2 What to Do in an Emergency/Abnormal Situation
Stopping the Robot 19
Fire Response 19
Entrapment and Brake Release Button 20
2.3 Safety Precautions
2.4 Robot Behavior
Hardstops 21
Limiting Devices 21
Singularities 21
2.5 Intended Use of the Robots
2.6 Additional Safety Information
Manufacturer’s Declaration of Incorporation 22
Robot Safety Guide 22
Emergency Stop Circuit and Buttons 22
Manual Control Pendant 22
19
19
20
21
21
21
Chapter 3: Robot Installation 23
3.1 Transport and Storage
3.2 Unpacking and Inspecting the Hornet 565
Before Unpacking 23
Upon Unpacking 23
Unpacking 23
3.3 Repacking for Relocation
3.4 Environmental and Facility Requirements
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23
23
25
25
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Table of Contents
3.5 Mounting Frame
Robot-to-Frame Considerations 26
Mounting 26
3.6 Mounting the Robot Base
Robot Orientation 27
Mounting Surfaces 27
Mounting Procedure 27
Install Mounting Hardware 28
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Aligning the Platform with the Base 29
Attaching the Outer Arms 30
Attaching the Theta Drive Shaft 34
3.8 Mounting the Front Panel
3.9 End-Effectors
Attaching an End-Effector 35
Aligning an End-Effector 35
Grounding 36
Accessing Vacuum 36
Routing End-effector Lines 36
25
27
29
35
35
Chapter 4: System Installation 39
4.1 System Cables, eAIB Only (no SmartController EX)
List of Cables and Parts 40
Cable Installation Overview 41
Optional Cables 42
4.2 System Cables, with SmartController EX
Installing a SmartController EX Motion Controller 43
List of Cables and Parts 44
Cable Installation Overview 45
Less Common Cables 45
4.3 System Cables for Systems with Belt Encoders
List of Cables and Parts 46
Cable Installation Overview 47
Pinouts for eAIB XBELT IO Adapter 48
4.4 ACE Software
User-supplied PC 49
Installing ACESoftware 49
4.5 Robot Interface Panel
4.6 Connecting 24 VDC Power to Robot
Specifications for 24 VDC Robot and Controller Power 51
Details for 24 VDC Mating Connector 51
Procedure for Creating 24 VDC Cable 52
Installing 24 VDC Robot Cable 52
4.7 Connecting 200-240 VAC Power to Robot
39
43
46
49
50
51
53
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Table of Contents
Specifications for AC Power 54
Details for AC Mating Connector 56
Procedure for Creating 200-240 VAC Cable 56
Installing AC Power Cable to Robot 57
4.8 Grounding the Hornet 565
Grounding Robot-Mounted Equipment 57
Grounding Robot Base to Frame 58
4.9 Installing User-Supplied Safety Equipment
Emergency Stop Circuits 63
Remote Manual Mode 65
User Manual/Auto Indication 65
User High Power On Indication 65
Remote High Power On/Off Control 65
High Power On/Off Lamp 66
Remote Front Panel or User-Supplied Control Panel Usage 66
Remote Pendant Usage 67
57
59
Chapter 5: System Operation 69
5.1 Robot Status Display Panel
5.2 Status Panel Fault Codes
5.3 Using the Brake-Release Button
Robot Brakes 70
Brake-Release Button 71
5.4 Optional Front Panel
5.5 Connecting Digital I/O to the System
I/O on the eAIB 74
I/O with an Optional SmartController EX 74
5.6 Using Digital I/O on eAIB XIO Connector
Optional I/O Products 78
XIO Input Signals 78
XIO Output Signals 80
XIO Breakout Cable 82
5.7 Starting the System for the First Time
Verifying Installation 84
Turning on Power and Starting ACE 85
Enabling High Power 86
Verifying E-Stop Functions 86
Aligning the Platform and J4 Motor 86
Verify Robot Motions 87
5.8 Robot Motions
Straight-line Motion 88
Containment Obstacles 88
5.9 Learning to Program the Hornet 565
69
70
70
72
74
76
84
88
88
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Table of Contents
Chapter 6: Options 89
6.1 Tall Frame Adapters
6.2 ePLC Connect
Configuration 90
Setting the Robot IP Address 90
Configuring the Omron PLC 92
Enabling High Power 92
6.3 SmartVision MX Industrial PC
6.4 SmartController EX Motion Controller
6.5 sDIO Module
6.6 IOBlox I/ODevice
6.7 eAIB XBELT IOAdapter Cable
6.8 Cable Inlet Box
Overview 93
Installation Procedure 94
6.9 Intelligent Force Sensor
6.10 Ball Stud Locks
Installing a Ball Stud Lock 100
Removing a Ball Stud Lock 101
89
90
92
92
92
92
92
93
99
99
Chapter 7: Maintenance 103
7.1 Cleaning
Water Shedding 103
Wash-Down 103
Chemical Compatibility 104
7.2 Periodic Maintenance Schedule
7.3 Checking Labels
Warning Labels 106
Informative Labels 107
7.4 Checking Safety Systems
7.5 Checking Robot Mounting Bolts
7.6 Checking for Gear Drive Oil Leakage
7.7 Checking Fan Operation
7.8 Theta Drive Shaft
Replacing the Drive Shaft Bushings 110
Removing the Drive Shaft 113
Installing a Drive Shaft 114
Aligning the Platform and J4 Motor 115
7.9 Replacing the Encoder Battery Pack
7.10 Non-Periodic Maintenance
7.11 Changing the Front Panel High-Power Indicator Lamp
103
104
106
107
108
108
109
110
115
118
118
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7.12 Replacing a Platform
7.13 Replacing a Ball Joint Insert
7.14 Replacing Outer Arm Spring Assemblies
7.15 Replacing the eAIB Chassis
Removing the eAIB Chassis 124
Installing a New eAIB Chassis 128
7.16 Commissioning a System with an eAIB
Safety Commissioning Utilities 129
E-Stop Configuration Utility 130
E-Stop Verification Utility 131
Teach Restrict Configuration Utility 131
Teach Restrict Verification Utility 132
120
120
120
124
128
Chapter 8: Technical Specifications 135
8.1 Dimension Drawings
8.2 Robot Specifications
8.3 Environmental Specifications
Operating 139
Shipping and Storage 139
8.4 Payload Specifications
Payload 140
Torque 140
8.5 Performance
Repeatability, Unidirectional 141
Cycle Times 141
Power Consumption 141
Stopping Time and Distance 142
Payload Mass vs. Acceleration 148
Payload Inertia vs. Acceleration 148
8.6 Robot Mounting Frame
135
139
139
140
141
149
Chapter 9: Environmental Concerns 155
9.1 Ambient Environment
9.2 Cleanroom Classification
9.3 Design Factors
Robot Base and Components 156
Inner Arms 156
Ball Joints 156
Outer Arms 156
Spring Assemblies 157
Platforms 157
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155
155
155
Page 10
Page 11
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
x3
Joint 2
Inner Arm
(Spring Assemblies
not shown)
1.1 Hornet 565, Product Description
The Hornet 565 is a three-arm parallel robot. The three identical arm 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 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
eAIB Amplifier
The Hornet 565 uses an eAIB amplifier. The robot is powered and controlled using the eAIB.
The amplifiers and full servo control for the Hornet 565 are contained in the eAIB, which is
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Chapter 1: Introduction
embedded in the base of the robot. The eAIB also provides the platform for running the eV+ OS
and language.
The eAIB features:
l
On-board digital I/O: 12 inputs, 8 outputs
l
Low EMI for use with noise-sensitive equipment
l
No external fan for quiet operation
l
8 kHz servo rate to deliver low positional errors and superior path following
l
Sine-wave commutation to lower cogging torque and improve path following
l
Digital feed-forward design to maximize efficiency, torque, and velocity
l
Temperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
l
Hardware-based E-Stop and Teach Restrict controls
For improved safety relative to European standards implemented in 2012.
Figure 1-2. eAIB
Hornet 565 Base
The Hornet 565 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.
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
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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
figure shows an inner arm from a Hornet 565. 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 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, a stainless steel theta drive shaft attaches to a U-joint 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)
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 29.
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Chapter 1: Introduction
Platform Shipping
l
The platform, outer arms, and theta drive shaft are removed.
l
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 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.
SmartController EX
The optional SmartController EXmotion 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. SmartController EX
Refer to the SmartController EX User’s Guide for SmartController specifications.
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1.2 Installation Overview
The system installation process is summarized in the following table. Also, refer to System
Installation on page 39.
NOTE:For dual-robot installations, see the Dual-Robot Configuration Procedure,
which is available in the Document Library.
Task to be Performed Reference Location
If purchased, mount the optional cable box. Options on page 89.
Mount the robot to a level, stable mounting frame. Mounting on page 26.
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
Chapter 1: Introduction
Table 1-1. Installation Overview
30.
page 34.
Install the Front Panel and Pendant, if purchased,
and ACE software.
Create a 24 VDC cable and connect it between the
robot and the user-supplied 24 VDC power supply.
Create a 200-240 VAC cable and connect it between
the robot and the facility AC power source.
Install user-supplied safety barriers in the workcell. Installing User-Supplied Safety
Connect digital I/O through the robot XIO connector. Using Digital I/O on eAIB XIO Con-
Start the system, including system operation testing. Starting the System for the First Time
Install optional equipment, including end-effectors,
user air and electrical lines, external equipment, etc.
System Cables, eAIB Only (no
SmartController EX) on page 39 and
ACE Software on page 49.
Procedure for Creating 24 VDC Cable
on page 52.
Connecting 200-240 VAC Power to
Robot on page 53.
Equipment on page 59.
nector on page 76.
on page 84.
Options on page 89.
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1.3 How Can I Get Help?
Refer to the corporate websites:
http://www.ia.omron.com
and
http://www.adept.com
Corporate Addresses
Omron Adept Technologies, Inc.
4550 Norris Canyon Road, Suite 150
San Ramon, CA 94583
USA
925 245-3400
Omron Corporate Headquarters
Shiokoji Horikawa, Shimogyo-ku, Kyoto 600-8530 Japan
Chapter 1: Introduction
TEL: 81-75-344-7000 FAX: 81-75-344-7001
Related Manuals
This manual covers the installation, operation, and maintenance of a Hornet 565 system.
There are additional manuals that cover programming the system and adding optional components. See the following table. These manuals are available on the software media shipped
with each system.
Table 1-2. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for our robots.
A printed copy of this guide ships with each robot.
ACE User’s Guide Describes the installation and use of ACE.
T20 Pendant User's Guide Describes the use of the optional T20 manual control pendant.
SmartController EX User’s
Guide
SmartVision MX User's
Guide
Contains complete information on the installation and operation of the optional SmartController EX and sDIO products.
Instructions for use of the optional SmartVision MX industrial
PC.
ePLC Connect 3 User’s Guide Describes the installation and use of the ePLC Connect 3 soft-
ware, for using a user-supplied PLC as controller.
IO Blox User’s Guide Describes the IOBlox product.
Dual-Robot Configuration
Procedure
Hornet 565 Robot User's Guide, 14608-000 Rev F
Contains cable diagrams and configuration procedures for a
dual-robot system.
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2.1 Warnings, Cautions, and Precautions
There are six levels of special alert notation used in our manuals. In descending order of
importance, they are:
DANGER: This indicates an imminently hazardous electrical situation which,
if not avoided, will result in death or serious injury.
DANGER: This indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING: This indicates a potentially hazardous electrical situation which,
if not avoided, could result in injury or major damage to the equipment.
WARNING: This indicates a potentially hazardous situation which, if not
avoided, could result in injury or major damage to the equipment.
Chapter 2: Safety
CAUTION: This indicates a situation which, if not avoided, could result in
damage to the equipment.
Precautions for Safe Use: This gives precautions on what to do and what not
to do to ensure safe product use.
2.2 What To Do in an Emergency/Abnormal Situation
Stopping the Robot
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.
Fire Response
If a fire occurs, use CO2to extinguish the fire.
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Entrapment and Brake Release Button
In case of entrapment of a person by the robot, or any other emergency or abnormal situation,
the robot can be manually moved to a safe state without high voltage electric power. Arms 1
through 3 are held by brakes, which can only be released with the brake release button. This
requires 24 V power to the robot.
DANGER: Hornet 565s are not collaborative robots. They require a dedicated
work area that will prevent personnel from coming into contact with them during operation.
2.3 Safety Precautions
DANGER: During maintenance, disconnect AC power from the robot, and
install a lock-out tag-out to prevent anyone from reconnecting power.
DANGER: A Hornet robot can cause serious injury or death, or damage to
itself and other equipment, if the following safety precautions are not observed:
Chapter 2: Safety
l
All personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot.
Figure 2-1. Read Manual and Impact Warning Labels
l
All personnel who design the robot system must read this guide, read the Robot Safety
Guide, and must comply with all local and national safety regulations for the location in
which the robot is installed.
l
The Hornet 565 must not be used for purposes other than described in Intended Use of
the Robots on page 21. Contact Customer Support 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.
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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2.4 Robot Behavior
Hardstops
If the Hornet 565 runs into one of its hardstops, the robot’s motion will stop completely, an
envelope error will be generated, and power to the robot motors will be cut off.
The robot cannot continue to move after hitting a hardstop until the error has been cleared.
The Hornet 565’s hardstops are capable of stopping the robot at any speed, load, and maximum or minimum extension.
Limiting Devices
There are no dynamic or electro-mechanical limiting devices provided by Omron Adept Technologies, Inc. The robot does not have safety-rated soft axis or space limiting.
However, the user can install their own safety rated (category 0 or 1) dynamic limiting devices
if needed, that comply with ISO10218-1, Clause 5.12.2.
Singularities
No singularities exist that cause a hazardous situation with a Hornet 565 robot.
Chapter 2: Safety
2.5 Intended Use of the Robots
DANGER: Hornet 565s are not collaborative robots. They require a dedicated
work area that will prevent personnel from coming into contact with them during operation.
The normal and intended use of these robots does not create hazards.
The Hornet 565 has been designed and constructed in accordance with the relevant requirements of IEC60204-1.
The Hornet 565 is intended for use in parts assembly and material handling for payloads up
to 3 kg (6.6 lb), or 8 kg (17.6 lb) with the fixed platform. See Robot Specifications on page 139
for complete information on the robot specifications. Refer to the Robot Safety Guide for details
on the intended use of our robots.
Hornet 565 robots are not intended for:
l
Use in the presence of ionizing or non-ionizing radiation
l
Use in potentially explosive atmospheres
l
Use in medical or life saving applications
l
Use in a residential setting. They are for industrial use only.
l
Use before performing a risk assessment
2.6 Additional Safety Information
We provide other sources for more safety information:
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Chapter 2: Safety
Manufacturer’s Declaration of Incorporation
This lists all standards with which the robot complies. The Manufacturer’s Declarations for
the Hornet 565 robot and other products are in the Manufacturer's Declarations Guide.
Robot Safety Guide
The Robot Safety Guide provides detailed information on safety for our robots. It also gives
resources for more information on relevant standards. It ships with each robot.
Emergency Stop Circuit and Buttons
The E-Stop provided complies with ISO 10218-1 (Clause 5.5.2), with stop category 1 (per IEC
60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d
per ISO 13849.
If you design your own front panel, it must meet the requirements of ISO13849, and be at least
PL-d. The E-Stop button must comply with IEC 60204-1 and ISO13850, Clause 5.5.2.
If you choose to use your own E-Stop buttons, they must meet the requirements of IEC 60204-1
and ISO 13850, Clause 5.5.2.
Manual Control Pendant
The protective stop category for the pendant enable switch is category 1, which complies with
the requirements of ISO 10218-1.
The pendant is designed in accordance with the requirements of IEC 60204-1 and ISO 13849.
The E-Stop button is ISO 13850.
NOTE:Omron Adept Technologies, Inc. does not offer a cableless
(wireless)pendant.
The manual control pendant can only move one robot at a time, even if multiple robots are
connected to a SmartController EX, and the pendant is connected to the SmartController EX.
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Chapter 3: Robot Installation
3.1 Transport and Storage
This equipment must be shipped and stored within the range –25 to +60° C (-13 to 140° F).
Humidity should be less than 75%, non-condensing. The robot should be shipped and stored
in the 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 Hornet 565 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).
3.2 Unpacking and Inspecting the Hornet 565
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.
l
If the items received do not match the packing slip, or are damaged, do not sign the
receipt. Contact your local Omron Support as soon as possible (see How Can I Get
Help? on page 17).
l
If the items received do not match your order, please contact your local Omron Support
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 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.
1.
Remove the Klimp®fasteners holding the top to the rest of the crate. See the following
figure.
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Chapter 3: Robot Installation
Figure 3-1. 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 U-joints
attached, but separate from the robot and platform.
2.
Lift the top off of the crate sides, and set it aside.
Figure 3-2. Crate, with Top Removed
3.
Remove all cardboard boxes from inside the crate. These will include the outer arms,
theta drive shaft, and platform.
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Chapter 3: Robot Installation
4.
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.
5.
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.
3.3 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.
3.4 Environmental and Facility Requirements
The Hornet 565 system installation must meet the operating environment requirements shown
in the following table.
Table 3-1. Robot System Operating Environment Requirements
Ambient temperature 1 to 40° C (34 to 104° F)
Humidity 5 to 90%, non-condensing
Altitude up to 1000 m
NOTE: See also Dimension Drawings on page 135
3.5 Mounting Frame
The design of the robot mounting frame is the user’s responsibility.
l
The flatness of the frame mounting tabs is critical. See Robot-to-Frame Considerations
(following) and Mounting Surfaces on page 27.
l
The frame must be stiff enough to prevent excessive vibration.
l
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.
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Chapter 3: Robot Installation
The Hornet 565 is designed to be mounted above the work area suspended on a user-supplied
frame. The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace.
While we do 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 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 137 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 Ydirections, (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 135 shows the mounting hole pattern for the Hornet 565. 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:We suggest 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 3: Robot Installation
3.6 Mounting the Robot Base
Robot Orientation
We recommend mounting the Hornet 565 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 135.
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 within 0.75mm 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 has three mounting pads. Each pad has one hole with an M12 x 1.75 springlock Heli-Coil®.
1.
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.
2.
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 3: Robot Installation
Mounting Pad
Lifting Slots
Figure 3-3. Two of Six Lifting Slots
3.
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.
4.
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.
5.
Follow the instructions in Install Mounting Hardware that follow.
Install Mounting Hardware
Because of the possible variability of the mounting frames, mounting hardware is user-supplied. 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.
NOTE:When mounting the robot, note the following:
l
Verify that the robot is mounted squarely before tightening the mounting bolts.
l
Insert the bolts through the holes in the frame and into the threaded holes in the robot
base mounting pads.
l
Ground the robot base to the mounting frame.
Refer to Grounding Robot Base to Frame on page 58.
l
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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Page 29
Chapter 3: 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
x3
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 108.
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Figure 3-4. Major Robot Components
The Hornet 565 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.
NOTE:The remainder of this section only applies to the J4 platform.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Chapter 3: 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.
WARNING: Incorrect alignment of the platform with the robot base will result
in incorrect robot performance and possible damage to the drive shaft.
Both the theta drive shaft attachment on the robot base and on 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 Joint 1 on the robot base, 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.
l
Each outer arm has a ball joint socket at each end.
l
The inner arms and the platform have corresponding pairs of ball studs.
Figure 3-5. J4 Platform Orientation, Top View
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 30 of 160
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Chapter 3: Robot Installation
Inner
Arm
Ball Joint
Socket
Ball Joint
Socket Insert
Outer Arm Springs
Spring
Horseshoe
Pressed Pin
Ball Joint Stud
Outer Arms
Figure 3-6. Inner Arm Ball Studs
WARNING: Pinch hazard. Ball joints are spring-loaded. Be careful not to
pinch your fingers.
l
Outer arm pairs are shipped assembled. Each pair has two springs and two horseshoes
at each end. See the following figure.
Figure 3-7. Ball Joint Assembly
CAUTION: Ensure that the bearing insert is in place in the end of each outer
arm.
NOTE:In the following steps, take care not to trap debris between the ball studs
and their sockets.
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Page 32
Chapter 3: Robot Installation
NOTE:The procedure for attaching outer arms is the same for both platforms.
1.
Attach one pair of outer arms to each inner arm.
a.
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.
b.
Slip one ball joint socket over the corresponding ball stud.
c.
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 3-8. Installing Ball Joints
2.
Attach one pair of outer arms to each of the three pairs of ball studs on the platform.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Chapter 3: Robot Installation
a.
Swing the bottom end of the outer arm pair to the right, as far as possible.
b.
Slip the right ball joint socket over the right ball stud. (Move the platform
as needed to do this.)
c.
Move the platform and outer arm pair to the left as you slip the left ball
joint socket over the corresponding ball stud.
3.
Ensure that all spring hooks are fully-seated in the grooves of the horseshoes, as shown
in the following figure:
Figure 3-9. Horseshoe and Spring Assembly
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Chapter 3: Robot Installation
Theta
Drive
Shaft
Set
Screw
U-Joint
J4 Shaft
(Motor or
Platform)
Upper U-Joint
at J4 Motor
Center Section
of Drive Shaft
CylinderSection
of Drive Shaft
Lower U-Joint
at J4 Platform
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.
l
Connect the upper U-joint to the drive shaft of the J4
motor. This will be the wider cylinder section.
The upper (J4 motor)end of the drive shaft is labeled
with a temporary label, indicating Top. Remove the
label before use.
l
Connect the lower 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 upsidedown 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:
1.
Slide 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 3-10. U-Joint
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Chapter 3: Robot Installation
10 - 15 mm
3 mm
2.
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.
l
Use Loctite 242.
l
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.
Figure 3-11. Short 3 mm Hex Key
NOTE:The platform and the J4 motor will have to be aligned after the ACE software is installed and the robot is powered-on. See Aligning the Platform and J4
Motor on page 86.
3.8 Mounting the Front Panel
The Front Panel must be installed outside of the workspace.
NOTE:European standards require that the remote High Power push-button be located outside of the workspace of the robot.
3.9 End-Effectors
The user is 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 137 for dimensions of the
tool flange.
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.
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Chapter 3: Robot Installation
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 57.
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 drill or tap the tool flange, as this would weaken it.
Routing End-effector Lines
End-effector lines (either vacuum/air lines or electrical wires) can be routed to the platform by:
l
Attaching them to the inner and outer arms, and then to the platform.
l
Routing them from the robot support frame to the outer arms.
l
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:
l
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.
l
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.
l
Verify that the platform can be fully-rotated at all positions without affecting or being
affected by the lines.
l
Verify that any service loop or excess line does not hang down below the end-effector at
any platform position.
l
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:
l
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.
l
Ensure that the lines (and retraction mechanism) do not apply significant force, in any
direction, to the platform.
l
Ensure that lines going to the robot base do not block your view of the status LED.
l
Ensure that lines going to the robot base do not interfere with the inner arm movement.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Page 37
User-added end-effector lines:
l
Should be checked for the entire work envelope being utilized. They must reach without
being pulled, and without impeding arm or platform movement.
l
Cannot pull against the platform with significant force. Robot performance will be
affected.
l
Must be considered as part of the payload, if they add weight to the platform or outer
arms.
l
Are the user’s responsibility for maintenance.
They are not covered in the Maintenance section of this manual.
Chapter 3: Robot Installation
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Page 38
Page 39
Chapter 4: System Installation
DC
IN
24 V
GND
AC
200 -
240 V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
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 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
2
3
4a
A
B
G
H
J
4a
4
4
1
5
6
7
9
8
L
M
Q
P
E
K
D
N
3
85 - 264 VAC
Universal
Input
DC
IN
24V
GND
AC
200 240V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
Ethernet to eAIB
FP Jumper Plug
F
Either Front Panel or
FP plug must be used
3a
2a
C
Ethernet from eAIB
to SmartVision MX
R
9b
9a
User-supplied
Switch
User-supplied
PLC Option
SmartVision MX (option)
R
S
7a
M
DC Power
Cable
Camera
(option)
T
10
4.1 System Cables, eAIB Only (no SmartController EX)
NOTE:See System Installation on page 39 for additional information on system
grounding.
Figure 4-1. System Cable Diagram, without SmartController EX (eAIB Only)
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Chapter 4: 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
SmartVisionMX
S Ethernet switch, cable for
SmartVision MX.
n/a n/a option,
user-supplied
T Camera and cable n/a n/a option
WARNING: The XUSR, XMCP, and XFP jumpers intentionally bypass safety
connections so you can test the system functionality during setup. Under no circumstances should you run a Hornet 565 system, in production mode, with all
three jumpers installed. This would leave the system with no E-Stops.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Chapter 4: 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 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
B
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 Hornet 565 on page
G
or
H
n/a
57.
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,
M
7a Connect 24 VDC and shield ground to SmartVision MX, if used. See SmartVi-
sion 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 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 E-Stop button and
to enable power to the robot. To operate without the standard Front Panel, the
user must supply equivalent circuits.
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Page 42
Optional Cables
NOTE:The following cables are not covered in the steps in the preceding table.
Part Description Notes
Chapter 4: 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 82.
Cables for adding belt encoders are covered in System Cables for Systems with Belt Encoders
on page 46.
Available as option
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Page 43
Chapter 4: System Installation
T20 Adapter
Cable
XMCP
Jumper
Plug
T20 Bypass
Plug
T20
Pendant
(option)
Either T20 Pendant,
T20 Bypass Plug, or
XMCP Jumper Plug
must be used
SmartVision MX (option)
Front
Panel
Cable
Front Panel (option)
FP
Jumper
Plug
Either Front Panel or
FP plug must be used
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
Universal
Input
DC
IN
24V
GND
AC
200 240V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
Ethernet to
SmartController EX
User-supplied Camera (option)
User-Supplied
Ground Wire
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
DC
IN
24 V
GND
AC
200 -
240 V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
D
A
E
3
1
6
8
P
9
Q
3
3a
F
C
2
2a
B
4a
4
4a
4
G
H
J
K
L
M
M
N
7
5
7
5b
5a
7a
10
10
1
S
R
P
8
4.2 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 SmartController EX User’s Guide for complete information on installing the optional
SmartController EX. This list summarizes the main steps.
Figure 4-2. System Cable Diagram with SmartController EX
1.
Mount the SmartController EX and optional front panel.
2.
Connect the optional front panel to the SmartController EX.
3.
Connect the optional pendant to the SmartController EX.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 43 of 160
Page 44
4.
Connect user-supplied 24 VDC power to the controller.
Instructions for creating the 24 VDC cable, and power specification, are covered in the
SmartController EX User’s Guide.
5.
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, SmartCon-
D Front Panel (option) or user-supplied
E Front Panel Cable or user-supplied
F Front Panel Jumper Plug standard,
Chapter 4: System Installation
troller EX
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
power supply/cable kit, P/N 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
SmartVisionMX
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.
WARNING: Under no circumstances should you run a Hornet 565 system, in
production mode, with all three jumpers installed. This would leave the system
with no E-Stops.
Hornet 565 Robot User's Guide, 14608-000 Rev F
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Page 45
Chapter 4: System Installation
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
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,H
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 the SmartController
EXUser's Guide for location.
5b Connect user-supplied ground to SmartVision MX, if used. See the SmartVision
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
9 Connect Ethernet cable to SmartVision MX, if used. Q
10 Connnect IEEE1394 cable between SmartController EXand eAIB SmartServo R
11 Connect optional camera and cable to SmartVision MX, if used. S
A, E
n/a
n/a
WARNING: A front panel must be installed to provide an E-Stop button and
to enable power to the robot. To operate without the standard Front Panel, the
user must supply equivalent circuits.
Less Common Cables
NOTE:The following cables are not covered in the steps in the preceding table.
Part Description Notes
XIO Breakout Cable, 12 inputs/8 outputs, 5 M Available as option
Y Cable, for XSYS cable connections to dual robots Available as option with
eAIB XBELT IO Adapter Cable Available as option
Hornet 565 Robot User's Guide, 14608-000 Rev F
SmartController EX
Page 45 of 160
Page 46
Chapter 4: System Installation
DC
IN
24 V
GND
AC
200 -
240 V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
XBELT IO
13463-000
HDB26
FEMALE
BELT
ENCODER
FORCE/
EXPIO
RS232
BELT ENC.
09443-000
DB15
FEMALE
12
RS-232
Force/EXPIO
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 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
2
3
4a
A
B
G
H
J
4a
4
4
1
5
6
7
8
L
M
Q
E
K
D
N
3
85 - 264 VAC
Universal
Input
DC
IN
24V
GND
AC
200 240V
Ø
1
XBELTIO
XIO
Servo
ENETENET
XSYSTEM
Ethernet to eAIB
FP Jumper Plug
F
Either Front Panel or
FP plug must be used
3a
2a
C
XBELTIO - Belt/Force/RS232
Belt Y-Splitter
to Belt Encoder 1
to Belt Encoder 2
Belt
U
V
11
10
8
The XIO Breakout cable is for using the I/O on the eAIB. See XIO Breakout Cable on page 82.
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.
4.3 System Cables for Systems with Belt Encoders
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 eAIBXBELT IO Adapter cable splits the eAIB XBELTIO port into a belt encoder
lead, an Intelligent Force Sensor or IOBlox lead, and an RS-232 lead.
Figure 4-3. System Cable Diagram with Belt Encoder Cables
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 46 of 160
Page 47
Chapter 4: System Installation
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.
4 Connect T20 adapter cable to eAIB XSYSTEM cable XMCP connector or J, K
B
D, E
A, E
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 Hornet 565 on page
57.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 47 of 160
G
or
H
n/a
Page 48
Chapter 4: System Installation
:NOITPIRCSED:OT :MORF
BEL
T ENC - PIN 15 HDB26 - PIN 2 B_ENC_A1+
BELT ENC - PIN 7 HDB26 - PIN 3 B_ENC_A1BELT
ENC - PIN 14 HDB26 - PIN 11 B_ENC_B1+
BELT
ENC - PIN 6 HDB26 - PIN 12 B_ENC_B1-
BELT
ENC - PIN 13 HDB26 - PIN 19 B_ENC_Z1+
BELT
ENC - PIN 5 HDB26 - PIN 20 B_ENC_Z1-
BEL
T ENC - PIN 11 HDB26 - PIN 4 B_ENC_A2+
BEL
T ENC - PIN 3 HDB26 - PIN 5 B_ENC_A2BELT ENC - PIN 10 HDB26 - PIN 13 B_ENC_B2+
BELT
ENC - PIN 2 HDB26 - PIN 14 B_ENC_B2-
BELT
ENC - PIN 9 HDB26 - PIN 21 B_ENC_Z2+
BELT
ENC - PIN 1 HDB26 - PIN 22 B_ENC_Z2-
BEL
T ENC - PIN 4 HDB26 - PIN 1 BELT_5V
BEL
T ENC - PIN 12 HDB26 - PIN 10 GND
BELT ENC - SHELL HDB26 - SHELL SHIELD
DXT_232SR52 NIP- 62BDH3 NIP- 232SR
DXR_232SR62 NIP- 62BDH2 NIP– 232S
R
DNG81 NIP- 62BDH 5 NIP– 232S
R
DLEIHSLLEHS– 62BDHLLEHS– 232SR
:NOITPIRCSED:62BD OIPXE OT:1PJ
+ KLC7 NIP- 62BDH5 NIP- 1PJ
- KLC8 NIP- 62BDH 4 NIP- 1PJ
V5_TLEB6 NIP- 62BDH6 NIP- 1P
J
DNG51 NIP- 62BDH1 NIP– 1PJ
+ATAD61 NIP- 62BDH3 NIP– 1PJ
-ATAD71 NIP- 62BDH 2 NIP– 1PJ
DLEIHSLLEHS- 62BDHLLEHS 9BD
Step Connection Part
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
Pinouts for eAIB XBELT IO Adapter
Belt Encoder
M
RS232
FORCE/EXPIO
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 48 of 160
Page 49
4.4 ACE Software
User-supplied PC
The user loads the 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.
Installing ACESoftware
The ACE disk will display a ReadMe file when inserted in your PC. This contains hardware
and software requirements for running ACE software.
You install ACE from the Software disk. ACE needs Microsoft .NET Framework. The ACE
Setup Wizard scans your PC for .NET, and installs it automatically if it is not already
installed.
1.
Insert the disk into the disk drive of your PC.
If Autoplay is enabled, the 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.
Chapter 4: System Installation
2.
Especially if you are upgrading your ACE software installation: from the ACE software
disk menu, click Read Important Information.
3.
From the ACE software disk menu, select:
Install the ACE Software
The ACE Setup wizard opens.
4.
Follow the online instructions as you step through the installation process.
5.
When the installation is complete, click Finish.
6.
After closing the ACE Setup wizard, click Exit on the disk menu to close the menu.
NOTE:You will have to restart the PC after installing ACE software.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 49 of 160
Page 50
4.5 Robot Interface Panel
Chapter 4: System Installation
Figure 4-4. 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 mat-
ing 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 76. That section also contains details on
how to access these I/O signals via eV+.
XBELTIO — adds a belt encoder, EXPIO, (which supports either IOBLOX 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 arm.
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.
ENET - Two Ethernet ports are available. One will be needed to connect to a PC running ACE
software.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 50 of 160
Page 51
Chapter 4: System Installation
4.6 Connecting 24 VDC Power to Robot
Specifications for 24 VDC Robot and Controller Power
Table 4-1. VDC User-Supplied Power Supply
User-Supplied Power Supply 24 VDC (± 10%), 150 W (6 A)
(21.6 V< Vin< 26.4 V)
Circuit Protection
a
Output must be < 300 W peak, or
8 Amp in-line fuse
Power Cabling 1.5 – 1.85 mm² (16-14 AWG)
Shield Termination Braided shield connected to ground at
both ends of cable. See User-Supplied 24
VDC Cable on page 53.
a
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.)
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. We recommend 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 4-2. Recommended 24 VDC Power Supply
Vendor Name Model Ratings
Mount
OMRON S8JX-G15024C 24 VDC, 6.5 A, 150 W Front Mount
OMRON S8JX-G15024CD 24 VDC, 6.5 A, 150 W DIN-Rail Mount
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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 51 of 160
Page 52
Chapter 4: System Installation
Table 4-3. 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 40.
1.
Locate the connector and pins shown in the preceding table.
2.
Use 14-16 AWG wire to create the 24 VDC cable. Select the wire length to safely reach
from the user-supplied 24 VDC power supply to the robot base.
NOTE:Separate 24 VDC cables are required for the optional SmartController EX
and SmartVision MX. Those cables use different styles of connectors. See the
SmartController EX User’s Guide and the SmartVision MX User’s Guide.
3.
Crimp the pins onto the wires using the crimping tool.
4.
Insert the pins into the connector. Confirm that the 24 VDC and ground wires are in the
correct terminals in the plug.
5.
Prepare the other end of the cable for connection to your 24VDC power supply.
Installing 24 VDC Robot Cable
1.
Connect one end of the shielded 24 VDC cable to the user-supplied 24 VDC power supply. See the following figure.
l
The cable shield should be connected to frame ground on the power supply.
l
Do not turn on the 24 VDC power yet. See System Operation on page 69.
2.
Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the
interface panel of the eAIB, which is on top of the robot.
3.
Connect the cable shield to the ground point on the interface panel.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 52 of 160
Page 53
Chapter 4: System Installation
–
+
24 V, 6 A
Frame Ground
24 V, 5 A
–
+
User-Supplied
Power Supply
24 VDC
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
+
4.7 Connecting 200-240 VAC Power to Robot
Figure 4-5. User-Supplied 24 VDC Cable
NOTE:We recommend that DC power be delivered over a shielded cable, with the
shield connected to ground at both ends of the cable.
WARNING: Appropriately-sized branch circuit protection and lockout/tagout
capability must be provided in accordance with the National Electrical Code
and any local codes.
Ensure compliance with all local and national safety and electrical codes for
the installation and operation of the robot system.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 53 of 160
Page 54
Chapter 4: System Installation
Specifications for AC Power
Table 4-4. 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
a
Maximum
Operating
Voltage
Frequency/
Phasing
External Circuit
Breaker,
User-Supplied
10 Amps
1-phase
a
Specifications are established at nominal line voltage. Low line voltage can affect
robot performance.
NOTE:The Hornet 565 robot 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 Lineto-Neutral or Line-to-Line.
WARNING: Hornet 565 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 Robot Safety Guide. During installation, unauthorized third
parties must be prevented, through the use of fail-safe lockout measures, from
turning on power. This is mandated by Clause 5.2.4 of the ISO 10218-1.
Failure to use appropriate power (less than or more than the rated voltage
range of 200-240 VAC) can lead to malfunction or failures of the robot or hazardous situations.
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 IEC1131-2, the following
information may be helpful. IEC 1131-2 requires that the installation must ensure that
CategoryII 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 CategoryII, 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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 54 of 160
Page 55
AC Power Diagrams
EENNL
L
F1 10 A
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
L1
L2
F5 10 A
F4 10 A
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
Figure 4-6. Typical AC Power Installation with Single-Phase Supply
Chapter 4: System Installation
Figure 4-7. Single-Phase Load across L1 and L2 of a Three-Phase Supply
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 55 of 160
Page 56
Chapter 4: System Installation
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 4-5. 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 40.
Procedure for Creating 200-240 VAC Cable
1.
Locate the AC mating connector shown in AC Mating Connector Details on page 56.
2.
Open the connector by unscrewing the screw on the shell and removing the cover.
3.
Loosen the two screws on the cable clamp. See AC Power Mating Connector on page 57.
4.
Use 18 AWG wire to create the AC power cable. Select the wire length to safely reach
from the user-supplied AC power source to the robot base.
5.
Strip 18 to 24 mm insulation from each of the three wires.
6.
Insert the wires into the connector through the removable bushing.
7.
Connect each wire to the correct terminal screw and tighten the screw firmly.
8.
Tighten the screws on the cable clamp.
9.
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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 56 of 160
Page 57
Chapter 4: System Installation
Figure 4-8. AC Power Mating Connector
Installing AC Power Cable to Robot
1.
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 55 and SinglePhase Load across L1 and L2 of a Three-Phase Supply on page 55.
2.
Plug the AC connector into the AC power connector on the interface panel on the robot.
3.
Secure the AC connector with the locking latch.
4.8 Grounding the Hornet 565
Proper grounding is essential for safe and reliable robot operation.
NOTE:The resistance of the ground conductor must be ≤ 10 Ω.
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 endeffector 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 60VDC.
If there will be hazardous voltages present at the tool flange or end-effector, you must:
l
Connect the mounting frame to protective earth ground.
l
Ground the robot base to the mounting frame.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 57 of 160
Page 58
Chapter 4: System Installation
The eAIB is grounded to the robot base through a conductive gasket.
l
Ground the end-effector to the 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.
l
Use any of the three M12 mounting screws for this connection.
Each of the mounting points is labeled as a ground:
Figure 4-9. Ground Label
Screws must be stainless or zinc-plated steel.
l
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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 58 of 160
Page 59
Chapter 4: 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
4.9 Installing User-Supplied Safety Equipment
Figure 4-10. 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 Robot
Safety Guide for a discussion of safety issues.
Refer to the SmartController EX User's Guide for information on connecting safety equipment
into the system through the XUSR connector on the optional SmartController, details 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 4-7. for the
XFP pin-out descriptions. See the figure E-Stop Circuit on XUSR and XFP Connectors on page
62 for the XUSR wiring diagram.
Table 4-6. 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
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 59 of 160
Page 60
Chapter 4: System Installation
Pin
Pairs
Description Comments
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 the Hornet 565 System
7, 20 E-Stop indication CH 1 Contacts are closed when Front Panel,
pendant, and customer E-Stops are not
8, 21 E-Stop indication CH 2 (same as pins
tripped
7, 20)
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
Table 4-7. 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
1.
Optional - jumper closed for Auto
Mode-only operation
Manual = Open Automatic = Closed
4, 12 Remote Manual/Automatic switch CH
2.
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 Supplied 5 VDC and GND for High
Power On/Off Switch Lamp
Hornet 565 Robot User's Guide, 14608-000 Rev F
Page 60 of 160
User must supply lamp, or use 1 W,
47 ohm resistor - system will not oper-
Page 61
Chapter 4: System Installation
Pin 1
Pin 8
Pin 9
Pin 15
XFP
Pin
Pairs
Description Requirements for User-Supplied
Front Panel
ate if not present
a
7, 15
Controller system 5 V power on LED, 5
Optional - indicator only
V, 20mA
8 No connection
See the figure Front Panel Schematic on page 63 for a schematic diagram of the Front Panel.
a
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 a factory Front
Panel. If you provide a substitute front panel, this could void UL compliance.
Table 4-8. 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
39 for a description of the functionality of this circuit.
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Chapter 4: 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 4-11. E-Stop Circuit on XUSR and XFP Connectors
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Chapter 4: System Installation
ESTOPSRC
24 VS
5 VD
D
SYSPWRLT 7
6
5
4
2
3
1
17
16
8
10
9
11
12
13
14
15
XFP
15PDSUBM
MANUALSRC1
HIPWRREQ
MANUALRLY2
MANUALRLY1
HIPWRLT
ESTOPFP2
ESTOPFP1
HPLT5V
NC
MANUALSRC2
"MANUAL/AUTO""System Power LED"
MANUALSRC1
SW1
MANUALRLY2
MANUALRLY1
MANUALSRC2
24 VS
"HIGH POWER ON/OFF"
SWL1
HIPWRREQ
HPLT5 V
HIPWRLT
D
ESTOPSRC
"EMERGENCY STOP"
SW2
ESTOPFP2
ESTOPFP1
5 VD
D
2-PIN_MINI
SYSPWRLT
Front Panel Schematic
Figure 4-12. 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 4-11.
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
User E-Stop Indication Contacts - Remote Sensing of E-Stop
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.
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.
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Chapter 4: System Installation
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
ENABLE, or the Muted Safety gate. If you have a specific need in this area, contact
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 30VAC 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 ENISO 13849 operation (see Figure 4-11. and the
table System Installation on page 39 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 62 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
Robot Safety Guide), wearing safety equipment and carrying a 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
39).
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 4: System Installation
Remote Manual Mode
The optional Front Panel provides for a Manual Mode circuit. See Remote High Power On/Off
Control on page 65 for further details about the customer Remote Manual Mode circuitry.
The 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 Front Panel may be required.
See Front Panel Schematic on page 63. In this situation, a pair of contacts should be wired in
series with the Front Panel Manual/Automatic mode contacts. Thus, both the 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 standard 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.
WARNING: Any safeguards that were suspended must be returned to full
functionality prior to selecting Automatic Mode.
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 39), 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 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 63) for details of the Front Panel’s wiring. In
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Chapter 4: System Installation
this situation, a second momentary contact for high power on/off would be placed in 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 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 Front Panel High-Power Indicator Lamp on page 118 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 63 for a schematic drawing of the Front Panel, and see the
table System Installation on page 39 for a summary of connections and pin numbers.
NOTE:The system was evaluated by Underwriters Laboratory with a factory-supplied 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 Front Panel in a remote location.
The extension cable must conform to the following specifications:
l
Wire Size: must be larger than 26 AWG.
l
Connectors: must be 15-pin, standard D-sub male and female.
l
Maximum cable length is 10 meters.
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Chapter 4: System Installation
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:
l
Wire Size: must be larger than 26 AWG.
l
Connectors: must be 15-pin, standard D-sub male and female.
l
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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Chapter 5: System Operation
5.1 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 5-1. Robot Status Display Panel
Table 5-1. 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
1
See Status Panel Fault Codes on page 70.
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2-Digit Status
Panel Display
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Description
1
1
Page 70
Chapter 5: System Operation
5.2 Status Panel Fault Codes
The Status Display, shown in Robot Status Display Panel on page 69, 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 nofault 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 5-2. 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 #)
See Major Robot Components on page 11 for Joint # locations.
5.3 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.
This braking system does not prevent you from moving the robot manually, once the robot has
stopped (and high power has been disabled).
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Chapter 5: System Operation
BrakeRelease
Button
Status Display
Panel
Joint 1
Joint 2
Joint 3,
Ball Joints
Status LED/
High-power
Lamp
Inner Arm
Motor Plug
Joint 4 Cover
Robot Base
Robot Base
Cover
Mounting Pad x3
Tool Flange
J4 Platform and
Ball Joints
Theta
Drive
Shaft
Outer Arms
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.
Figure 5-2. 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.
WARNING: 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.
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 ACE software. The parameter is
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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.
If an alternate (user-supplied) brake release button is used, ensure that the brake release button
displays a warning similar to the preceding WARNING. This is to comply with ISO 10218-1,
Clause 5.13.
5.4 Optional Front Panel
NOTE:The factory-supplied Front Panel E-Stop is designed in accordance with the
requirements of IEC 60204-1 and ISO 13849.
WARNING: Any user-supplied front panel E-Stop must be designed in accordance with the requirements of IEC 60204-1 and ISO 13849. The push button of
the E-Stop must comply with ISO 13850 (Clause 5.5.2).
Chapter 5: System Operation
Figure 5-3. Front Panel
1.
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 eAIBXSYSTEM cable.
2.
System 5 V Power-On LED
Indicates whether or not power is connected to the robot.
3.
Manual/Automatic Mode Switch
Switches between Manual and Automatic mode. In Automatic mode, executing programs control the robot, and the robot can run at full speed. In Manual mode, the system limits robot speed and torque so that an operator can safely work in the cell.
Manual mode initiates software restrictions on robot speed, commanding no more than
250 mm/sec.
There is no high speed mode in manual mode.
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Chapter 5: System Operation
WARNING: If an operator is going to be in the work cell in manual
mode, it is strongly recommended that the operator carry an enabling
device. The Enable button on the manual control pendant is such a
device.
WARNING: Whenever possible, manual mode operations should be
performed with all personnel outside the workspace.
4.
High Power On/Off Switch and Lamp
Controls high power, which is the flow of current to the robot motors. Enabling high
power is a two-step process. An “Enable Power” request must be sent from the user-supplied PC, an executing program, or the 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.
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.
WARNING: Disabling the High Power button violates IEC 60204-1. It is
strongly recommended that you not alter the use of the High Power button.
5.
Emergency Stop Switch
The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements. Pressing this button turns off high power to the robot motors.
NOTE:A Front Panel or equivalent circuits must be installed to be able to Enable
Power to the robot. To operate without the standard Front Panel, the user must supply the equivalent circuits.
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Chapter 5: System Operation
5.5 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 5-3. Digital I/O Connection Options
Product I/O Capacity For more details
XIO Connector on eAIB 12 inputs
8 outputs
IOBlox, using
optional eAIB XBELT IO Adapter
Cable
12 inputs
8 outputs
see Using Digital I/O on eAIB
XIO Connector on page 76
IO Blox User’s Guide
I/O with an Optional SmartController EX
Table 5-4. 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 SmartController EX
User’s Guide
see the SmartController EX
User’s Guide
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Chapter 5: System Operation
Optional
IO Blox
Device
IO Blox #1
8 Input signals: 1113 to 1120
8 Output signals: 0105 to 0112
eAIB XBELTIO
Adapter Cable
RS-232
XBELT
EXPIO
DC
IN
24 V
GND
AC
200 240 V
Ø
1
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
Figure 5-4. Connecting Digital I/O to the System
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Chapter 5: System Operation
Table 5-5. 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
Outputs 0065 - 0096
Robot 1 XIO connector Inputs 1097 - 1108
Outputs 0097 - 0104
For Dual Robot systems, see the Dual-Robot Configuration Procedure.
5.6 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.
l
12 Inputs, signals 1097 to 1108
l
8 Outputs, signals 0097 to 0104
Brake Release and LED Light
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Chapter 5: System Operation
Pin 1
Pin 9
Pin 10
Pin 18
Pin 26
Pin 19
Table 5-6. 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
XIO 26-pin female
connector on Robot
Interface Panel
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Chapter 5: System Operation
Table 5-7. 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:
l
XIO Breakout Cable, 5 meters long, with flying leads on user’s end. See XIO Breakout
Cable on page 82 for information. This cable is not compatible with the XIO Termination Block.
Pin Locations
l
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 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 5-6. ), or
through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.
For REACTI programming, high-speed interrupts, or vision triggers:
l
With a SmartController EX, you can only use the EX XDIO inputs.
l
With a Hornet robot without a SmartController EX, you can only use the XIO inputs.
See the eV+ Language User’s Guide for information on digital I/O programming.
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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
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
Chapter 5: System Operation
Table 5-8. XIO Input Specifications
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
Factory-Supplied Equipment
User-Supplied Equipment
Signal 1097
Part Present Sensor
4
Signal 1098
Feeder Empty Sensor
5
Signal 1099
Part Jammed Sensor
6
Signal 1100
Sealant Ready Sensor
7
Signal 1101
8
Signal 1102
+24V
GND
9
Bank 1
Common
Bank 2
Common
3
2
1
Signal 1103
13
Signal 1104
14
Signal 1105
15
Signal 1106
16
Signal 1107
17
Signal 1108
18
12
GND
10
+24V
11
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 5: 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
the driver IC turns off and back on automatically to reduce the temperature of the IC. The
Figure 5-5. 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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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 77), or through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.
XIO Output Specifications
Table 5-9. XIO Output Circuit Specifications
Parameter Value
Power supply voltage range See System Installation on page 39.
Operational current range,
I
≤ 700 mA
out
per channel
Total Current Limitation,
I
≤ 1.0 A @ 40° C ambient
total
all channels on
I
≤ 1.5 A @ 25° C ambient
total
ON-state resistance (I
Output leakage current I
= 0.5 A) Ron≤ 0.32 Ω @ 85° C
out
≤ 25 µA
out
Turn-on response time 125 µsec max., 80 µsec typical (hard-
ware only)
Turn-off response time 60 µsec. max., 28 µsec typical (hard-
ware only)
Output voltage at inductive load turnoff (I
out
= 0.5 A,
(+V - 65) ≤V
demag
≤ (+V - 45)
Load = 1 mH)
DC short circuit current limit 0.7 A ≤ I
LIM
≤ 2.5 A
Peak short circuit current I
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ovpk
≤ 4 A
Page 82
Chapter 5: System Operation
M
Factory-Supplied Equipment User-Supplied Equipment
Outputs 1-8
Typical User Loads
XIO Connector – 26-Pin Female D-Sub
+24 VDC
19
Signal 0097
20
Signal 0098
21
Signal 0099
22
Signal 0100
23
Signal 0101
24
Signal 0102
25
Signal 0103
26
Signal 0104
GND
GND
Load
1
Customer
AC Power
Supply
10
M
Load
Load
L
N
(equivalent
circuit)
Wiring
Terminal
Block
Typical Output Wiring Example
Figure 5-6. 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.
Hornet 565 Robot User's Guide, 14608-000 Rev F
Figure 5-7. Optional XIO Breakout Cable
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Chapter 5: System Operation
Pin 9
Pin 1
Pin 18
Pin 10
Pin 19
Pin 26
Table 5-10. 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 5: System Operation
5.7 Starting the System for the First Time
Follow the steps in this section to safely bring up your robot system. The tasks include:
l
Verifying installation, to confirm that all tasks have been performed correctly
l
Starting up the system by turning on power for the first time
l
Verifying that all E-Stops in the system function correctly
l
Moving the robot with the pendant (if purchased), to confirm that it 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
l
Verify that the robot is level and that all fasteners are properly installed and tightened.
l
Verify that any platform tooling is properly installed.
l
Verify that the platform has been aligned with the J4 motor (J4 version only).
l
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.
l
Front Panel to the XSYSTEM on the eAIB, or
XFP port on a SmartController EX.
l
Pendant to the XSYSTEM on the eAIB, or
XMCP port on a SmartController EX, or a loop-back dongle installed.
l
XUSR to the XSYSTEM on the eAIB, or
XUSR port on a SmartController EX,
or XUSR jumper installed.
l
User-supplied 200/240 VAC power to the robot 200/240 VAC connector.
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l
User-supplied 24 VDC power to the robot 24 VDC connector.
l
Ethernet cable from PLC (if used) to eAIB or SmartController EX (if used)
If you are using an optional SmartController EX:
l
User-supplied 24 VDC power connected to the SmartController.
l
User-supplied ground wire installed between the SmartController and ground.
l
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.
l
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 39.
l
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 ACE
After the system installation has been verified, you are ready to turn on AC and DC power to
the system and start up ACE.
1.
Turn on the 200-240 VAC power. See System Installation on page 39.
WARNING: Make sure personnel are skilled and instructed—refer to
the Robot Safety Guide.
2.
Turn on the 24 VDC power to the robot. See System Installation on page 39. The Status
Panel displays OK. The Robot Status LED will be off.
3.
If you have a standard Front Panel, verify the Auto/Manual switch on the Front Panel is
set to Auto Mode.
4.
Turn on the user-supplied PC and start the ACE software.
l
Double-click the ACE icon on your Windows desktop,
or
l
From the Windows Start menu bar, select:
Start > Programs > Omron > ACE <major>.<minor>
5.
On the ACE Getting Started screen:
l
Select Create New Workspace for Selected Controller
to make the connection to the controller.
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Chapter 5: System Operation
l
Select the IP address of the controller you wish to connect to, or manually type in
the IP address.
6.
Click OK. You will see the message “Working, please wait”.
Enabling High Power
NOTE:If you are controlling the robot with a PLC, see Options on page 89.
After you have started the ACE software and connected to the controller, enable high power to
the robot motors:
1. From the ACE main menu, click the Enable High Power icon:
2.
If the High Power button on the Front Panel is blinking, press and release it.
The optional Front Panel is shown in Optional Front Panel on page 72. (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.
WARNING: Disabling the High Power button violates IEC 60204-1. It is
strongly recommended that you not alter the use of the High Power button.
This step turns on high power to the robot motors and calibrates the robot.
l
The Robot Status LED glows amber.
l
The code on the Robot Diagnostic Panel displays ON (see Robot Status Display Panel on page 69).
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.
1.
Within the ACE software, open the Hornet565 robot object.
2.
In the Configure tab, click Adjust J4 Zero.
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Chapter 5: System Operation
This will launch a utility for aligning the theta drive shaft.
3.
Follow the instructions in the utility.
Figure 5-8. Aligning Pinhole with Joint 1
Contact your local Omron Support for more information on this procedure.
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 T20 Pendant
User’s Guide for complete instructions on using the pendant.
The Hornet 565 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.
l
If one joint must be moved separately, release the brakes (while supporting the platform) and move the joint manually.
l
If the optional pendant is not installed in the system, you can move the robot using the
Robot Jog Control in the ACE software. For details, see the ACE User’s Guide.
Verify that the Teach Restrict speed limitation is working correctly by running the Teach
Restrict verification procedure. Refer to the Teach Restrict Verification Utility on page 132.
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Chapter 5: System Operation
5.8 Robot Motions
Straight-line Motion
Joint-interpolated motion is not possible with the Hornet 565, 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, 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 136 and Technical Specifications on page 135. Other
obstacles can be defined within this obstacle.
5.9 Learning to Program the Hornet 565
To learn how to use and program the robot, see the ACE User’s Guide, which provides information on robot configuration, control and programming through the ACE software “point and
click” user interface.
For eV+ programming information, refer to the eV+ user and reference guides.
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Chapter 6: Options
This section covers options that are available to enhance the Hornet 565. The options available
are:
l
Tall Frame Mounting Adapters
For mounting the Hornet 565 in a taller (competitor’s) frame.
l
ePLC Connect
For using a user-supplied PLC to program the robot’s motions.
l
SmartVision MX industrial PC
To add vision-processing power and connectivity to the robot.
l
SmartController EX motion controller
To increase connectivity, I/O, conveyor tracking and general processing speed for the
Hornet 565.
l
sDIOModule
Add 32 inputs and 32 outputs, up to 4 sDIOmodules per system.
l
IOBlox I/ODevices
Add 8 inputs and 8 outputs, up to 4 IOBlox devices per system.
l
eAIBXBELTIOAdapter cable
Splits the EXPIO port into a belt encoder lead, a RS-232 lead, and a lead for either
IOBlox or an Intelligent Force Sense System.
l
Inlet Cable Box
To increase the overall robot’s IP rating to IP65.
l
Intelligent Force Sense System
Allows quick detection of forces in six dimensions at the gripper.
l
Ball Stud Locks
To ensure that ball joints do not separate under extreme use.
6.1 Tall Frame Adapters
The Hornet 565 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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6.2 ePLC Connect
The Hornet 565 can use a user-supplied PLC, with the ePLC Connect software, to control the
robot motions.
Refer to ePLC Connect 3 User’s Guide.
Hornet 565s that use a PLC, but do not use a SmartController EX, rely on the user-supplied
PLC for all digital I/O.
Configuration
The user-supplied PLC and Hornet 565 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 ACE software installation completely.
Chapter 6: Options
Setting the Robot IP Address
Configure the IP address of the Hornet 565 using ACE software.
1.
Connect the PC and the robot, either through a shared network or with an Ethernet
cable between them.
2.
Start the ACE software. Refer to ACE Software on page 49.
3.
Click the Detect and Configure button, circled in red in the following figure.
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Chapter 6: Options
Figure 6-1. 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 6-2. IP Addresses Detected
4.
You can change the IP address and subnet mask in the Desired Address and Desired
Subnet fields, if needed.
5.
Click OK. The ACE software will ask you to wait for the controller to reboot.
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Chapter 6: Options
Configuring the Omron PLC
Refer to the EtherNet/IP Connection Guide (P649-E1-01) for configuring the Omron PLC to
work with Omron Adept robots. Refer to Resources on Omron Web Sites on page 3.
Using your PLC software, set the IP address for the PLC to connect to on the robot.
Enabling High Power
The details of enabling high power to the robot are covered in the EtherNet/IP Connection
Guide (P649-E1-01).
Once high power is enabled, the Robot Status Panel displays ON, and the amber Robot Status
LED is on.
6.3 SmartVision MX Industrial PC
The SmartVision MX is a Windows®7 Embedded industrial PC designed to run the ACE software. It is compatible with the Hornet 565, with or without the SmartController EX motion controller.
For inspection applications, the SmartVision MX industrial PC is designed to be a “plug-andplay” vision system. Using a USB or GigE camera, along with the ACESight 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 the SmartVision MX User's Guide.
6.4 SmartController EX Motion Controller
The optional SmartController EXmotion 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 the SmartController EX User’s Guide.
6.5 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.
6.6 IOBlox I/ODevice
Adds 8 inputs and 8 outputs per device. Up to 4 devices can be used. Requires the eAIB
XBELT IO Adapter cable.
6.7 eAIB XBELT IOAdapter Cable
Splits the EXPIO port into a belt encoder lead, one RS-232 lead, and one lead for either IOBlox
or Intelligent Force Sense System.
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The belt encoder lead can be split into two belt encoder leads with the belt encoder Y-adapter.
185
(Mounting Surface)
Cable Exit from Rear of Box
See System Cable Diagram with Belt Encoder Cables on page 46.
6.8 Cable Inlet Box
The addition of the cable inlet box raises the entire robot’s IP rating to IP65.
Chapter 6: Options
Figure 6-3. Cable Inlet Box Mounted on a Hornet 565
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.
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Components
l
Cable harness
l
eAIB Cable Seal Housing, 2 gaskets, 4 screws (Cable Seal Housing (left), Installed (right,
AIB shown) on page 95)
l
Cable Entry Top Cover assembly, screw (Cable Entry Top Cover Assembly on page 95)
This includes the Roxtec CF 8 frame
l
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 96.
l
Roxtec grease, used to assemble and seal the modules (Greasing a Roxtec Module on
page 96).
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 95.
Chapter 6: Options
Tasks
Measure and mark cables to establish service length.
1.
Install eAIB cable inlet box.
2.
Adapt Roxtec modules to fit cables.
3.
Install cables through cable entry top cover assembly.
4.
Attach cables to eAIB.
5.
Attach cable entry top cover to eAIB cable inlet box.
Installation Procedure
1.
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 97.
2.
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.
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Chapter 6: Options
Figure 6-4. Cable Seal Housing (left), Installed (right, AIB shown)
Figure 6-5. Cable Entry Top Cover Assembly
Figure 6-6. Bottom of Cable Entry Top Cover, CF Frame
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Chapter 6: Options
3.
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.
Figure 6-7. Adapting a Module to the Cable Size, Checking the Gap
4.
Grease the Roxtec modules, using Roxtec grease. See the following figure.
Figure 6-8. Greasing a Roxtec Module
5.
Grease the inside of the CF frame, where the modules will touch, using Roxtec grease.
6.
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 6-11.
Figure 6-9. Installing Roxtec Modules into the Frame
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Chapter 6: Options
7.
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 6-10. Tightening the Compression Unit
Figure 6-11. Cable Entry Assembly with Cables
8.
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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Chapter 6: Options
Figure 6-12. Ground Lug Attachment
9.
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.
l
Slide the top cover over the seal housing lip, as shown in the following figure.
l
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.
l
Lower the top cover onto the seal housing, and secure with one screw.
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Chapter 6: Options
Figure 6-13. Installing Cable Entry Top Cover Assembly
6.9 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 threshold is passed. Requires the eAIB XBELT IO Adapter cable.
Refer to Intelligent Force Sensing System User’s Guide.
6.10 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 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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Chapter 6: Options
Figure 6-14. Ball Stud Locks
Figure 6-15. 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.
1.
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.
2.
Twist the ball stud lock back-and-forth slightly, after installation, to ensure that it is
fully seated.
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