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AdeptOne-MV/AdeptThree-MV Robot Instruction Handbook

1. Figure 3 1 Components a Category 3 E Stop System 72 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Overview of Safety System Introduction The Emergency Stop system on this type of Adept robot has several components see Figure 3 1 The most important component is the Security Panel because it controls the Category 3 E Stop system It works together with the AUTO MANUAL operating mode keyswitch on the external Front Panel It is important to understand the interconnections between the Security Panel and the other Adept parts EH E Control Rail X1 e T Category 3 E Stop Board Teach Restrict Interface Board Powe
2. Controller Power Chassis ae ea z aff A anl Ano 7 Adept Robot elit m 4 Ule a Arm Power Cable Front Panel SIO DIO to Cat3 E Stop Cable Cable Force connector not used Ej User Connector adaf Q User to E Stop RUNNING PENDANT ioca NETWORK Saar INI b Teach Restrict Cable Teach Restrict to B Amp Cable Power Cord from Power Chassis VFP to Cat3 E Stop Cable ooo ooo 555 User supplied 3 phase power cord MCP Security Panel Figure 2 16 AdeptOne MV and AdeptThree
3. 216mm 290mm e e e eje e e ele e A Al Al A 479 mm TEE UN E 18 mm Side View Front View Figure 6 9 Adept PA 4 Power Chassis Dimensions 122 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions of the External Front Panel 482 6 mm 19 in Dimensions 35 mm 0 25 in 6 Y SYSTEM HIGH POWER zs MANUAL AUTO o POWER ON OFF c Q S N Q EMERGENCY STOP 57 41 mm 132 6 2 26 ca 5 22 in PROGRAM PROGRAM D LOCAL NETWORK START RUNNING 1 gt m Soo oT 14 3 mm 0 56 in Cs 90 mm 3 5 in 48 3 mm 1 9 in 81 3 mm 3 2 in Figure 6 10 Adept External Front Panel Dimensions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 123 Chapter 6 Technical Specification Dimensions of the Security Panel
4. 482 6 19 0 in i 37 7 mm 1 48 in C 101 6 mm 4 0 in gt 399 2 15 7 120 6 mm 4 75 in O00 O00 CR US 101 6 mm 4 0 in ojojo Y n 14 7 0 578 6 8 mm 0 268 n n 1 150 5 9 Figure 6 11 Dimensions of the Security Panel 124 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions Dimensions of the Mounting Brackets 266 mm eje 3 2 mm e g e e g A CAN CAN 22 2 mm e i o 133 35 mm e e MN od d e e 479 Power Chassis with mounting brackets installed 146 05 mm 481 ppe a e i o 133 35 mm e je eletet
5. The Control Rail contains the terminals for customer supplied safety equipment terminal blocks TB4 and 5 are for customer Emergency connections The terminal block TB4 supplies the terminals for three additional Emergency Stop switches that are user supplied These switches are two pole switches that are normally closed N C The switches must comply with the safety requirements of all European and national standards If the switches do not comply the whole installation will not provide sufficient safety for Category 3 WARNING Do not use switches in the E Stop circuit that do not comply with Category 3 requirements The specifications for user supplied E Stop and safety barrier switches are two pole redundant contacts positive drive per EN 60204 1992 Section 10 7 3 minimum switching power 24 VA minimum switching voltage 24 VDC minimum switching current 1 0 A DC The terminals for the user supplied E Stop and safety barrier switches and the names of the connectors and signals are given in Table 3 1 See also Table 3 1 76 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop and Teach Restrict Equipment Terminal Assignments for Customer E Stops The table below gives the terminal assignments of the terminal block TB4 on the Control Rail of the Security Panel
6. DC Power Supply Install Power Install Power Cord Cord from to 30 AC Power Power Chassis Figure 2 25 Connectors on Power Rail AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 57 Chapter 2 Installation of the Robots Connecting AC Power to the Security Panel The main AC power supply for the robot is connected to the circuit breaker F1 on the Power Rail X2 The 3 phase AC power cord must be supplied by the user The current rating should equal or exceed that in Table 2 9 The cord must meet all applicable European and national standards and regulations for current voltage ratings wire gauge colors etc Connect each conductor of the power cord securely to your AC power source using the first two columns of Table 2 10 for the color code Install the other end of the power cord to the terminals shown in the Terminal Number column The installation must meet all applicable European and national standards and regulations WARNING Electrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord or an incorrect installation can injure or kill anybody that touches the equipment in the robot workcell Table 2 9 Customer Supplied AC Power Cord Specifications for Security Panel Cord rating 25 amps Number and size of 380 415 VAC 2 5x 2 5 mm
7. Typical Power Distribution Rail Equipment Cabinet Ground Point Customer Earth Ground Figure 2 23 Robot System Grounding Diagram AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 53 Chapter 2 Installation of the Robots 2 17 Connecting to AC Power AC power must be connected separately to the Adept MV controller and the Adept PA 4 power chassis but the power should come from the same source See Figure 2 26 and Figure 2 27 The AC power to the power chassis is routed via the contactors on the security panel Connecting AC Power to the MV Controller The Adept MV Controller can operate at two different voltage settings On the identification ID label you will find the model and serial numbers and the voltage and current ratings The label is located on the left side of the controller chassis A smaller serial number label is also located on the front of the chassis above the On Off switch You should always have this serial number available when you call Adept Customer Service for technical support The Adept MV 8 and MV 19 controllers operate at either 100 120 VAC or 200 240 VAC single phase controllers are shipped from the factory set to 200 240 VAC single phase Contact Adept Customer Service for details on changing to 100 120 VAC configuration AC Power Requirements Table 2 5 Adept MV Controller Power Requirements
8. 92 Enable High Power with the MCP seen 92 Iri Automate 92 Manua MOCIS rts some Or URS RES 93 Calibration of the Robot with 93 4 8 Using the Safety 94 4 9 Moving the Robot with the MCP 94 MAN HALT Button for Selecting Joint 5 95 Joint Axis Control Buttons aaua iis nn 95 SpeeocLBOlss sz i ay sence ema CRAP aah 95 Selecting Joint State and Moving the 96 Selecting and Moving 1 2 2 22 97 Selecting and Moving Joint 2 eee 97 Selecting and Moving Joint 3 lee 97 Selecting and Moving 4 2 2 22 97 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 85 Chapter 4 Commissioning the System 4 1 Introduction This chapter covers commissioning or putting into service the Adept robot system This includes verifying that the installation is complete starting and stopping the robot and how to move the robot with the In a system with the Manual Mode Safety Package you must run the Safety Utility program see Appendix C to verify that the E Stop system both Adept supplied and customer suppl
9. 22 2 5 Adept Shipment Specifications 23 2 6 Transport and 23 2 7 Unpacking and Inspecting the Adept Equipment 24 2 8 Repackaging For Relocation 24 2 9 Robot Installation eed he eee ed Ter ee Ens 25 Tool and Equipment 2 2 25 Installing a Base for the Ropon inerek ur Ane kE nnn 26 Installing Mounting Plate 2 22 2 27 Installing a MOUNTING 5 29 Installing Robot Base 30 2 10 Installation of the Adept MV Controller and the Adept PA 4 Power Chassis 32 Joining an Adept PA 4 Power Chassis to an Adept MV Controller 32 Joining at the sax ise eid yanks c te e Mes Pee ones 33 eee rov 33 space Areurid thie Chassis s iue enses e me y Os 34 Installation in a Rack or Panel 34 Pariel MOUNTING x soc todo ae Yu ade wns ro UR RR Rc N 34 RECKIMOUMTING ie een ode i WR os CC OO RR oe 34 2 11 Installing the A Series Monitor and Keyboard 37 Iristallation PIecedutes s
10. Terminal Signal Name TB5 1 Customer E Stop 1 OUT Voltage Free Contacts TB5 2 Customer E Stop 1 OUT Voltage Free Contacts TB5 3 Customer E Stop 2 OUT Voltage Free Contacts TB5 4 Customer E Stop 2 OUT Voltage Free Contacts TB5 5 Customer System Power On OUT Voltage Free Contacts TB5 6 Customer System Power On OUT Voltage Free Contacts TB5 7 Customer Manual Mode 1 OUT Voltage Free Contacts TB5 8 Customer Manual Mode 1 OUT Voltage Free Contacts TB5 9 Customer Manual Mode 2 OUT Voltage Free Contacts TB5 10 Customer Manual Mode 2 OUT Voltage Free Contacts TB5 11 Customer Safety Relay IN Feedback Contacts TB5 12 Customer Safety Relay IN Feedback Contacts N C Pin 11 and 12 Jumper closed if not used The Customer System Power On OUT contacts are controlled by the System Power switch on the VFP When this switch is on the contacts are closed The System Power signal can be used to control auxiliary equipment If more than 2 amps are required this signal should be used to control a contactor Note the VFP System Power switch also controls the power relay inside the Adept MV 8 or MV 19 controller AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 79 Chapter 3 Preparation for Safe and Effective Use of the Robot Digital Inputs and Outputs of the System Input Output SIO Module The digital input and output signals of the System Input Outp
11. A Series Keyboard Trackball rrr ees ER 1 3 Figure 2 12 Connecting the A Series Monitor and Keyboard 2 Connect the monitor signal cable to the MONITOR connector on the VGB module AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 37 Chapter 2 Installation of the Robots 3 Connect the double ended keyboard cable to the KEYBOARD connector and the POINTER connector on the VGB module 4 Verify the voltage range marked on the monitor is compatible with your local voltage source Connect the color monitor AC power cord to the monitor then plug it into an appropriate voltage source 2 12 Installing a Terminal in an S Series System With an S Series Adept MV controller system the customer must supply the terminal and cable to interface to the controller The terminal must be a Wyse Model 60 or 75 with an ANSI keyboard or a compatible terminal You may also be able to use a computer with suitable terminal emulation software For DOS or Windows compatible computers the programs Procomm or Procomm for Windows available from many computer stores include software emulation for the Wyse 75 Recommended Terminal for S Series Systems The recommended terminal for use with the Adept MV c
12. 14 1 18 What to Do in an Emergency 14 1 19 HowTo Get Help cioe o eee y te Rey WX es 15 IMEWO DS ruti 64 MOREE SRO BASES Re 15 Amend States suo mes ae exa nex 15 Outside Continental United States or 16 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 1 Chapter 1 Safety 1 1 Introduction The AdeptOne MV AdeptThree MV and Adept PackOne MV robots are four axis SCARA robots see Figure 1 1 Joints 1 2 and 4 are rotational and Joint 3 is translational See Figure 1 3 for a description of the robot joint locations The AdeptOne MV AdeptThree MV and Adept PackOne MV robots are designed to interface with the Adept MV controller and PA 4 power chassis see Figure 1 2 The control and operation of the robot is programmed and performed through the controller Additional safety features are controlled by the Security Panel AdeptThree MV Robot Figure 1 1 Adept Robots Adept MV 8 Controller Adept PA 4 Power Chassis Figure 1 2 Adept MV 8 Controller and PA 4 Power Chassis AdeptOne MV Adept
13. Figure 2 19 Robot to VJI Cable Installation AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 45 Chapter 2 Installation of the Robots Installing Signal Cables MV Controller to Power Chassis The VJI to Amp cable is the interconnect between the controller and the power chassis This cable assembly has a single plug on one end for the and four plugs on the other end for the amplifiers 1 Connect the cable end with the single connector to the connector marked Amplifier Signal upper on the VJI module See Figure 2 19 2 The other end of the cable with four plugs must be connected in the following pattern a Connect the plug labeled Amplifier Crtl 1 to the Control Signal connector on A Amp fH Tighten the two captive screws securely b Connect the plug labeled Amplifier Crtl 2 to the Control Signal connector on Amp 2 Tighten the two captive screws securely c Connect the plug labeled Amplifier Crtl 3 to the B1 Control Signal connector on the Amp Tighten the two captive screws securely d Connect the plug labeled Amplifier Crtl 4 to the B2 Control Signal connector on the Amp Tighten the two captive screws securely 3 Verify that all connectors are secure and fully inserted and installed in the correct location WARNING Verify that all connectors are fully inserted and screwed down Failure to do this could cause unexpected robot motion Also a
14. Recommended Nominal Minimum Maximum E Frequency External Circuit Voltage Operating Operating Range Pens Voltage Voltage Breaker 5 5 5 user supplied 200V to 240V 50 60Hz 180V 264V 10 amps factory 1 phase setting 100V to 120V 50 60Hz 90V 132V 10 amps 1 phase Power to the Adept MV controller and PA 4 power chassis must come from a single source The maximum interruption time operating voltage below specification tolerated by the controller is 16 milliseconds Power Entry Module The power entry module is located at the lower left side of the controller front panel It contains e the On Off power switch 1 On O Off the AC power cord socket the two incoming AC line fuses 54 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Connecting to AC Power p 27 adept technology inc WARNING FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE WU UY Mx Iu V U V AV Figure 2 24 Adept MV Controller Power Entry Module Connecting AC Power Cord The AC power cord is included in the accessory kit The controller end of the power cord is fitted with an IEC 320 connector The user end of the cord is unterminated WARNING Electrical hazard Th
15. 5 1 4 Precautions and Required 6 RoboEksStaliGEoOICes i2 ha trig e ee teme S eL ba ce ed ie etie 6 saos ac oed ER eed pae e eor E PR PRU 6 Additional Safety Information csse nn 8 1 5 Intended Use of the Robots 9 1 6 Robot Modifications 10 Acceptable Modifications errre rikere nn 10 Unacceptable Modifications liii e 10 1 7 Endangerment Through Additional Equipment 11 1 8 Sound Emisslons ep RID LeidET Tu e ema eve 11 1 9 Thermal Hazard turra lI I 11 1 10 Working Areds eer RR x RE See bees 11 1 11 Qualification of Personnel 12 1 12 Transpott l ik oceano ERES EE SY eG LATER 12 1 13 Safety Equipment for 13 1 14 Protection Against Unauthorized 13 1 15 Operating Modes of Adept 13 Atomene Modez eru ee bito 13 352 de ad dea ERE WERE 13 1 16 Safety Aspects While Performing 14 1 17 Risks That Cannot Be
16. 88 4 5 Description of the Manual Control Pendant 90 X AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Table of Contents HOw to Hold The In E TO UPS 90 Description of Buttons on the 2 2 9 Mode Control and Joint Axis Control 5 91 5 arb italy sen 91 4 6 How to Stop Robot in Manual 92 4 7 How to Start the 2 2 92 Enable High Power with the MCP 92 MAVAE MOC a cst Races C RR Rea 92 Iri Maria Mode x e RR aes 93 Calibration of the Robot with the 93 4 8 Using the Safety Utility 2 rmi Ex a eee ee 94 4 9 Moving the Robot with the MCP 94 MAN HALT Button for Selecting Joint 5 95 Joint Axis Control Buttons iia mem memet 95 Speedl Bolsa m etd acer ats os te E EO he 95 Selecting Joint State and Moving the 96 Selecting and Moving Joint 1 ees 97 Selecting and Moving Joint 2 97 Selecting and Moving JOINTS
17. 97 Selecting and Moving Joint 4 lle 97 5 Maintenance PE 99 5 1 Introduction Y A ucl aia 100 5 2 Using the Safety 100 5 3 Robot Lubtrication nt ea REX 101 Recommended Grease for AdeptOne MV AdeptThree MV Robot 101 Recommended Grease for Adept PackOne MV Robot 101 Lubricating the Upper Quill Shaft seen 101 Lubricating the Lower Quill Shaft AdeptOne MV Adept PackOne MV 22 2 2 22 222 1 2 103 Lubricating the Lower Quill Shaft AdeptThree MV Robot 104 5 4 Check Robot Mounting Bolt 106 5 5 Joint 3 Bellows Replacement Adept PackOne MV 106 5 6 Maintenance and Inspection of Air 107 Draining Moisture from AdeptOne MV AdeptThree MV Robot Compressed Air Filter ed ORDRE ER EU a 107 Maintaining Compressed Air Filter of Adept PackOne MV Robot 107 Draining Moisture from the Air Filter 107 Replacing the Filter Cartridge eee 107 HyperDrive Robot Fan Filter Inspection and Cleaning 107 Adept 4 Fan Filter Inspection and 108 Adept MV Controller Fan Filter Inspection and
18. 37 2 12 Installing a Terminal S Series 5 38 Recommended Terminal for S Series Systems 38 Installation 1 ree Pcr dey HERD Genie RR NEC 38 2 13 Installing the External Front 39 Contrels and dnadiedlots za e en taped v ego Wa eS 39 Installing the External Front Panel 40 2 14 Installation of the Adept Security 41 Enclosure Requirements 2 2 22 2 2 2 2 22 2 2 41 Installation of the Security 41 2 15 Signal Interconnection Installation 42 System Cable Connections 2 2 22 2 2 2 2 4 4 42 system Cable css re tuer pur 43 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 17 Chapter 2 Installation of the Robots 18 Connecting the Robot to the Power Chassis 43 Installing Signal Cables Robot to MV 45 Installing Signal Cables MV Controller to Power 55 46 Connecting the to the 46 Connecting the Security 4
19. 177 User Air Lines e uoc at e aC ac 177 Spare Air LING seo exaratae RUP S ERR S re ae 179 AdeptThree MV 2 2 2222 22 2222 2 179 Solenoid Valve Assembly 179 UserAir Ens ica ce yes e ey IIS ER 179 SGre AID LING s d dun taxon e ders voee deste a 179 E 2 Installing Extra Lines in the PackOne User Flange Assembly 180 Outer Link Mounting Holes on AdeptOne MV 181 E 4 Limiting Joint Travel 182 DOMSTODS e oa a E a ads anit Both en 182 ma A Re RO OR a Rb 182 Index ee dA eden aie Sam itat d a eek Saar Gants 185 Xiv AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 2 20 Figure 2 21 Figure 2 22 Figure 2 23 Figure 2 24 Figure 2 25 Figure 2 26 Figure 2 27 Figure 2 28 Figure 2 29 Figure 2 30 Figure 2 31 Figure 2 32 Table of Contents List of Figures Adept
20. 72 2525 Atay bee 73 security Panel FUNCTIONS 4 iss e ae 73 Description of Mute Capability 74 Operating in Manual Mode 75 3 2 Category 3 Emergency Stop and Teach Restrict Equipment 76 Terminal Assignments for Customer 5 77 Voltage Free Contacts for Monitoring E Stop Circuitry Passive E Stop 78 Digital Inputs and Outputs of the System Input Output SIO Module 80 ves cnr ta es Chats 80 OUTPUT 82 4 Commissioning the System 85 4 1 Introduction RR menm Rx n EOD cR ein 86 4 2 Check Of Physical 86 Physical Connections Lei ke EHE 86 4 3 VFP Operating 87 Manual Operating 0 4 87 Automatic Operating 87 4 4 Using the Brake Release Button 88 ee dna ste epus Nees 88 Brake Release BUTTON RE Eden Mace eines 88 Remote Brake Release
21. 138 Category 3 E Stop e espe race ache d 143 Features cere pee Ree eee debe ed A a 147 Bellows DOetGll 3 3 arido awe ege a c gi 151 TeSFEOCGHIOEDS iei xot E hed e edad ia 159 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Figure C 2 Figure C 3 Figure 4 Figure C 5 Figure C 6 Figure E 1 Figure E 2 Table of Contents Removing the Rear 2 21 2 4 4 4 44 4 167 Removing the HyperDrive Fan 170 AdeptOne MV and AdeptThree MV 171 5 2 ous Pr aetas pst br Rae Qa reden NAS a S 171 Testing the AdeptThree MV Dump 173 User Connections in the AdeptOne MV 178 Mounting Holes on Top Side of Outer Link on AdeptOne MV Robot 181 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Xvii Table of Contents Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 2 6 Table 2 7 Table 2 8 Table 2 9 Table 2 10 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 5 1 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table A 1 Table B 1 Table D 1 Table E 1 Table E 2 Table E 3 Table E 4 Xviii List of Tables Adept Hardware and Soft
22. 7 Additional Safety Information csse nn 8 1 5 Intended Use of the Robots 9 1 6 Robot Modifications 10 Acceptable 2 21 242 2 4 4 10 Unacceptable 2 2 nnn 10 1 7 Endangerment Through Additional Equipment 11 1 8 Sound EMISSIONS 7a dentem 11 1 9 Thermal Hazard scole Ry RR Rey ka XE EE TE 11 1 10 Working 22 2 lt ks 11 1 11 Qualification of Personnel 12 1 12 Trenspott utate seri aA 12 1 13 Safety Equipment for 13 1 14 Protection Against Unauthorized 13 1 15 Operating Modes of Adept 13 Automatic MOOS 13 Manu Mode xe eva e X ek eec da 13 1 16 Safety Aspects While Performing 14 1 17 Risks That Cannot Be 14 1 18 What to Do in an Emergency 14 1 19 How To Get Help cic ei EEG E EX RE GO ed XU 15 Licet eto rye eie nbi tetti seu
23. 2490 dia 8 18 15 1 27 dia thru Taper 3 500 per foot 4 40 UNC 2B thru 6x 45 002 0 500 00 0 060 deep 2 100 dia 8 32 UNC 2B thru 4 places All linear dimensions in inches 1 0 1 inch 25 4 mm 0 116 dia thru 2 places Counter Bore 0 20 dia 0 13 deep Figure 6 5 User Quill Flange Dimensions for AdeptOne MV and AdeptThree MV Robots 118 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions User Quill Flange Dimensions for Adept PackOne Robot Quill ID Tube Cap Threaded Hole Air Line 1 of 2 EX Union Fitting plugged 577 at both ends 1 of 2 Screw to remove tube cap 1 of 4 for Union 1 of 4 10 75 Quill ID Tube gt Gasket i 25 l 1 28 30 i 0 058 mM Mora 0 105 002 1 75 000 User 2 38 Flange Q 2 49 256 m Alignment Pin Hole 0 199 001 4 x 8 32 x 3 8 0 15 deep max Socket Head on 2 100 bolt circle Cap screws to remove flange assembly from robot 4 x 8 32 UNC 2B 0 47 deep max on 2 100 bolt circle for user end effector mounting Figure 6 6 User Quill Flange Dimensions for Adept PackOne Robot AdeptOne
24. 105 Bolt Resealing Detail xs Rae eaten ean ke o 111 AdeptOne MV HyperDrive Robot Top and Side Dimensions 114 AdeptThree MV Robot Top and Side Dimensions 115 Adept PackOne MV Robot Top and Side Dimensions 116 AdeptOne MV Robot with Calibration Fixture 117 User Quill Flange Dimensions for AdeptOne MV and AdeptThree MV Robots seen 118 User Quill Flange Dimensions for Adept PackOne 119 Adept MV 8 Dimensions 2 2 22 2 120 Adept MV 19 Dimensions 2 2 2 7 121 Adept PA 4 Power Chassis 122 Adept External Front Panel 5 123 Dimensions of the Security 124 Adept MV 8 and 4 With Mounting Brackets Installed 125 MCP Cradle Dimensions 2 21 4 4 4 4 126 Joints MOTIONS oti dete one ate pe dua de n o ata goo die e 127 Joint 2 Motion and LEFTY RIGHTY 128 Jonta xncd Jointsd MOONS xh e oi e Coq einen 129 AdeptOne MV Robot Working Envelope 132 AdeptThree MV Robot Working Envelope 135 Adept PackOne MV Robot Working Envelope
25. Default Softstop Hardstop approximate Joint 1 150 152 Braketrack 300 Joint 2 X147 149 5 Joint 3 2 5 to 197 5 mm 2 5 to 202 mm Standard 0 1 to 7 8 0 1 to 7 9 Joint 3 2 5 to 297 5 mm 2 5 to 302 mm Optional 0 1 to 11 6 0 1 to 11 9 Joint 4 277 280 In between the softstop and hardstop Joint 1 has a braketrack An internal proximity sensor will cause a V error condition and shutdown High Power to the robot if the braketrack area is entered Table E 3 AdepiThree MV Robot Softstop and Hardstop Specs Default Softstop Hardstop approximate Joint 1 150 X152 Braketrack 300 Hardstop Joint 2 150 152 Joint 3 0 to 305 mm 2 5mm to 320 mm 0 to 12 0 1 to 12 6 Joint 4 270 280 n between the softstop and hardstop Joint 1 has a braketrack An internal proximity sensor will cause a V error condition and shutdown High Power to the robot if the braketrack area is entered Table E 4 Adept PackOne MV Robot Softstop and Hardstop Specs Default Softstop Hardstop approximate Joint 1 150 152 Braketrack 300 Hardstop Joint 2 145 148 6 Joint 3 0 to 196 mm 2 5 to 198 mm Standard 0 to 7 7 0 1 to 7 8 Joint 3 0 to 295 mm 2 5 to 297 mm Optional 0 to 11 6 0 1 to 11 7 Joint 4 277 280 In between the softstop and hardstop Joint 1 has a braket
26. o RE PEOR 2 Adept MV 8 Controller and PA 4 Power 2 Adept Robot Joint Eocations sesso Tate keen tec e a 3 Robot Impact and Trapping Point 2 7 Recommended Mounting 5 5 21 Adept Robot on a Transportation Pallet 24 Mounting Hole Pattern 5 26 Mounting Hole Pattern 5 27 Mounting Plate to Floor Installation 28 Mounting Spool to Floor Installation Detail 30 Liftirig Robot FromrEyebolts 3222 AT ram be ea 31 Joining the Power Chassis and Controller at the 32 Joining the Power Chassis and Controller at the 33 Installing Mounting Brackets on an Adept MV 35 Installing Mounting Brackets on Adept PA 4 Power Chassis 36 Connecting the A Series Monitor and 37 External Front Panel 2 22 2 22 2222 22 2 39 External VME Front Panel Installation 40 Secu POREM enar tend eet vfu TD cade du heec ee 41 AdeptOne MV AdeptThree MV System Cable In
27. Amp Voltage Restrict test passes Press ENTER to continue Press ENTER to continue with the next test or return to the main menu VFP Switch and Button Test The VFP HIGH POWER button and lamp are tested to ensure that they are operational The following message is displayed VFP test LAMP TEST button test Press the LAMP TEST button Do all lights come on Y N If the answer is N the test fails and the main menu is displayed If the answer is Y the MANUAL AUTO and LOCAL NETWORK keyswitches are tested by changing their position The following is displayed Keyswitch test Switch the MANUAL AUTO keyswitch to MANUAL and LOCAL NETWORK keyswitch to NETWORK Switch the MANUAL AUTO keyswitch to AUTO and LOCAL NETWORK keyswitch to NETWORK Switch the MANUAL AUTO keyswitch to MANUAL and LOCAL NETWORK keyswitch to LOCAL Switch the MANUAL AUTO keyswitch to AUTO and LOCAL NETWORK keyswitch to LOCAL As the keyswitch positions are changed SAFE UTL verifies their state If the test fails the main menu is displayed If the test passes the PROGRAM START button is tested and the following is displayed AdeptOne MV AdeptThree MV Robot Instruction Handbook 163 Appendix C Using the Safety Utility PROGRAM START button test Press and hold the PROGRAM START button Release the PROGRAM START button As the PROGRAM START button is pressed SAFE verifi
28. Press ENTER to continue Press ENTER to continue with the next test or return to the main menu 164 AdeptOne MV AdeptThree MV Robot Instruction Handbook B Tests Performed at Time of Commissioning MCP E STOP Functions The Hold To Run switch on the MCP is tested to ensure that it is operational The following message is displayed MCP E STOP Test MCP test 1 Release the Hold To Run switch Is the red E STOP LED on the SIO Module on Y N When the Hold To Run switch opens the ESTOP LED on the SIO module should turn on If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Attempting to enable HIGH POWER with the Hold To Run switch released Cat 3 external E Stop Code 0 The External E Stop error is expected If HIGH POWER can be switched on the test fails and an error message is displayed If HIGH POWER cannot be switched on the test passes MCP test 2 Press and hold the Hold To Run switch Is the red E STOP LED on the SIO Module off Y N When the Hold To Run switch closes the ESTOP LED on the SIO module should turn off If the response is N the test fails and an error message is displayed If the response is Y the system attempts to enable High Power If High Power cannot be switched on the test fails and an error message is displayed If High Power is switched on the HIGH POWER button is
29. 200 240 VAC 4x 2 5 mm Table 2 10 Connection of Main AC Power Cord to the Circuit Breaker on the Power Rail X2 Wire Description Wire Color Terminal Number Color code 30 380 415VAC line 1 black X2 F1 L1 line 2 black X2 F1 L2 line3 brown X2 F1 L3 neutral blue X2 N ground green yellow X2 PE Color code 30 200 240VAC line 1 black X2 F1 L1 line 2 black X2 F1 L2 line 3 brown X2 F1 L3 ground green yellow X2 PE 58 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Connecting to AC Power Typical AC Power Installation Diagrams 30 12 380 415 20A N 200 240 380 415 200 240 24VDC Adept 4 30 380 415 ll F4 10A L1 10 200 240V Adept MV 8 MV 19 Note F4 is user supplied Figure 2 26 Typical 380 415 V AC Connection for Category 3 System L1 1 200 240V 30 12 be 200 240 e 20A EN ll ll F5 10A 20 1 200 240 VAC poU APT 24VDC Xe s s 2 T 12 Li Adept PA 4 Adept MV 8 MV 19 30 200 240 10 200 240V Note F4 and F5 user supplied Figure 2 27 Typical 3 Phase 200 240 V AC Connection for
30. Connector for Valve 1 J11 Connector for Valve 2 J13 iP 9 o o S uh LIESS Pa Esset Brake Button Connector for HyperDrive Fan J7 Figure C 4 AdeptOne MV and AdeptThree MV Base Connector for Valve 1 J11 D Connector for Valve 2 J13 0 J13 J11 6 Brake Release Button Figure C 5 PackOne MV Base AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 173 Appendix C Using the Safety Utility Testing the Dual Dump Valves If the tests are being performed on an AdeptThree MV robot SAFE UTL displays the following message AdeptThree Dual Dump Valve tests 1 Turn off the PA 4 power chassis switch 2 Disconnect the robot User signal cable from the security panel and place the User jumper plug on the cable 3 Raise the Joint 1 cover on the robot base to gain access to the dump valves Perform the following steps 1 Turn High Power off 2 Using a 5 32 hex wrench remove the eight screws that hold the Joint 1 cover in place 3 Raise the Joint 1 cover and secure it to allow access to the dump valves see Figure C 6 4 After the cover is raised perform the tests a
31. 120 Dimensions for Adept MV 19 121 Dimensions for Adept PA 4 Power 5 122 Dimensions of the External Front 123 Dimensions of the Security Panel 124 Dimensions of the Mounting Brackets 125 MGP Craadle Dirmersiorns sa e e t cr ea Ro IRR ic Ge 126 6 2 Joint Molions 2 eis exu Rn Ee nhe xU ncm Eon 127 Joint A 127 fume 127 JO s der de aede des ete ete Dee Tr ele 128 Mein Mc 128 6 3 AdeptOne MV Robot lt 130 AdeptOne MV Robot Working 132 6 4 AdeptThree MV Robot 5 133 AdeptThree MV Robot Working 135 6 5 Adept PackOne MV Robot Specifications 136 Adept PackOne MV Robot Working 138 6 6 Adept PA 4 Power Chassis 139 Xii AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Table of Contents Category 3 E Stop 141
32. 2 C 1633 mm 64 3 66 mm 2 6 Mounting Level 0 0 Figure 6 3 Adept PackOne MV Robot Top and Side Dimensions 116 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions Calibration Fixture Dimensions AdeptOne MV Robot Mounted on a Spool 432 mm 17 0 AdeptOne MV Robot Mounted on a Plate lh 133 5 25 8 317mm 12 5 Calibration Fixture LT Nominal Height 728 mm 28 65 Calibration Gauge Unit installs here Calibration Gauge Unit on Fixture 260 mm 10 25 84 2 381mm 15 0 Figure 6 4 AdeptOne MV Robot with Calibration Fixture NOTE The Calibration Fixture will have to be mounted to the robot as shown above if a joint encoder has to be replaced or other major repairs have to be performed Leave adequate space in the workcell if possible AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 117 Chapter 6 Technical Specification User Quill Flange Dimensions for AdeptOne MV and AdepiThree MV 1 27 dia thru on AdeptOne MV only AdeptThree MV is 1 515 dia 10 2 0 3 QS 012 1 515 dia 55 Keyway NE lt 1 635 dia gt 0 060 0 105 lt 1 750 dia 901 gt 2 378 dia
33. dimensions 116 Joint 3 bellows replacement 106 lubrication of lower quill shaft 103 maintenance of exterior surface coating 109 operating environment specifications 19 protective cover for cleaning 110 specifications 136 user flange dimensions 119 working envelope 138 panelmounting 34 passive E Stops 78 Pendant connection on External Front Panel 40 Pinouts for 1 and TB2 81 for TB3 83 for TBA 77 for TB5 79 power chassis AC power requirements 56 changing voltage setting 60 circuit breaker 65 connecting to controller 46 connecting to robot 43 dimensions 122 fuses 65 grounding 51 interlock circuit 66 joining to controller 32 panel mounting 34 rack mounting 34 power cord from power chassis specifications 58 power entry module on controller 54 Power Rail connecting power cord from power chassis 57 drawing of components 57 preventive maintenance recommended schedule 100 Program Running lamp on External Front Panel 39 Program Start switch on External Front Panel 39 protective cover installation on PackOne MV for cleaning 110 190 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Index Q qualification of personnel 12 Quill verticalstroke 128 R rack mounting 34 Remote Brake Release connection 88 Righty configuration 127 risks that cannot be avoided 14 robot calibrating from MCP 93 compressed air filter draining moisture 107 definition of industrial 4 grounding 51 how to start 92 how
34. gt B A gt MCP gt Brak gt Dual gt Dual 1 ll V mp Voltage Restrict Switches and Buttons E STOP Functions e Holding Force Brake Solenoid Dump Valve Enter Selection NOTE The Dual Dump Valve test is performed only on AdeptThree MV robots In order for the robot to be marked as commissioned option 1 must be selected The other options can be selected individually to test a component that has failed a test After testing the individual component option 1 must be selected again to test all components The system is marked commissioned only after all tests pass WARNING In order to perform tests on the dual brake valve and dual dump valves some access covers must be removed HIGH POWER should be turned off and the PA 4 Amplifier Chassis should be switched off These tests should be performed only by trained personnel Required Tools The following tools are required to perform the tests AdeptOne MV robots require a Philips screwdriver AdeptThree MV robots require a Philips screwdriver and a 5 36 inch hex wrench Adept PackOne MV robots require a 7 16 inch wrench 168 AdeptOne MV AdeptThree MV Robot Instruction Handbook B Tests Performed Periodically Testing the Dual Brake Valves SAFE UTL displays the following message Dual solenoid tests 1 Turn off the PA 4 power chassis switch 2 Disconnect the robot User signal ca
35. 0 108 5 7 Check eno ea ea ar t CR cR Ac RC aC E E 108 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Xi Table of Contents 5 8 Special Maintenance for Adept PackOne MV Robot 109 General Inforrnctiornm s 55 4 tk em Ya 109 Exterior Surface 2 2 2 109 Rotary Seal Assemblies 109 109 Cleaning Information aee D tte 109 Removing the End Effector for Cleaning 109 Washdown Procedure 6 ae 110 Installing Protective 110 Drying Time Before Operation 110 5 9 Bolt Removal Resealing Procedure PackOne MV Robot 111 6 Technical Specification 113 6 1 Dimensions A ee OG a ee AE ea SERE 114 Dimensions for AdeptOne MV HyperDrive 114 Dimensions for AdeptThree MV 115 Dimensions for Adept PackOne MV 116 Calibration Fixture Dimensions ees 117 User Quill Flange Dimensions for AdeptOne MV and AdeptThree MV 118 User Quill Flange Dimensions for Adept PackOne Robot 119 Dimensions for Adept MV 8
36. 1229 mm 48 40 1181 mm 46 50 1123 mm 44 20 dO 1060 mm 41 75 41 50 4 79 mm dia 933 mm 3 13 902 mm 36 75 35 50 Standard 7 7 Quill 188 mm dia 877 34 52 7 40 679 mm 26 75 Optional 11 6 Quill ote with quill extended 775 mm 30 52 480 mm 18 91 a 168 mm dia with quill extended 6 6 413 mm 16 25 349 97 mm dia 13 757 3 80 5 80 Psp m See AdeptThree MV robot drawing 13 007 for non HyperDrive AdeptOne MV robot i base dimensions 117 mm 4 62 i 51 I s 43 2 mm 2 00 1 7 Mounting Level 0 0 Figure 6 1 AdeptOne MV HyperDrive Robot Top and Side Dimensions 114 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions Dimensions for AdeptThree MV Robot 558 8 mm 508 mm 22 0 d 20 0 99 mm 8 9 oe 200 6 mm 7 9 R 76 2 mm 3 0 R 139 7 mm WM a m 65 6 52 1407 1 mm 55 4 172 7 mm 6 8 lt lt 114 3 mm PT 1788 1 mm 4 5 70 4 R 106 7 mm bru 4 2 A 2718 1386 8 mm 10 7 gt 54 6 1242 mm 1209 mm 48 9 47 6 1110 mm 43 7 1069 3 mm 1064 2 mm 139 7 mm dia 41 97 5 5 911 8 35 9
37. otherwise the E Stop circuit is not closed and it is not possible to enable High Power C shaped metal jumpers are supplied in the accessory kit AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 77 Chapter 3 Preparation for Safe and Effective Use of the Robot 78 The Category 3 safety system provides two independent E Stop loops 1 and 2 The signals designated 1 and 2 represent pairs of signals from a two pole switch The 1 switches are in series with the number 1 contacts of the E Stop switches on the and the MCP It is the same for the 2 contacts The Customer E Stop IN 1 and 2 signals should be from a two pole switch or multiple two pole switches These contacts are for additional customer E Stop switches or circuitry for example light curtains or pressure sensitive mats They would open the E Stop circuit and shut down High Power when activated The Customer Safety Barrier 1 and 2 connectors should be from one or more two pole switches the switches that are mounted on safety barriers and safety gates should be installed in series making two separate loops Then they are connected to the Customer Safety Barrier 1 and 2 input terminals on TB4 Between the Customer Safety Barrier 1 and 2 Mute connectors the same type of switch should be installed as between the connectors described above In Automatic mode this switch or series of switches has the same function as the normal Customer Sa
38. DIO Output Specifications SIO 82 Digital Output Signal Assignments on Terminal Block 83 Recommended Preventive Maintenance Schedule 100 AdeptOne MV Robot Performance 130 AdeptThree MV Robot Performance 133 Adept PackOne MV Robot Performance 5 136 Power Consumption for 4 Power Chassis with an AdeptOne MV 5 ees 139 Description of numbers in the Category 3 E Stop 144 Pipe fitting flow equivalents in feet of straight 148 EMG TGST ReSUlTS dp mate eie e ae 175 User Air Line Command Summary sens 178 AdeptOne MV Robot Softstop and Hardstop 5 5 183 AdeptThree MV Robot Softstop and Hardstop 5 5 183 Adept PackOne MV Robot Softstop Hardstop 5 5 183 AdeptOne MV AdeptThree MV Robot Instruction Handbook Introduction 2 um rechte uo ethos a ub x teda 2 Adept Equipment Compatibility csse 3 Definition of a Manipulating Industrial 4 1 2 Notes Cautions and 0 5 4 1 3 Risk Assessment Category 3 System
39. EP button The accelerometer has tripped as expected The MCP controlled move is repeated If the test passes the following is displayed Accelerometer test passes Press ENT ER to continue Pressing ENTER will either begin the next test to be performed or display the main menu If the test fails the main menu is displayed AdeptOne MV AdeptThree MV Robot Instruction Handbook 161 Appendix C Using the Safety Utility Amp Voltage Restrict Test WARNING The user must remain outside the robot workcell with all safety barriers closed while conducting these tests Failure to observe this warning could cause serious injury As this test is started High Power must be enabled as described in the previous test The voltage restrict circuitry is tested to ensure that it is operational The following messages are displayed as the program sequence progresses B Amp Voltage Restrict test Joint 3 MCP controlled move no E STOP expected Release then press the Hold To Run button Press the HIGH POWER but Use the MCP to drive Joi ton when it blinks nt 3 back and forth at top speed Do NOT drive the robot onto a soft stop Press REC DONE on the MCP when done If an error occurs press CLR ERR button until REC DONE flashes Press the COMP PWR button then the REC DONE button when motion is completed The voltage restri
40. Hev B 63 Chapter 2 Installation of the Robots B Amplifier Module Overview The Amplifier module is a plug in module that contains the circuitry and amplifying components to drive two robot motors In a typical Adept robot system there is one B Amplifier module in the Adept PA 4 power chassis This Amp module located to the right of the A Amp modules drives the motors for Joints 3 and 4 Connectors and Indicators Status LEDs The left hand column of LEDs is for the first motor controlled by this module the right hand column is for the second motor controlled by this module When an LED is turned on it indicates the following conditions High Volts On indicates the high voltage to the amps is turned on DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED S cupiata PWM On indicates that current servo is on It does not go on HGH voLTs on ae until calibration is complete towvorts on O Qeon Low Volts On indicates the low voltage supply in the power O m sseoven OO sre chassis is on Bi B2 Note the three LED pairs below indicate faults and are visible momentarily before the system turns off JB Open Ckt Fault indicates that an open circuit in the motor leads has been detected HV Sag Over Temp indicates that either the input voltage has dropped below the specified level or an over tempera ture fault has been detected o
41. To change the voltage setting remove the selector rotate it 180 so the required setting is shown and replace it See Figure 2 30 11 Close the grill and secure the two screws 12 Clearly mark or alter the ID label on the side of the chassis to show the new voltage configuration 13 Clearly mark or paste an alternative label over the existing label below the circuit breaker on the front of the chassis to show the new voltage configuration 14 Re connect the controller and Security Panel to the AC power source AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 61 Chapter 2 Installation of the Robots 62 Adept PA 4 Power Chassis with Front Air Intake Grill Removed ad p technology inc 380 415 V E Os Go Voltage Selector Voltage Selector Plug Socket Figure 2 30 Changing Voltage in Power Chassis A in 380 415 V position AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Additional Power Chassis Information 2 18 Additional Power Chassis Information A Amplifier Module Overview The A Amplifier module is a plug in module that contains the circuitry and amplifying components to drive the Joint 1 or Joint 2 motor in an AdeptOne MV or an Adept Three MV robot In a typical robot system there are two A Amplifier modules
42. connector could get pulled out or dislodged unexpectedly Connecting the MCP to the VFP The optional MCP is connected to the system at the Pendant connector on the VFP see Figure 2 20 See Chapter 4 for instructions on using the MCP Install the MCP to the connector that is marked PENDANT on the WARNING The VFP has two key switches One to select the device that controls program execution and one to select the operating mode Before it is possible to use the MCP in the workcell the operating key switch must be set to MANUAL and the other one to LOCAL This will prevent program execution from being started from the keyboard or terminal CAUTION The coiled cable on the MCP III has been tested to withstand 500 V of repetitive electrical bursts per EN61000 4 4 Exposing the MCP to voltages higher then 500 V may cause the robot to shut down In this event it may be necessary to unplug then reconnect the MCP to restart the robot 46 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Signal Interconnection Installation External Front Panel VFP SYSTEM HIGH POWER em AUTO POWER ON OFF cede WS Meu O NETWORK MCP Bypass Plug Install if no MCP Manual Control Pendant Figure 2 20 MCP Connection MCP Cradle The MCP is stored in the MCP cradle wh
43. d a 4 330 2 mm TE 35 1 13 0 850 9 Lid 878 8 inimi 33 5 34 6 zx 574mm 22 6 168 mm dia 4 6 6 353 mm 289 5 mm 13 9 11 47 See AdeptOne MV robot drawing 267 mm for AdeptThree MV HyperDrive robot 10 5 base dimensions 43 2 mm 1 7 Mounting Level 0 Figure 6 2 AdepiThree MV Robot Top and Side Dimensions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 115 Chapter 6 Technical Specification Dimensions for Adept PackOne MV Robot 1329 mm ref gt 52 3 375 mm 14 76 59 mm 4 2 32 81 to mounting mm surface 3 2 gt 437 i R 58 mm 7 60 2 3 R 135 mm 5 3 PM 117 mm 4 719mm 3 87 pl 469 a 28 3 1532 mm 60 3 C 190 mm dia NS 216 mm dia gt 7 5 1265 mm 49 8 1237 mm 48 7 1219 mm 48 0 1143 mm 45 0 1092 mm 43 0 1072 mm 42 2 7 7 1062 mm 41 8 140 mm dia 5 5 919 mm 36 2 869 34 2 876 34 5 Standard Joint 3 Travel 195 mm 7 7 4 168 mm dia 6 6 681 mm 26 8 249 mm dia 5 439 mm 17 3 373 mm 14 7 9 8 Optional Joint 3 Dimensions Travel 295 mm 11 6 A 480 mm 18 9 775 mm 30 5 261 mm 8 5
44. industrial automation applications is called a manipulating robot ISO 10218 1992 E 1 2 Notes Cautions and Warnings There are four levels of special notation used in this instruction handbook In descending order of importance they are WARNING If the actions indicated in a WARNING are not complied with injury or major equipment damage could result A Warning statement will typically describe the potential hazard its possible effect and the measures that must be taken to reduce the hazard AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Risk Assessment Category 3 System WARNING If in a WARNING the actions are indicated with an lightning bolt instead of an exclamation mark an electrical danger or shock is possible for personnel working with the system CAUTION If the action specified in the CAUTION is not complied with damage to your equipment could result NOTE A NOTE provides supplementary information emphasizes a point or procedure or gives a tip for easier operation Risk Assessment Category 3 System Without special safeguards in its control system the AdeptOne robot could inflict serious injury upon an Operator working within its work envelope As a consequence of 1 the potential for fatal injury 2 the likelihood that the Operator would need to be within the work envelope for significant periods of time during the commissioning or reteaching of th
45. 0003 TB3 9 Output 0004 10 Output 0004 TB3 11 Output 0005 12 Output 0005 NOTE Digital Output signals 0006 to 0008 from the SIO module are not available because they are used for the Category 3 safety system AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 83 Commissioning the System AN 86 4 2 Check Of Physical 86 Physical Corrections x aec AUR ocu c X ando o 86 4 3 VFP Operating 87 Manual amp perating MOode SN re owe Rees des 87 Automatic Operating 87 4 4 Using the Brake Release 88 BOROT sco idee cato X then edunt ande 88 Brake Release BURON aare eera EE VEP a E hen 88 Remote Brake Release Connection 88 4 5 Description of the Manual Control Pendant 90 How to Hold the s iex e Re ed nom xr eem 90 Description of Buttons on the 9 Mode Control and Joint Axis Control 9 e ac e e een OR dea ee 9 4 6 How to Stop a Robot in Manual Mode 92 4 7 How to Start the
46. 107 HyperDrive Robot Fan Filter Inspection and Cleaning 107 Adept 4 Fan Filter Inspection and 108 Adept MV Controller Fan Filter Inspection and 0 108 5 7 Check Lamps on 25225 Tw EET Tee RR EE eda 108 5 8 Special Maintenance for Adept PackOne MV Robot 109 General 109 Exterior Coating i re UR e 109 Rotary Seal Assemblies iens 109 Fixediseals eee Pee pe vue a Y 109 s aca x Oi oq es ER A 109 Removing the End Effector for 109 Washdown Procedure ie ue ee sace e RR Re a 110 Installing Protective 110 Drying Time Before 110 5 9 Bolt Removal Resealing Procedure PackOne MV Robot 111 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 99 Chapter 5 Maintenance 5 1 Introduction The AdeptOne MV Adept PackOne MV and AdeptThree MV robots require very little maintenance due to the direct drive design Joints 1 and 2 need no maintenance at all This chapter describes the preventive maintenance procedures that are required to keep the robot system operating properly The Adept PackOne MV robot requires additional maintenance relatin
47. 8 flat head screws into the chassis on the left hand side Replace the cover on each unit Joining at the Bottom 1 Turn the two units over so you have access to the bottom side Locate the cutout bracket in the accessory kit 2 3 4 Place the bracket over the feet of the units as shown in Figure 2 9 Install the four M4 x 8 flat head screws in the holes indicated in Figure 2 9 to secure the brackets CAUTION Do not use screws longer than 8 mm to install the bracket Doing so could cause damage to your equipment Bottom View Install flat head Phillips screws in 4 places to secure bracket 6 OO OO OO 4 Adept 8 Adept 4 Controller Power Chassis Figure 2 9 Joining the Power Chassis and Controller at the Bottom AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 33 Chapter 2 Installation of the Robots 34 Space Around the Chassis When the controller and power chassis are installed you must allow 50 mm 2 inches at the front of each chassis and 25 mm 1 inch at the top of each chassis for proper air cooling CAUTION It is important to keep the air filters clean so the forced air cooling system can work efficiently See section 5 6 on page 107 for details on cleaning the filters Installation in a Rack or Panel Mount The power chassis and controller can be mounted in a rack or panel by
48. Additional Power Chassis Information 63 A Amplifier Module Overview iie n 63 Connectors and Indicators 63 B Amplifier Module es 64 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Table of Contents Connectors and Indicators 64 Power Chassis Circuit Breaker and Fuse Information 65 Chassis Circuit Breaker nca Ra 65 Chassis and Amplifier Module Fuses 65 Removing and Installing Amplifier 65 Removing Amplifier Modules 65 Installing Amplifier 66 2 19 Connecting Compressed Air Supply to the 66 2 20 Installing End Effectors on an AdeptOne MV AdeptThree MV Robot 67 Clamp mounted End Effector csse 67 Screw mounted End Effector on AdeptOne MV and Adeptihree MV ROBOTS sii sient re Sos eic edet e ath CRI 68 2 21 Installing End Effectors on an Adept PackOne MV Robot 69 69 Clamp mounted End 69 Screw mounted End Effector lisse 70 3 Preparation for Safe and Effective Use of the Robot 71 3 1 Overview of Safety 5
49. Brake Release is for manual use only It should not be incorporated into automatic acting circuits or systems A momentary switch must be used for the remote brake release i e no permanent acting N C or N O switches The brakes are not designed to be used as a routine method of stopping robot motion 88 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Using the Brake Release Button NOTE The Remote Brake Release connector is not available on the Adept PackOne robot Remote Brake Brake Release Button Release Connector Figure 4 1 Robot Base Showing Brake Release Button and Connector AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 89 Chapter 4 Commissioning the System 4 5 Description of the Manual Control Pendant MCP The MCP assists the operator in teaching robot locations to be used in application programs The MCP is also used with custom applications that employ teach routines that pause execution at specified points and allow an operator to teach or re teach the robot locations used by the program The Adept AIM software system makes extensive use of the pendant for teaching robot locations A description of the necessary basic operations with the such
50. COARSE mode 134 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B AdeptThree MV Robot Specifications AdeptThree MV Robot Working Envelope Maximum Intrusion Contact Radius 1143 mm 45 0 Inner Link Radius 508 mm 20 Pd 4 A 7 1 m Joint 2 Limit o 150 Joint 1 Limit 2 Xe 4150 Maximum Radial Reach Functional Area 1067 mm 42 0 Minimum Radial Reach Inaccessible Area 279 mm 11 0 Joint 1 Limit 150 Figure 6 18 AdeptThree MV Robot Working Envelope AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 135 Chapter 6 Technical Specification 6 5 Adept PackOne MV Robot Specifications specifications subject to change without notice Table 6 3 Adept PackOne MV Robot Performance Specifications Reach Maximum radial 800 mm 31 5 in Minimum radial 245 mm 9 1 in Vertical clearance bottom of base to end effector flange Standard 7 7 in stroke with maximum Joint 3 retraction 876 mm 34 5 in with maximum Joint 3 extension 681mm 26 8 in Optional 11 6 in stroke with maximum Joint 3 retraction 775 mm 30 5 in with maximum Joint 3 extension 480 mm 18 91 in Vertical Stroke Z direction Standard Joint 3 195 mm 7 7 in Optional Joint 3 295 mm 11 6 in Joint Rotation Joint 1 300 Joint 2 290 Joint 4 540 Paylo
51. Category 3 Emergency Stop 141 B Qn MERC 145 Introduction 146 B2 Installation sl ies 146 Vacuum REQUITEMENTS saari es 146 Instellemabi pne heo eror ot meiste Pep Eee 147 Vacuum SUPPI PUM e tet e o Rh 147 PIPES SIZE etie on taco ded Mop beo ey 148 Mec ums WITGL erm o ct eere ena Roe RECEN CR INR 149 TESTING THE 149 Bellows 149 Required Materials and 5 2 149 Removing the 4 4 4 4 150 Installing the New BellowS iie men 150 Further 151 Using the Safety 153 Introduction 2 eee ewe Rew ates eon ERIS 154 Category Robot Components ees 154 AGCOleFOITielel s oor matar e aes eh hin ew abe D eee aT a 154 B Amplifier Voltage 5 154 Switches and Buttons 2 2 154 Hola To Run Switch lise 154 Dual Brake Solenoid 155 Dual Dump Valves AdeptThree MV 155 Robot Brake
52. Chassis Monitor 0 54 m 21 in 0 51 m 20 in 0 51 m 20 in 23 kg 50 Ib WARNING The center of gravity of the robot shipping crates is not in the middle of the boxes Pay attention when you transport the crates 2 6 Transport and Storage For the transport and storage of the crates and boxes use a adequate tool for instance a pallet jack or a fork lift See Figure 2 2 WARNING Heavy load Do not attempt to transport the robot boxes by hand Always use a pallet jack fork lift etc The robots must be always stored and shipped in an upright orientation Do not lay the crate on the side or another position A different position other than standing on the robot base could damage the robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 23 Chapter 2 Installation of the Robots 2 7 Place forklift or p m M pallet jack here Figure 2 2 Adept Robot on a Transportation Pallet Unpacking and Inspecting the Adept Equipment 2 8 Compare the actual items received not just the packing slip with your equipment purchase order and verify that all items are present and that the shipment is correct Inspect each item for external damage as it is removed from its container If any damage is evident contact Adept at the numbers listed at the end of Chapter 1 Retain all containers and packagi
53. Installing End Effectors on an AdeptOne MV AdeptThree MV Robot Providing an end effector or other end of arm tooling is the responsibility of the User An end effector can be attached to the flange by using a ring clamp supplied or four 8 32 screws supplied If hazardous voltages are present at the end effector you should install a ground connection from the base of the robot to the end effector See section 2 16 on page 51 Also see Chapter 6 for dimensions of the User flange Clamp mounted End Effector The following procedure describes the installation of a typical end effector using the ring clamp Refer to Figure 2 31 1 2 Disconnect the air supply to the robot Remove the plugs from the Open and Close air lines where they protrude from the quill flange Place the ring clamp over the quill flange Install the Open and Close air lines onto the appropriate fittings on the end effector Test the operation of the end effector to ensure that the Open and Close functions are not reversed Mate the end effector flange to the quill flange Rotate the end effector until its key aligns with the keyway in the quill flange then place the ring clamp over both flanges and tighten the clamp screw Quill Flange acc Ring Open Close Air Lines Figure 2 31 Clamp mounted End Effector Installation AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 67 Chapter 2 Installation of the Robots
54. MV AdeptThree MV Robot Instruction Handbook Rev B 119 Chapter 6 Technical Specification Dimensions for Adept MV 8 Controller 479 mm 120 Front View 216 mm Y Top View 52 mm 290 mm 136 18 Side View Figure 6 7 Adept MV 8 Dimensions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Dimensions Dimensions for Adept MV 19 Controller 290 mm aues Figure 6 8 Adept MV 19 Dimensions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 121 Chapter 6 Technical Specification Dimensions for Adept PA 4 Power Chassis Top View
55. MV System Cable Installation 42 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Signal Interconnection Installation System Cable Lengths Table 2 4 System Cable Lengths Cable Length Arm Power and Arm Signal Standard 4 57 m 15 ft Optional 7 62 m 25 ft and 15 24 m 50 ft VJI to Amp MV 8 0 9 m 3 ft MV 19 2 1 m 7 ft SIO DIO to Cat3 E Stop 3 05 m 10 ft VFP to Cat3 E Stop 3 05 m 10 ft User to E Stop Teach Restrict 1 8 m 6 ft Teach Restrict to B Amp 1 8 m 6 ft Front Panel SIO to VFP 2 m 6 5 ft PA 4 Power Cord 2 9 m 9 5 ft Connecting the Robot to the Power Chassis The cable between the robot and power chassis is called the Arm Power cable The robot end of the cable has a single large rectangular connector with a thumb screw The opposite end of the cable has four separate square connectors that go to the power chassis See Figure 2 16 the fourth connector is not used and is not shown on the drawing If you have an AdeptOne MV or AdeptThree MV start at step 1 On a Adept PackOne MV robot the Arm Power cable is already connected with the robot see Figure 2 18 Please start at step 2 1 Connect the large rectangular end of the arm power cable to the Arm Power connector on the back plate of the robot Tighten the thumb screw securely 2 Connect the other end of the Arm Power cable to the matching connectors on the A and Amp modules
56. Screw mounted End Effector on AdeptOne MV and AdepiThree MV Robots The following procedure describes installing an end effector using four screws See Figure 2 32 1 Disconnect the air supply to the robot 2 Remove the plugs from the Open and Close air lines where they protrude from the quill flange 3 Install the Open and Close air lines onto the appropriate fittings on the end effector 4 Mate the end effector flange to the quill flange Rotate the end effector until its key aligns with the keyway in the quill flange 5 Test the operation of the end effector to ensure that the Open and Close functions are not reversed 6 Insert four 8 32 screws through the mounting holes and tighten Recommended torque is 1 69 Nm 15 in Ib If the screws protrude slightly through the flange align the cutouts in the Joint 3 hardstop located just above the quill flange to accommodate the screw tips CAUTION Do not allow the mounting screws to protrude up into the hardstop any farther than the cutouts because this can prevent proper seating of the flange against the hardstop Improper seating against the hardstop will prevent the robot from calibrating properly and will cause all of the previously taught robot locations to have the wrong height Joint 3 Hardstop 20 Flange Thickness Open and Close Air Lines 8 32 4 places H Figure 2 32 Screw mounted End Effector Installation 68 AdeptOne MV AdeptThree M
57. a uolet pg 15 Edrope GermaLniy s ats ete acd c canos Ried fe Ata es bled ac 15 t eno ee usta D Ub an vine b pd 15 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Table of Contents lev TATE 15 IA TNS ntted STOTSS s cep RS ROC lata a RR qnt i 15 Service Galle os tert eter trado lec dead ite des 15 Applicatiori 15 Applications Internet E Mail 0 655 15 Ipternmelllob 4 232 tite D nt cede pes 15 Outside Continental United States or Europe 16 2 Installation of the Robots 17 2 1 Environmental and Facility Requirements for 19 Facility Ambient Air Quality For Robots 19 Compressed Air for the AdeptOne MV and AdeptThree MV Robot nn 19 Additional Facility Requirements of the Adept PackOne MV ROBOTS e LP c r E 19 Mounting Surface Specifications 2 2 2 222 2 2 20 acest oh eee te fas oe tah ee alerta doa D Er nay et 20 SDOOl ade ese eine aden ae deat her ast 21 2 2 Environmental and Facility Requirements for Controller 22 2 3 Environmental and Facility Requirements for Power Chassis 22 2 4 Before Unpacking the Adept
58. are not supplied with connection fittings at either end At the base the end of the air lines can be routed through either one of the access holes capped with removable plastic plugs Figure E 1 To gain access to the spare air line at the base remove eight cap head screws that secure the base top cover then lift and turn the cover out of the way Be careful not to disturb exposed parts and wiring when top cover is off At the outer link location the air line can be accessed by removing the outer link access cover AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 181 Appendix E Additional Robot Information E 2 Installing Extra Lines in the PackOne User Flange Assembly 182 The PackOne user flange assembly consists of the user flange and the Quill ID tube and cap This entire assembly can be removed from the robot to install extra lines The Quill ID tube cap see Figure 6 6 on page 119 has four pass through holes with 5 32 union bulkhead fittings that allow lines to come from inside the robot out to the user flange Two of these bulkhead fittings pass the Open and Close air lines that are installed at the factory The other two fittings are plugged at both ends and are provided for running extra lines either air or electrical to the flange Follow the procedure below to run extra lines CAUTION If you remove the quill cover you must reseal the bolts when the cover is reinstalled Refer to the procedure in
59. disable High Power if a system failure occurs The following situations may result in risks that cannot be avoided purposely defeating any aspect of the safety E Stop system improper installation or programming of the robot system unauthorized use of cables other than those supplied or use of modified components in the system failure of a second device in a redundant safety circuit Take precautions to ensure that these situations do not occur 1 18 What to Do in an Emergency Situation Press any Emergency Stop button a red push button on a yellow field and then follow the internal procedures of your company or organization for an emergency situation If a fire occurs use CO to extinguish the fire 14 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B How to Get Help 1 19 How to Get Help When calling with an equipment related question please have the serial number of the robot controller and power chassis The serial numbers are located on the product data labels on each piece of equipment The serial numbers can also be determined by using the ID command see the V Operating System User s Guide In Europe Europe Germany Adept Technology maintains a European Customer Service Center in Dortmund Germany The phone numbers are 49 231 75 89 40 Monday to Friday 8 00 to 17 00 CET 49 231 75 89 450 FAX France For customers in France Adept Technology maintains a Customer S
60. displayed If the response is Y the following message is displayed Dual Solenoid test 2 Plug the first solenoid into J11 Unplug the second solenoid from J13 and press the brak release button Do the brakes remain engaged Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Dual Solenoid test 3 Plug the second solenoid into 413 Press the brake release button on the RSC Do the brakes release Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed While still pressing the brake release button unplug the first solenoid from 11 Do the brakes engage Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Dual Solenoid test 4 Plug the first solenoid into J11 Press the brake release button on the RSC Do the brakes release Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed While still pressing the brake release button unplug the second solenoid from J13 Do the brakes engage Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed 170 AdeptOne MV AdeptThree MV Robot Inst
61. et eT eT 6 8 mm 4x Ua e eje eje eje e C Y E 1 8 56 5 e o 33 1 mm 10 3 Controller and Power Chassis with mounting 4x brackets installed Figure 6 12 Adept MV 8 and PA 4 With Mounting Brackets Installed AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 125 Chapter 6 Technical Specification MCP Cradle Dimensions 4 X 10 2 mm 0 4 2 28 7 1 13 4 N S 2X 203 2 mm 8 271 5 mm 10 69 gt 4 X 4 8 mm ds 0 188 4X97 mm 1 0 38 4 X 09 7 mm Y 20 38 201 7 9 221 8 70 Figure 6 13 Cradle Dimensions 126 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Joint Motions 6 2 Joint Motions Joint 1 Joint 1 also referred to as the shoulder provides the rotational movement of the inner link and the column Travel of the inner link is limited by software to 300 Refer to Figure 6 14 150 Figure 6 14 Joint 1 Motion Joint 2 Joint 2 also referred to as the elbow is the pivot point between the inner link and the outer link Outer link travel is limited by hardstops located on top of the inner link Travel of Joint 2 is limited by software to the value set by
62. following parts of an AdeptOne MV AdeptThree MV and Adept PackOne MV are not grounded to protective earth the Joint 3 quill the tool flange and all access covers If hazardous voltages are present at any user supplied robot mounted equipment or tooling you must install a ground connection from that equipment tooling to the ground point on the robot base Hazardous voltages can be considered anything in excess of 30VAC 42 4VAC peak or 60VDC WARNING Failing to ground robot mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end effector when an electrical fault condition exists 52 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Grounding Information Typical Customer Supplied Equipment Cabinet Customer Supplied Ground Wire for End of Arm Tooling Y Robot A QN Ground Point Equipment Cabinet Ground Point Adept Robot Customer Supplied Ground Wire for Robot
63. in the Adept PA 4 power chassis The A Amp module on the left hand side called Amp 1 drives the motor for Joint 1 The A Amp module to the right hand side called Amp 2 drives the motor for Joint 2 Connectors and Indicators Status LED s When an LED is turned on it indicates the following conditions High Volts On indicates the high voltage to the amps is turned on PWM On indicates that current servo is on It does not go on until calibration is complete DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY EXTINGUISHED wien vots on O towvouts on OPEN ext FAULT HVsaciover A PHASE SHORT FAULT B PHASE SHORT FAULT Low Volts On indicates the low voltage supply in the power chassis is on Open Ckt Fault indicates that an open circuit in the motor leads has been detected C PHASE SHORT FAULT HV Sag Over Temp indicates that the input voltage has dropped below the specified level or an over temperature fault has been detected on an amp module Phase A B C Short Fault indicate that an over current in the motor leads to one of the phases has been detected Amplifier Control connector the VJI to Amp cable connector is installed here Motor Power Output connector the Arm Power cable is installed here zmzov AdeptOne MV AdeptThree MV Robot Instruction Handbook
64. in the Adept MV Controller The communication between the Adept MV Controller and the Security Panel requires this connection The SIO DIO to Cat3 E Stop cable connects the Digital I O connector on the SIO module in the Adept MV Controller with the Category 3 Emergency Stop PCA on the Security Panel Installation procedure for the SIO DIO to Cat3 E Stop cable 1 Make sure that controller On Off switch is turned off 2 Connect the 50 pin D Sub female connector of the cable to the connector J2 on the Category 3 Emergency Stop Tighten the two captive screws securely 3 Connect the 50 pin D Sub male connector at the other end of the cable to the connector Digital I O connector I O 24V 100mA on the SIO Module Tighten the two captive screws securely 48 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Signal Interconnection Installation Connecting the Security Panel to the External Front Panel Communication between the external Front Panel and the Security Panel is through the VFP to Cat3 E Stop cable The has on its back side a board with a 25 pin D Sub male connector with the label J5 On the Category 3 E Stop board is a 25 pin D Sub female connector with the label J3 The VFP to Cat3 E Stop cable connects J5 on the with J3 on the Category 3 E Stop board Installation procedure for the VFP to Cat3 E Stop Cable see Figure 2 22 1 Make sure that Adept MV controller On Off switch is turned
65. manually when the operating mode key switch is in the MANUAL position and the HIGH POWER light on the is illuminated When Manual mode is selected motion can only be initiated from the Manual Control Pendant MCP Per EN 775 ISO 10218 the maximum speed of the robot is limited to 250 mm per second 10 ips in Manual mode In this mode work that requires close approach to the installation or robot can be performed such as teaching points program verification or troubleshooting operations AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 13 Chapter 1 Safety NOTE The MCP has two operating modes In MAN Manual mode the MCP can initiate a robot motion In COMP Automatic mode the MCP works like a terminal 1 16 Safety Aspects While Performing Maintenance Only skilled persons with the necessary knowledge about the safety and operating equipment are allowed to maintain the robot controller and power chassis WARNING During maintenance and repair the power of the Adept PA 4 power chassis and the Adept controller must be turned off Unauthorized third parties must be prevented from turning on power through the use of fail safe lockout measures Turn off the circuit breakers lock the cabinet and remove the key 1 17 Risks That Cannot Be Avoided The Category 3 AdeptOne MV AdeptThree MV and the Adept PackOne MV Robot Control system implementation has a series of electro mechanical devices that
66. other modules It should not be necessary to use excess pressure or force to engage the connector If the board does not properly connect with the rear power connector remove the module and inspect the connector and guide slots for possible damage or obstructions Tighten the captive screws at the top and bottom of the module WARNING There is an interlock circuit that prevents enabling power if the amp module screws are not tightened securely This also applies to any blank panel cover s There are dangerous voltages present inside the power chassis do not attempt to operate without blank panel cover s installed in any unused slots 2 19 Connecting Compressed Air Supply to the Robot The user must supply all tubing and fittings to plumb the facility air supply to the robot The robot is supplied with an air filter with a standard 1 4 inch Industrial Interchange nipple The compressed air to the robot must meet the specifications listed in section 2 1 on page 19 For the Adept PackOne MV robot you must supply a desiccant or refrigerated compressed air dryer 66 CAUTION The compressed air supply to the Adept PackOne MV Robot must be turned on 24 hours per day to provide constant protection from internal condensation Failure to supply air to the robot 24 hours per day can void the warranty AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installing End Effectors on an AdeptOne MV AdeptThree MV Robot 2 20
67. section 5 9 on page 111 for complete details Also the user flange assembly is sealed to prevent moisture from getting inside the robot If you install additional electrical lines through the cap you must ensure that a water tight seal is maintained Sealant recommendations are listed in the following procedure Lower the quill to its lower stop Turn off High Power to the robot disconnect the compressed air supply and remove any installed end effectors Remove the Upper Quill cover to expose the two air lines and disconnect them from the unions at the quill tower bracket Remove four 8 32 socket head cap head screws from the user flange face This allows the entire user flange assembly to be removed from the quill so you have access to the two unused pass through holes Remove the Quill ID tube cap from the Quill ID tube assembly by removing four plastic screws see Figure 6 6 on page 119 Remove the plugs on either side of the two unused bulkhead fittings to install additional lines If you are adding 5 32 air tubing then no additional sealing is needed If you are adding electrical lines or other types of lines that would not be sealed by the union fittings then you must use a sealant to make a water tight seal through the cap Adept recommends Dow Corning 732 multipurpose USDA approved silicone adhesive sealant The union fittings can be unscrewed and removed if the added lines are too large to pass through make su
68. selected from the Joint Axis control buttons Joint 2 Joint 1 Joint 2 Joint 3 J Joint 3 ccm Joint 4 Joint 4 Figure 4 7 Joint State SCARA In Joint State only the selected joint moves After the calibration of the robot switching into Manual mode and re enabling High Power you must select the joint mode 1 Press the MAN HALT button to enable the MCP The MCP is in the correct mode when a The LED on the MAN HALT button is illuminated If it is not illuminated press the MAN HALT button b Oneof the manual state LEDs is also illuminated the Manual state LEDs indicate the type of manual motion that has been selected either World Tool Joint or Free 2 Press the MAN HALT button see Figure 4 5 several times until the JOINT LED is illuminated When the LED on the MAN HALT button and the JOINT LED are lit Joint state is selected and movement of a specified joint must be selected 96 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Moving the Robot with the MCP Selecting and Moving Joint 1 Before you can move Joint 1 you must select it with the On the right side of Figure 4 7 you can see the buttons for selecting a joint in the Joint State After pressing the X1 button that selects Joint 1 the LED on the button will turn on Then you can move the robot with the speed bars NOTE The operator must keep pressing the Hold to Run button to retain High Power w
69. tested Press and release the HIGH POWER button while the button is flashing Press ENTER to begin the test Release the Hold To Run switch and press ENTER to continue When ENTER is pressed the system will attempt to turn on High Power If High Power cannot be switched on the test fails and an error message is displayed If High Power is switched on the MCP Hold To Run test passes The next test menu is displayed AdeptOne MV AdeptThree MV Robot Instruction Handbook 165 Appendix C Using the Safety Utility Keep the Hold To Run switch pressed MCP test 3 Press the MCP E STOP button Is the red E STOP LED on the SIO Module on Y N Attempting to enable HIGH POWER with the E STOP button pressed Cat 3 external E Stop Code O0 Pressing the panic button should cause an E STOP condition MCP test 4 Release the MCP E STOP button Is the red E STOP LED on the SIO Module off Y N Attempting to enable HIGH POWER with the E STOP button released After releasing the the system will attempt to enable High Power If successful the following is displayed Press and release the HIGH POWER button while the button is flashing Press ENTER to begin the test Press the MCP E STOP button a nd press ENTER to continue When the panic button is released the test is complete Releas
70. tests SAFE UTL V2 must be run Follow the steps below to load and execute the program 1 Remove all end effectors from the quill flange m Enable High Power and calibrate the robot See section 4 7 on page 92 e Load the utility program into system memory with the command LOAD C NUTILNSAFE UTL V2 4 Start execution of the program with the command EXECUTE 1 a safe utl The following menu is displayed Adept CE Category 3 Test Program Version 11 3B Copyright c 1996 by Adept Technology Inc Robot 1 XXX XXXX Language Selection English Deutsch 0 1 Enter Selection The appropriate language selection can be made from this menu The following is displayed 158 AdeptOne MV AdeptThree MV Robot Instruction Handbook B Tests Performed at Time of Commissioning C 3 WARNING The current robot will be marked as not commissioned and will be marked as commissioned only after passing all tests Do you want to continue Y N If the system has previously been commissioned responding Y marks the system as not commissioned The robot cannot be operated in the manual mode until all tests are completed and passed If the response is N the system is left unchanged and the program halts WARNING These tests must only be performed by skilled or instructed persons Tests Performed at Time of Commissioning NOTE The screen displa
71. the softstop This motion can be likened to an elbow capable of acting in either a left or right hand configuration See Figure 6 15 The robot can reach a given location in either a right hand Righty or left hand Lefty configuration However when Vt moves the arm to a location it must sometimes make assumptions about which configuration to use While this generally produces the result desired by the programmer sometimes the system assumption may differ from the programmer s expectations In those cases the programmer must specify within the program RIGHTY or LEFTY operation AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 127 Chapter 6 Technical Specification LEFTY RIGHTY Joint 2 Hardstops Figure 6 15 Joint 2 Motion and LEFTY RIGHTY Configurations Joint 3 AdeptOne MV and Adept PackOne MV Joint 3 provides vertical movement of the quill at the end of the outer link with a standard stroke of 196 mm 7 7 inches An extended length version of the AdeptOne MV and Adept PackOne MV robot provides a Joint 3 stroke of 295 mm 11 6 inches Refer to Figure 6 16 AdeptThree MV The motion of Joint 3 on the AdeptThree MV is the same as the AdeptOne MV There is only one stroke length it is 305 mm 12 0 Joint 4 Joint 4 also referred to as the wrist provides rotation of the quill over a range defined by the softstop This motion is similar to that of the human hand involved in tighten
72. the test N indicates no while Y indicates yes Accelerometer Test WARNING The user must remain outside the robot workcell with all safety barriers closed while conducting these tests Failure to observe this warning could cause serious injury The accelerometer is tested to ensure that it is operational The following message is displayed Accelerometer test MCP controlled move no E STOP expected The MANUAL AUTO and LOCAL NETWORK key switches are checked by SAFE UTL V2 If a Switch switch is in the improper position the following message is displayed the MANUAL AUTO keyswitch to MANUAL and LOCAL NETWORK keyswitch to LOCAL When the key switches are in the proper position High Power will be enabled displaying a request to cycle the Hold To Run button See E STOP Functions on page 165 If you are not familiar with operating the MCP review section 4 9 Moving the Robot with the MCP When High Power is enabled the following message is displayed Use the MCP to drive Joint 1 at top speed Do NOT drive the robot onto a soft stop Press REC DONE on the MCP when done If an E until REC DONE flashes then press REC DONE STOP or other error occurs press CLR ERR button Press the COMP PWR button then the REC DONE button when motion is completed During this test the accelerometer should not be tripped If there is a fault make caref
73. to completing the work they will need to use a source of customer supplied helium to do leak detection tests AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 111 Technical Specification 6 1 DimenslOns Re Reds Wed a EE 114 Dimensions for AdeptOne MV HyperDrive 114 Dimensions for AdeptThree MV Robot 115 Dimensions for Adept PackOne MV Robot 116 Calibration Fixture 2 nen 117 User Quill Flange Dimensions for AdeptOne MV and AdeptThree MV 118 User Quill Flange Dimensions for Adept PackOne Robot 119 Dimensions for Adept MV 8 Controller 120 Dimensions for Adept MV 19 Controller 121 Dimensions for Adept 4 Power 1 122 Dimensions of the External Front 123 Dimensions of the Security 124 Dimensions of the Mounting 1 125 MCP Cradle 1 4 4 4 4 126 6 2 Joint MOTIONS e hea takes ve EX eA EPUA NAKNA 127 ctetuer ate detected du vd ated a ticdu cfe dde 127 Joint 2 3 vetas totg tei d och detis p Wath ek 127 Stet ite ave tet
74. using the mounting brackets that are shipped in the accessories kit The brackets can be attached at the rear of the controller power chassis for panel mounting or they can be attached to the front of the controller power chassis for rack mounting Panel Mounting To panel mount the controller or power chassis install one bracket on each side near the back of the chassis Use the screws and washers from the accessories kit See Figure 2 10 and Figure 2 11 Rack Mounting To rack mount the Adept PA 4 power chassis joined to an Adept MV 8 controller in a standard 19 inch equipment rack you must use the mounting brackets screws and washers from the accessories kit The brackets can be installed in two positions for rack mounting flush and set back See Figure 2 10 and Figure 2 11 To rack mount the controller or power chassis by itself in a standard 19 inch equipment rack you must first install the mounting brackets then build an extender panel and attach it to the bracket on one side of the chassis AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installation of the Adept MV Controller and the Adept PA 4 Power Chassis M4 x 25mm pan head screw 2 places Fo o o To Install Mounting Brackets on Adept MV controller Remove and discard 3 existing countersunk screws from side of chassis at locations shown o o in drawing Place bracket in desired position and secure S with indicated M4 screws a
75. 05 mm Sq 127 View View Option 1 Option 2 Material Carbon Steel Mounting Surface Flatness 0 5 mm 0 02 e Mounting Surface Level within 0 25 2 5 mm 0 01 over 610 mm 24 diameter Figure 2 1 Recommended Mounting Spool Specifications AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 21 Chapter 2 Installation of the Robots 2 2 Environmental and Facility Requirements for Controller The Adept MV controller installation must meet the operating environment requirements shown in Table 2 2 See Table 2 5 on page 54 for electrical requirements Table 2 2 Operating Environment Requirements Ambient temperature controller while accessing floppy or hard drive 5 C to 40 32 to 104 controller while not accessing floppy or hard drive 5 C to 50 C 32 to 122 F power chassis 5 C to 40 C 32 to 104 F Humidity 5 to 90 non condensing Altitude up to 2000 m 6500 ft Pollution degree 2 Free space around controller and power supply for proper cooling 50 mm 2 in front 25 mm 1 at top Sub assembly protection class unmounted IP20 NEMA Type 1 Requirements for customer supplied enclosure with Adept controller and power chassis mounted inside enclosure Enclosure must meet EN 60204 requirements and be rated at IP54 Also enclosure must provide a method of locking the
76. 17 amps phase 50 60Hz 3 phase Watts 1 65 kW 3 kW In the 380 415 VAC configuration the Adept system draws current for a short duration during the positive peak voltage only AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 139 Category 3 E Stop Circuit Category 3 Emergency Stop Circuitry The Category 3 Emergency Stop circuitry is mounted on the Security Panel The components are on two DIN rails the Control Rail and the Power Rail The safety relay and power contactor diagram on the following two pages should help to understand the circuitry and to install the user supplied parts of the Category 3 Emergency circuit NOTE For clarity some components are omitted such as current limiting resistors and inductive protection diodes AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 141 Appendix A Category 3 E Stop Circuit 142 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop Circuitry ESTOP24V 2 L4 j BF E STOP VA E Ded 7 0 FESTOP24V E STOP _V ESTOPINP 7 D 24 SR4 MCP Hold to Run m 24 SR5 B41 TB4 7 5 V ESTOPINP emus EM 00 TB5 1 4 24 4 8 4 3 4 9 2 peu Li Ls 33 fc m 5 2 TB4 4 4 TB
77. 2 Module Assy FD HD SIO2 30332 12351 P2 SYSIO 2 Module Assy FD 10332 00800 P2 PCA VME Digital I O DIO 10332 10250 P3 PCA VME Graphics Board VGBIII 10332 00600 P2 PCA VME Frame Grabber VIS 10332 11400 P4 PCA VME Motion Interface MI 3 10332 12400 P2 PCA VME Motion Interface MI 6 10332 00500 P2 PCA VME Joint Interface VJI IIT Table 2 Plug in Modules and Accessories that may be installed in MV 8 and MV 19 Controllers but must first be tested in the final system configuration to assume full compliance Part Number Minimum Acceptable Description Revision 90332 02020 AdeptNet 10BaseT Kit 10330 00970 PCA VME Analog I O AIO 90211 00000 Adept Force Kit P N 01840 00030 Rev P1 Table of Contents 1 1 Deb SINMOGUCTIONS EM 2 Adept Equipment Compatibility csse 3 Definition of a Manipulating Industrial 4 1 2 Notes Cautions and 05 4 1 3 Risk Assessment Category 3 System 5 1 4 Precautions and Required 6 RolbotStatic FOCOS sess Oh bah AE to def poet ERU P Ee dx 6 6 Impact and Trapping 2 7 Hazards from Expelling a Part or Attached Tooling
78. 4 10 TB5 3 34 24 12 24 12 SR5 LJ N 5 7 57 33 5 4 2 11 23 11 DPI INE TB4 5 5 4 11 5 7 4 6 TB4 12 34 24 SR6 o Ly SR8 588 SR9 a 11 23 _1B5 9 KEYSWO 34 1 SR7 Mo ee eet TB5 10 SIOCOM N s RF2 AUTO MANUAL ul V PASESTOP 43 44 SR7 43 V PASESTOP P P 2 P P amp amp 2 2 NV NV SR6 SR7 RL1 SR5 SR4 mS mS RL3 RL2 ESTOPCOM M 6 M M 5 5 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 143 Appendix A Category 3 E Stop Circuit 144 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop Circuitry ESTOP24V L1 DW AP1 KEYSW2 y _ x ect B AP2 SIOCOM 785 11 T 0 27774522 13 A 12 Di L PA 0 LLL M ROBOT 12VDC g RF5 AP2 L 34 BAKEL SR1 33 44 la 3 12 SR1 RL3 RL2 SR2 34 95 1 1 11 SR2 33 44 24 24 34 24 12 SR2 SR3 V SRI SR3 V SR2 7 SR1 23 23 33 23 11 R3 SR3 6 11 a MT p 50 SOL2 P P P Y n _ 2 EUNT SR1 SR2 sr apt ROROTEOM M M e e T e ESTOPCOM Note The description of the numbers are in Table A 1 on page 146 Figure A 1 Cate
79. 7111 cA uu Figure 1 CleanRoom Features Vacuum Installation Vacuum Supply Pump In order to select a vacuum supply pump the customer must evaluate the distance between to robot and vacuum pump and pipe size AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 149 Appendix B CleanRoom Option Pipe Size The first topic in this section discusses rough rules of thumb to determine the pipe size required for an acceptable pressure drop The second topic lists optional features of installed piping and might be used as a check list by the installer Pipe sizes to be used when hooking up the robot to a vacuum source are a function of several factors air flow requirements of the system distance from vacuum pump to robot vacuum pump used discussions assume the use of PVC pipe due to its low cost ease of installation good flow characteristics and availability The first consideration in pipe size is the location of the vacuum pump with respect to the robot Given the location of the pump a diagram displaying the pipe layout should be drawn This allows the counting of fittings and their conversion to equivalent pipe distances Estimates of pipe fitting flows converted to straight pipe equivalents for three common pipe diameters are shown in Table B 1 These distances are then added to the nominal amount of straight pipe to create a total pipe length There are practical limits to the length
80. 8 2 16 Grounding Information 51 Adept MV Controller Grounding iin 5 Adept PA 4 Power Chassis 51 Security Panel Grounding 2 2 tes 51 Adept Robot Grounding saaana 51 Robot Mounted Equipment 52 2 17 Connecting to AC Power 54 Connecting AC Power to the MV 54 Connecting AC Power to the Adept PA 4 Power Chassis through the Security 2 2 4 2 2 4 4 56 2 18 Additional Power Chassis 63 A Amplifier Module 63 B Amplifier Module Overview es 64 Power Chassis Circuit Breaker and Fuse Information 65 Removing and Installing Amplifier 65 2 19 Connecting Compressed Air Supply to the 66 2 20 Installing End Effectors on an AdeptOne MV AdeptThree MV Robot 67 Clamp mounted End Effector sisse 67 Screw mounted End Effector on AdeptOne MV and AdeptThree MV Robots eee 68 2 21 Installing End Effectors on an Adept PackOne MV Robot 69 lgzuellenol EAE EE 69 AdeptOne MV AdeptThree MV Robot Instruct
81. Adept Utility Programs 38 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installing the External Front Panel 2 13 Installing the External Front Panel EMERGENCY STOP ccn CO PROGRAM PROGRAM PENDANT LOCAL NETWORK START RUNNING pe SYSTEM HIGH POWER MANUAL AUTO o POWER ON OFF Figure 2 13 External Front Panel VFP Controls and Indicators EMERGENCY STOP switch This push pull emergency stop switch removes HIGH POWER and brings any installed motion device to an immediate stop when pressed HIGH POWER ON OFF switch and lamp amber This push button switch works in conjunction with the Enable Power command When 1 flashing this lamp signals the operator to press the button to enable High Power If the amber lamp is on the robot is operating under servo control with the brakes released When the lamp is on pressing the button engages the brakes then disables High Power PROGRAM RUNNING lamp white When lit this lamp indicates that a V program is running It is a warning that the robot and other mechanisms in the workcell are under computer control and may move at any time SYSTEM POWER switch and lamp green This rotary on off switch controls the main AC power relay The green lamp is lit when main AC power is on PROGRAM START switch and lamp green A programmer can read the status of the button to trigger special events Operating Keyswitch The keyswitch i
82. B CleanRoom Option B T Introduction sa Rd rr 4684 146 B2 Insiallationi em E 146 Vacuum Requirements ee eens 146 IBsSTellemotb a cede PORE MPH E 147 Vocum SUPON PUMO 4 ited a e n Re Ie RAT 147 PIDE SIZE is dfi erc d dut bed den Pudet es 148 V OCUUPTEOWITCLE i dean oa OR UR RON EROR 149 Testing the VACUUM ab ac ecc t BERE NE E RE 149 Bellows Replacement 149 Required Materials and 5 2 149 Removing the 4 4 4 150 Installing the New 5 1 mmn 150 FarthierInstrucTlofis s op v Cr ec 151 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 147 Appendix B CleanRoom Option B 1 Introduction B 2 The CleanRoom option can be ordered with an AdeptOne MV robot During the manufacturing process the AdeptOne robot is modified to meet class 10 cleanroom specifications This package includes the following Integral seals on covers Quill bellows Vacuum fitting 1 1 4 male threaded 2 m Seals at Arm Signal and Arm Power Cable connectors NOTE Seals are present under the access covers see Figure B 1 If removal of an
83. Category 3 System AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 59 Chapter 2 Installation of the Robots Changing Voltage Setting for Power Chassis If you need to change the AC voltage setting from 3 phase 380 415 VAC to 3 phase 200 240 VAC you must follow the three part procedure below This procedure must be done only by a skilled person and should be performed before installing the power chassis WARNING Electrical hazard Changing the voltage setting in the power chassis must be done by a skilled person The power supply can injure or kill a person who does not perform this procedure correctly Part 1 Insulating Power Chassis Power Cord WARNING High AC voltage is coupled through EMI capacitors to the blue wire of the PA 4 power chassis power cord If you change the voltage setting from 380 415 VAC to 200 240 VAC you must insulate the blue wire according to the directions provided below 1 Make sure the power chassis and controller are turned off Disconnect the controller and the Security Panel from the AC power source Verify that power remains off during all three parts of this procedure 2 Disconnect the 5 wire power chassis power cord from the AP2 T1 T2 T3 Neutral and Protective Earth terminals on the Security Panel 3 Locate the two pieces of shrink tubing in the accessory kit one is 7 mm 1 4 inch diameter the other is 19 mm 3 4 inch 4 Place the 7 mm shrink tubing over the end of the blu
84. Checking 24 Volt Category 3 Power Supply Relay Board Front Panel VFP Teach Restrict Interface Board Figure 3 3 Main Components of the Safety System Per EN954 Category B refers to a component that meets the requirements of its environment voltage current temperature Such components are not necessarily fault tolerant 74 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Overview of Safety System Operating in Manual Mode The most important function of the Security Panel is to protect the operator in Manual mode To work in Manual mode the operator switches the lower key switch on the VFP to the LOCAL position and the operating mode key switch upper switch to the MANUAL position Then the operator gives the instruction to enable High Power either through the ENABLE POWER software instruction or pressing the COMP PWR button on the The system starts the process to enable High Power The sequence to enable High Power in Manual mode is as follows takes about 20 25 seconds system check of all E stops including Customer non mute safety barrier operator interactive test of MCP Hold to Run switch automatic test of Teach Restrict sensors in robot and power chassis cyclic checking the VFP HIGH POWER ON OFF push button starts blinking operator presses the HIGH POWER ON OFF button contactors close on Security Panel and power chassis amplifiers supply High Power to rob
85. ES ees 172 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 155 Appendix C Using the Safety Utility C 1 Introduction With a Category 3 system several components are in place to ensure safety when the robot is operating in the Manual mode It is required that some components be tested at the time of commissioning see Chapter 4 These components should also be tested periodically every six months Adept provides SAFE UTL V2 to test these components This section offers instructions for using SAFE UTL V2 and describes the tests required to commission the robot Additional tests should be performed periodically These tests are also described in this section Category 3 Robot Components Accelerometer An accelerometer is located in the outer link of the robot to prevent excessive acceleration of Joints 1 and 2 while operating in Manual mode If the accelerometer is tripped the emergency stop circuit is opened causing High Power to be disabled Amplifier Voltage Restrict Circuitry in the amplifier measures the voltage applied to the Joint 3 and 4 motors This will prevent excessive speed and acceleration while operating in manual mode If the voltage exceeds a preset limit the emergency stop circuit is opened causing High Power to be disabled VFP Switches and Buttons After the user requests High Power to be enabled the HIGH POWER lamp flashes Before High Power is turned on this button mu
86. Figure 4 6 Figure 4 7 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure A 1 Figure B 1 Figure B 2 Figure C 1 Xvi Clamp mounted End Effector Installation for Adept PackOne MV Robot 69 Screw mounted End Effector Installation for Adept PackOne MV Robot 70 Components of a Category E Stop 5 72 SecultityiPatiels oscuros aia ECCE Hos C qi EE 73 Main Components of the Safety 5 74 Category 3 E Stop Board and Teach Restrict Board on Control Rail 76 Robot Base Showing Brake Release Button and 89 Holding the ge en ues oe tack OR kee anh 90 HOV OUT 2 de Rete p dated e dte 9 Command CMD Function 2 2 2 2 2 2 94 Mode Gonirol BUTON usos de og are f acc ei ot 95 Speed Bases 2s ie eae Re ea TEC 95 JOINT STOIC SCARA Ys x eios phd eis pp tette taret ten edet teg uds 96 Upper CUMSHOTS tecto f a aote Sg ts tr o ens t 102 Lower Quill Shaft and Lip Seal Location 103 Lubrication of the Lower Quill Shaft of the AdeptThree MV Robot
87. Instruction Handbook AdeptOne MV AdeptThree MV Robot Including Manual Mode Safety Package Instruction Handbook AdeptOne MV AdeptThree MV Robot Including Manual Mode Safety Package 00841 00100 Rev B April 1996 ader 150 Rose Orchard San Jose CA 95134 USA Phone 408 432 0888 Fax 408 432 8707 1 42 Otto Hahn Strasse 23 44227 Dortmund Germany Phone 0231 75 89 40 Fax 0231 75 89 450 adept 11 Voie la Cardon 91126 Palaiseau France Phone 1 69 19 16 16 Fax 1 69 32 04 62 technology inc Via don Luigi Sturzo 39 41 52100 Arezzo Italy Phone 575 3986 11 Fax 575 3986 20 1 2 Aza Nakahara Mitsuya Cho Toyohashi Aichi Ken 441 31 Japan 0532 65 2391 Fax 0532 65 2390 The information contained herein is the property of Adept Technology Inc and shall not be reproduced in whole or in part without prior written approval of Adept Technology Inc The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology Inc This manual is periodically reviewed and revised Adept Technology Inc assumes no responsibility for any errors or omissions in this document Critical evaluation of this manual by the user is welcomed Your comments assist us in preparation of future documentation A form is provided at the back of the book f
88. Mot 128 128 6 3 AdeptOne MV 5 130 AdeptOne MV Robot Working 132 6 4 AdeptThree MV Robot 133 AdeptThree MV Robot Working Envelope 135 6 5 Adept PackOne MV Robot 136 Adept PackOne MV Robot Working 138 6 6 Adept PA 4 Power Chassis Specifications 139 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 113 Chapter 6 Technical Specification 6 1 Dimensions Dimensions for AdeptOne MV HyperDrive Robot 1105 mm 43 50 381 mm 8 00 425 mm 375 mm R 108 15 00 ae 16727 i 14 76 D R 53 mm 248 mm eS 9 75 4 N Lu gt T eui 170 mm dia Optional 11 6 Quill Y J 178mm dia 6 70 tod 1575 mm 62 00 89 mm 3 50 gt 005 117mm 5 Standard 7 7 Quill 4 6 1473 mm 58 00 09 000 0
89. One MV AdeptThree MV and PackOne MV robots in a runaway situation are listed in Table 1 3 Any tooling fixtures end effectors etc mounted to the user flange outer link or inner link of the robot must be attached by sufficient means to resist being expelled from the robot Additionally any payload must be attached to the end effector in a manner that prevents the payload from being expelled accidentally Table 1 3 Maximum Robot Joint Velocities in Runaway Situations Joint 1 maximum angular velocity 920 degrees second Joint 1 maximum linear velocity 10 7 meters second Joint 2 maximum angular velocity 1670 degrees second Joint 2 maximum linear velocity 20 8 meters second These velocities can only occur in a runaway or mechanical failure situation These not performance specifications see Chapter 6 for robot performance specifications The safety fence or barrier constructed around the robot must be designed to withstand the impact of any item expelled accidentally from the robot Projectile energy can be calculated using the formula E 1 2mv Here are two examples Example 1 4 kg payload mounted to end effector maximum possible projectile energy 1 2 4kg 20 8m s 865 638 ft Ib Example 2 6 kg payload mounted to elbow Joint 2 maximum possible projectile energy 1 2 6kg 10 7m s 343 J 258 ft Ib AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 7 Chapter 1 Saf
90. SCFM This compressed air is used to release the robot brakes and to provide air to the User air lines End effectors attached to the robot may require additional air flow Insufficient air pressure or flow will cause the brakes to engage which will disable High Power CAUTION Failure to supply clean dry oil free air may result in damage to mechanical electrical and pneumatic components inside the robot Additional Facility Requirements of the Adept PackOne MV Robot The Adept PackOne MV robot requires clean dry oil free compressed air at 5 5 7 6 bar 80 110 psi with a flow rate of 170 liters per minute 6 SCFM The Adept PackOne MV robot uses compressed air for internal condensation protection The design of the internal air flow is an important feature of the Adept PackOne because it helps to eliminate internal condensation and evaporate any moisture that gets inside AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 19 Chapter 2 Installation of the Robots CAUTION Insufficient air pressure or flow will allow the brakes to engage and disable High Power Compressed air must be supplied to the robot 24 hours per day Failure to supply air to the robot 24 hours per day can void the warranty The compressed air source must be equipped with a refrigerated or desiccant type air dryer that can achieve an air dew point at 5 5 bar 17 30 F below the minimum ambient temperature For example if the robot operates in
91. Signal cable Save this jumper for use with the Brake Release button see section 4 4 on page 88 3 Plug the 15 pin female connector marked User at one end of the User to Security Panel cable to the User connector on the robot Arm Signal cable Tighten the two captive screws securely NOTE The User signals normally available on the Tower assembly of non Category 3 Adept robots are not available on Category 3 systems AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 49 Chapter 2 Installation of the Robots 50 4 Theother end of the cable with two plugs must be connected on the Teach Restrict Interface Board a Connect the 9 pin D Sub male plug labeled TRS1 to the D Sub connector TRS1 on the Teach Restrict Interface Board Tighten the two captive screws securely b Connect the rectangular plug to the rectangular connector J4 on the Teach Restrict Interface Board CAUTION Verify that all components are fully inserted and screwed down Connecting the Security Panel to the Adept PA 4 Power Chassis For speed limiting of Joint 3 and 4 in Manual Mode the Teach Restrict to B Amp cable must be installed between the Adept PA 4 Power Chassis and the Teach Restrict Interface board on the Control Rail The Amplifier Module has a 15 pin high density D Sub female connector with the label Teach Restrict On the Teach Restrict Interface board on the Control Rail are two 9 pin D Sub female connectors with the label
92. These are electrostatically sprayed then baked on to each individual part prior to assembly These coatings are not paint that can be applied after the robot is assembled The coatings are tough and durable but can be damaged if mistreated Users maintenance personnel cleaning crews etc must take care to protect the robot surface from sharp or abrasive objects and strong chemical cleaning agents such as sodium hydroxide If the surface is damaged to the extent where the base material is exposed contact Adept Customer Service for information on possible rework Rotary Seal Assemblies The rotary seal assemblies used on the Adept PackOne robot are composed of carbon graphite reinforced teflon seal elements which wear against precision ground shafts These rotary seal assemblies are lubricated for life at the factory with a USDA H1 approved grease No further maintenance or lubrication is required During the initial wear in period some dry seal particles or seal wear particles mixed with grease may extrude from the seal to shaft interface These particles should be carefully wiped away during the normal cleaning process Fixed Seals The removable access covers are sealed with flat nitrile rubber gaskets The permanent joints between mating parts are sealed with silicone adhesive If these seals degrade or become worn due to physical abuse chemical attack etc they should be repaired or replaced immediately Please contact Adept Custo
93. Three MV Robot Instruction Handbook Rev B Introduction Outer Joint2 Link __ Quill Cover Joint 1 Joint 3 Joint 4 Quill V Joint 1 nner Lin Column Sell User Flange B Encl n Base Enclosure Figure 1 3 Adept Robot Joint Locations Adept Equipment Compatibility This handbook describes the AdeptOne MV AdeptThree MV and PackOne MV robots with the Manual Mode Safety Package The Manual Mode Safety Package provides a Category 3 level of safety as specified in EN 954 section 1 3 The Adept Category 3 robot system as described in this handbook must consist of the hardware and software listed in the following table All new systems shipped from the factory will include the correct equipment as shown If you have existing Adept equipment this table can help distinguish new equipment from older equipment especially since some of it is visibly similar See the product data label for the robot controller and power chassis for model number or part number information For information on the V 11 3 Operating System refer to the V 11 3 Release Notes that is shipped with each system AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 3 Chapter 1 Safety Table 1 1 Adept Hardware and Software Compatibility for Category 3 Systems Product Requir
94. V Robot Instruction Handbook Rev B Installing End Effectors on an Adept PackOne MV Robot 2 21 Installing End Effectors on an Adept PackOne MV Robot Provision of an end effector or other end of arm tooling is the responsibility of the User Also USDA or other regulatory agency acceptance of end effectors is the responsibility of the User If hazardous voltages are present at the end effector you should install a ground connection from the base of the robot to the end effector See section 2 16 on page 51 Also see Chapter 6 for dimensions of the User flange Installation An end effector can be attached to the flange by using a ring clamp supplied or a gasket and four 8 32 screws supplied The gasket attachment method is more hygienic but not as convenient as the ring clamp For details of the flange mounting surface and alignment pin specifications ask the Adept Customer Service Clamp mounted End Effector The following procedure describes the installation of a typical end effector using the ring clamp Refer to Figure 2 33 1 Disconnect the air supply to the robot 2 Remove the plugs from the Open and Close air lines where they protrude from the user flange 3 Place the ring clamp over the user flange 4 Install the Open and Close air lines onto the appropriate fittings on the end effector 5 Mate the end effector flange to the user flange Rotate the end effector until its alignment pin lines up with the a
95. V Robot Instruction Handbook Rev B Robot Lubrication 5 3 Robot Lubrication The Joint 3 quill shaft requires periodic lubrication The frequency of lubrication will depend on the operating environment and amount of usage Initially check the quill of the AdeptOne MV AdeptThree MV and Adept PackOne MVrobot once a week recording the results with the intent of producing a schedule appropriate to the particular system its environment and usage For the Adept PackOne MV robot plan on lubricating every three months To check for adequate lubrication at the Joint 3 quill run a finger along the quill A thin film of grease should be present If the shaft is dry it needs lubrication Recommended Grease for AdeptOne MV AdeptThree MV Robot Dow Corning MOLYKOTE BR2 PLUS a molybdenum disulfide based grease Dow catalog number 89570 81 Adept part number 85214 89570 CAUTION Using improper lubrication products on the AdeptOne MV or AdeptThree MV robot can cause damage to the robot Recommended Grease for Adept PackOne MV Robot Mobilux EP 2 USDA H2 approved extreme pressure grease Adept part number 85151 00001 CAUTION Using improper lubrication products on the Adept PackOne MV robot can cause damage to the robot Use only a USDA H2 or equivalent approved grease Lubricating the Upper Quill Shaft Lubrication of the robot requires that the quill be moved while HIGH POWER is off Use the Brake Release button at
96. a 10 cold room the compressed air dew point must 7 C 20 maximum If a desiccant type dryer is used it should be an automatically recharging type with a large enough capacity so it requires minimal servicing The Adept PackOne MV robot has an air filter and moisture trap on its inlet air fitting If clean dry air is not available additional user supplied filtering is required The air connection inlet is a 1 4 inch Industrial Interchange nipple located at the air filter at the base of the robot Mounting Surface Specifications The floor at the installation site must be concrete with a minimum thickness of 100 mm and must comply with all local codes The floor should be level Due to the very high torque more than 270 Nm 200 ft lb at the base transmitted by the robot it must be mounted to an extremely rigid structure Any mounting structure vibration or flexing will seriously degrade robot performance Adept recommends using either a mounting plate or a mounting spool Both have proven reliable over extended periods of use If another type of mounting structure is used it must adequately resist vibration and flexure NOTE Mounting the base on a surface other than the recommended steel plate or spool may make robot recalibration difficult Make robot recalibration as easy as possible by designing a workcell that allows for mounting of the calibration fixture without extensive dismantling of the workcell See Figure 6 4 on
97. access cover is necessary the seal must be put back in place The robot will not meet class 10 cleanroom specification unless all seals are in place and proper vacuum is maintained Installation The CleanRoom option requires the use of a vacuum supply provided by the customer This section details the vacuum requirements of the systems installation procedure and tests to assure that the system is maintaining adequate vacuum levels Vacuum Requirements 148 Negative air pressure applied to the inside of the robot creates flow from the outside to inside in two primary places the gap between the inner and outer links and the open bearing at the bottom of the quill This type of system gives excellent cleanliness but does not require high levels of vacuum The quill of the robot is covered by a polyurethane bellows The bottom of the bellows is clamped to a bearing so that the bellows flexes only in the Z up and down direction The vacuum system maintains enough air velocity and pressure differential so that no particles escape Because the volume contained by the bellows changes when Joint 3 moves up and down the system has been designed to accept this pumped air volume without allowing a positive pressure to develop across the bearing at the bottom of the quill The seal between the inner and outer links allows air to flow freely from the outside of the robot toward the negative pressure inside the robot pulling any particles i
98. ackOne MV exterior surface coating 109 recommended schedule 100 robot compressed air filter 107 robotlubrication 101 105 Manual Control Pendant calibrating robot 93 connection on External Front Panel 40 how to use 90 97 installation 46 Manual mode High Power enable process 75 how to stop robot 92 how to use 75 87 robot speed limited 75 87 Manual key switch position 39 MCP cradle dimensions 126 installation 47 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 189 Index see Manual Control Pendant mode control buttons on 95 modifications acceptable 10 unacceptable 10 moisture trap on robot air inlet 20 monitor installation 37 mounting bolts checking tightness 106 mounting brackets dimensions 125 install positions controller 35 power chassis 36 installation 34 mounting hole pattern plate or spool to floor 27 robot to plate or spool 26 mounting plate installation 27 specifications 20 mounting spool installation 29 specifications 21 mute function in Customer Safety Barrier 74 N Network key switch position 40 operating environment specifications controller and power chassis 22 robots 19 Operating Key Switch on External Front Panel 39 operating modes Automatic 13 87 Manual 13 87 P PackOne end effector installation 69 PackOne MV air dryer requirements 20 air filter replacement 107 bolt resealing procedure 111 cleaning information 109 compressed air requirements 19
99. ad Including End Effector 7 7 kg 17 Ib Inertia Load Maximum About Joint 4 axis standard 281 kg cm 96 Ib in2 maximum 2926 kg cm 1000 Ib in Force Joint 3 downward force without payload 16 8 kg 37 Ib Cycle Time 12 in 305 mm No payload standard 0 70 sec 9 kg 20 Ib payload standard 0 92 sec with HyperDrive 0 79 sec Resolution Joint 1 0 00078 Joint 2 0 00312 Joint 3 vertical Z 0 0033 mm 0 00013 in Joint 4 tool rotation 0 047 136 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Adept PackOne MV Robot Specifications Table 6 3 Adept PackOne MV Robot Performance Specifications Continued Repeatability X Y plane 0 05 mm 40 002 in Joint 3 vertical Z 0 1 mm 40 004 in Joint 4 rotational 0 094 Accuracy in X Y Plane 3 F temperature variation With optional HPS hardware and software 0 076 mm 0 003 in over 17 x 17 area Joint Speed maximum Joint 1 250 sec Joint 2 320 sec Joint 3 1000 mm sec 39 4 in sec Joint 4 3800 sec Weight Robot without options 240 kg 525 Ib Power chassis with 3 amplifier modules approximately 16 4 kg 36 Ib MV 8 controller with 030 SIO VGB approximately 14 5 kg 32 Ib Design Life 21 000 hours Maximum possible using modified servo gains and running at reduced speed P Th
100. ake solenoids are used to release the robot brakes If one solenoid fails by sticking open the brakes will still engage If one solenoid fails by sticking closed the brakes cannot be released These components were tested at the factory therefore it is not required that they be tested at the time of commissioning Both solenoid valves however must be tested periodically thereafter See Tests Performed Periodically on page 168 Dual Dump Valves AdepiThree MV Only Two dump valves are used on the AdeptThree MV robot Both dump valves open when the brake solenoids are closed allowing the brakes to engage rapidly If one dump valve fails by sticking closed the other valve will open allowing the brakes to still engage rapidly These components were tested at the factory therefore it is not required that they be tested at the time of commissioning Both dump valves however must be tested periodically thereafter See Tests Performed Periodically on page 168 Robot Brakes Brakes are in place to prevent robot motion when High Power is off and to stop the robot during an Emergency Stop The brakes can be manually released by pressing the brake release button at the base of the robot Brakes are used on Joints 1 2 and 3 The AdeptThree MV robot has an additional brake for Joint 4 SAFE UTL V2 Adept provides SAFE UTL V2 in the UTIL sub directory on the controller s hard disk drive C This utility must be used to test the C
101. akes released The HIGH POWER button must be pressed to switch on High Power After testing of Joint 1 is complete Joint 2 and 3 are also tested On AdeptThree MV robots Joint 4 is tested If the Brake Holding Force test passes and the main menu is displayed Exit SAFE UTL by selecting option 0 from the main menu The following message is displayed The robot NVRAM The current robot has passed all CE Category 3 tests will be marked as commissioned in controller Press ER to continue This allows the High Power to be enabled with the MANUAL AUTO key switch in the Manual position AdeptOne MV AdeptThree MV Robot Instruction Handbook 167 Appendix C Using the Safety Utility 4 Tests Performed Periodically The Category 3 robot components must be tested every six months These tests are performed using the SAFE UTL V2 utility as described earlier There are two tests in addition to the tests performed at the time of commissioning the dual brake solenoid valve test and the dual dump valve test AdeptThree MV only When SAFE UTL V2 is started after the system is successfully commissioned the utility program displays the following menu and prompts the user to select an option Adept CE Category 3 Test Program Version 11 3B Copyright c 1996 by Adept Technology Inc Robot 1 XXX XXXX gt EXIT gt All Tests gt Accelerometer
102. anual mode you must switch to Automatic mode After changing the operating mode the controller shuts off High Power automatically See the instructions above to enable High Power again The default time out value is 10 seconds this value can be changed using the CONFIG utility AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 93 Chapter 4 Commissioning the System 4 8 WARNING Impact Hazard In Automatic mode no personnel are allowed to stay in the workcell The robot can move at high speeds and exert considerable forces Calibration involves limited robot motion Observe all safety precautions 1 Set the VFP operating keyswitch to the AUTO position and verify that the other keyswitch is in the LOCAL position If necessary re enable High Power 2 Press the CMD soft button to display functions AUTO STORE START CALIB ALL CMD1 CMD2 Q OQ OQ OQ KO Figure 4 4 Command CMD Function Button 3 Press the soft button below the text CALIB in the display to start calibration Once the robot is calibrated you can move the robot If High Power is turned off after calibration is complete you have to Enable Power again but you do not have to calibrate If system power is turned off at the VFP then you must Enable Power and Calibrate Using the Safety Utility To complete the commissioning of the robot you must run the Safety Utility You cannot use the robot in Manual mode until the Safe
103. as enabling High Power calibration and moving the robot follows in the next sections How to Hold the MCP The pendant has a palm activated switch that is connected to the emergency stop circuitry of the Security Panel Whenever this switch is released High Power is turned off To operate the put your left hand through the opening on the left hand side of the pendant and use your left thumb to operate the pendant speed bars Use your right hand for all the other function buttons USER Q Depress the palm activated Hold to Run switch Figure 4 2 Holding the MCP NOTE The MCP must be stored in the MCP cradle to close the Hold to Run switch when it is not being held 90 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Description of the Manual Control Pendant MCP Description of Buttons on the MCP Liquid Crystal Display LCD 4 1 COL OL IGL GL C Function User LED RE loce E de Manual State LEDs Speed Bars Emergency Stop Switch pem Mode Control 8 Buttons Joint Axis m Control Buttons Hold to Run Switch Figure 4 3 Layout Mode Control and Joint Axis Control Buttons The mode control and joint axis control buttons are used to control the robot from the pendant Speed Bars The speed bars and slow button are used
104. assignments 79 Teach Restrict board location of connectors 76 temperature required range power chassis 22 robot 19 terminal block connectors for TB1 to TB5 76 77 U User Brake Release Jumper 49 88 user flange dimensions AdeptOne MV AdeptThree MV 118 PackOne MV 119 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 191 Index V VFP see External Front Panel VJI to Amp cable installation 46 voltage changing setting on power chassis 60 maximum operating controller 54 power chassis 56 minimum operating controler 54 power chassis 56 voltage free contacts 78 W washdown cleaning procedure on Pack One MV 110 192 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Adept User s Manual Comment Form We have provided this form to allow you to make comments about this manual to point out any mistakes you may find or to offer suggestions about information you want to see added to the manual We review and revise user s manuals on a regular basis and any comments or feedback you send us will be given serious consideration Thank you for your input NAME DATE COMPANY ADDRESS PHONE MANUAL TITLE PART NUMBER and REV level COMMENTS MAIL TO Adept Technology Inc Technical Publications Dept 150 Rose Orchard Way San Jose 95134 FAX 408 432 8707
105. at the California address Place Jose California USA Signed Date 1 February 1996 Full Name Richard Casler Jr Position Vice President Engineering P N 01840 00030 Rev P1 English Manufacturer s Declaration as defined in Machinery Directive 89 392 EEC Appendix We herewith declare that the machine as delivered by us complies with the relevant and fundamental safety and health requirements defined in the EC Directive Appendix 1 The machine must not be put into operation until all of the machinery into which it is incorporated has been declared in compliance with the provisions of the effective versions of the directives This includes all supplementary equipment and protective devices Deutsch Herstellererklarung im Sinne der EG Maschinenrichtlinie 89 392 EWG Anhang II B Hiermit erkl ren wir daf die nachstehende Maschine in der von uns gelieferten Ausf hrung einschl gigen grundlegenden Sicherheits Gesundheitsanforderungen der EG Richlinie Anhang I entspricht Wir weisen daraufhin daf die Inbetriebnahme der Maschine solange untersagt ist bis festgestellt ist dafs die Maschine in die diese Maschine eingebaut werden soll den Bestimmungen der Richtlinie in der jeweils gueltigen Fassung entspricht Dies schlie t die anwenderseitig die Maschine zu installierenden Erg nzungen und Schutzeinrichtungen ein Francaise D claration du Constructeur selon la Directive C
106. ategory 3 robot components during the commissioning procedure It is also used to test the components periodically Commissioned vs Not Commissioned As shipped from Adept the system is marked as not commissioned meaning the Category 3 components must be tested prior to system operation The brake solenoids and dump valves have been tested at the factory Prior to operating the robot in the manual mode the system must be marked as commissioned The system is marked as commissioned only after the SAFE_UTL V2 utility is executed and all tests pass If any of the tests fail carefully note any the messages then repeat the test If the failure persists contact Adept Customer Service The components should also be tested periodically every six months When the SAFE UTL V2 utility is started the system is marked as not commissioned In order for the system to be marked as commissioned all components must pass the tests AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 157 Appendix C Using the Safety Utility NOTE Testing all Category 3 components requires approximately 40 minutes If an attempt is made to enable High Power on a system marked as not commissioned while the MANUAL AUTO key switch is in the manual position the following error message is displayed User has not tested Cat 3 system Switch can t be enabled Starting the SAFE UTL V2 Utility To perform the necessary
107. bearing mount steady Place the top bellows clamp loosely around the top cuff of the bellows Putting your fingers between the first and second of the top convolutions push the top bellows cuff up and around the clamping diameter of the vacuum housing It must wrap smoothly around the diameter Tighten the clamp around the bellows cuff trying to minimize wrinkles The bellows cuff must be pushed up enough so that the clamp has full contact with the bellows cuff Mounting the bellows so that the top convolution is parallel with the bottom of the vacuum housing will help to extend the life of the bellows 152 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Bellows Replacement Top Bellows Clamp Vacuum Housing Quill lt lt Bellows Ta Quill A Cap screw threaded m E um Lower Bellows sliding pin for alignment 1 of 2 Through hole for sliding pin 1 of 2 Ppanng 4 40 x 3 16 Mount cap screw 8 32 threaded hole 1 of 2 for set screw 1 of 2 Figure B 2 Bellows Detail Further Instructions The vacuum must now be tested refer to Testing the Vacuum on page 151 If the vacuum test fails check the bellows for leaks and correct them if found After the vacuum has been tested the end of arm tooling can be put back in place and the robot can be returned to normal use AdeptOne MV Ad
108. before lubricating Improper quill positioning could result in excessive lubricant getting on the Joint 4 brake which could cause its failure Using a 5 16 inch Allen wrench remove the grease fitting access plug from the side of the Joint 4 housing See Figure 5 3 Whilelooking through the access plug hole rotate the quill until the zerk fitting is accessible Insert the tip of a grease gun and apply grease until excess grease squeezes out from the quill seal Remove the grease gun Reposition the quill to the bottom of its travel and wipe excess grease from the quill Replace the access plug Replace the quill cover AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Lubrication Joint 3 gt Quill Ballscrew Joint 4 3 Zerk Fitting inside Joint 4 housing Q Quill Cover Plug in Access Hole Quill Seal Figure 5 3 Lubrication of the Lower Quill Shaft of the AdeptThree MV Robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 105 Chapter 5 Maintenance 5 4 Check Robot Mounting Bolt Tightness 5 5 The robot mounting bolts should be checked periodically to make sure they are not loose Also check the tightness of all cover plate screws and all the captive screws of the cables Joint 3 Bellows Replacement Adept PackOne MV 106 The protective bellows covering the quill
109. ber 843 Cleanroom Model Number 843 modified with lass 10 Cleanroom Kit P N 90842 00000 PackOne MV Model Number 848 AdeptThree MV Model Number 643 in the form delivered by us to which this Declaration relates complies with the relevant and fundamental safety and health requirements defined in the EC Directive 89 336 EEC Appendix 1 and the following standards SO Qo SI gros S qu EN 55011 1991 Class A EN 50082 2 1992 EN 292 1992 EN 60204 1 1992 IP20 EN 954 Category 3 EN 775 1992 following the provision of Directives 89 336 EEC 89 392 EEC 73 23 EEC under the following usage and environmental conditions 1 The system must not be put into operation until all of the machinery into which it is incorporated has been declared in compliance with the provisions of the effective versions of the Directives This includes all supplementary equipment and protective devices 2 The system must be used in accordance with the Instruction Handbook for the AdeptOne MV Robot with Manual Mode Safety Package 3 The system must incorporate only those MV Plug in Modules listed in Table 1 or Table 2 If Plug in Modules listed in Table 2 are installed the user must verify conformance to the EMC Directive after installation 4 PackOne mechanism is IP55 This Declaration is based upon extensive tests and evaluation by T V Rheinland a Notified Body in their Project Number E9572254 The complete File is available
110. ble from the security panel and place the User jumper plug on the cable 3 Remove the rear cover on the robot to gain access to the solenoids 4 Verify that both solenoids are plugged into the RSC Perform the following steps Turn High Power off then switch the PA 4 amplifier chassis switch off Disconnect the User signal cable from the Security Panel Plug the User Brake Release jumper into the User connector Bu AG Remove the rear cover to gain access to the solenoid valve connections See Figure C2 for AdeptOne MV and AdeptThree MV robots Robots with the HyperDrive option require that the air filter be removed using the lift tabs The fan assembly must then be removed using a Philips screwdriver see Figure C 3 Unplug the fan from the connector labeled J7 See Figure C 5 for the Adept PackOne MV robot The nine bolts holding the cover in place must be removed using a 7 16 inch wrench Remove screws 8 6 amp amp Rear Cover Figure C 2 Removing the Rear Cover 5 After the cover is removed perform the tests as described on the screen AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 169 Appendix C Using the Safety Utility Dual Solenoid test 1 Unplug the first solenoid from J11 on the RSC and press the brake release button Do the brakes remain engaged Y N If the response is N the test fails and an error message is
111. cedure on PackOne MV 111 sealant type on PackOne MV 111 torque specs on PackOne MV_ 111 Brake Release button 88 Brake Release Remote connection 88 Brakes description 88 releasing for manual movement 88 cable connections system 42 calibration fixture dimensions 117 Category 3 equipment compatibility 3 list of Security Panel functions 73 risk assessment 5 Category 3 E Stop board location of connectors 76 circuit breaker on power chassis 65 cleaning procedure protective cover on PackOne MV 110 CleanRoom robot 146 151 bellows replacement 149 compatibility for Category 3 equipment 3 compressed air extra lines AdeptOne MV 177 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 187 Index installation at robot 66 requirements for AdeptOne AdeptThree 19 requirements for PackOne 19 spare line inside robot AdeptOne MV 179 spare line inside robot AdeptThree MV 179 User air lines AdeptOne MV 177 User air lines AdeptThree MV 179 Control Key Switch on External Front Panel 40 Control Rail location of connectors 76 controller connecting to power chassis 46 connecting to robot 45 dimensions MV 19 121 dimensions MV 8 120 grounding 51 joining to power chassis 32 panelmounting 34 rack mounting 34 current voltage ratings controller 54 power chassis 56 Customer E Stops 73 79 schematic 141 terminal assignments for TB4 77 terminal assignments for TB5 79 voltage free contacts 78 Customer Safety Barr
112. chor holes in the floor using care to align the three plate to floor holes with the anchor holes Ensure that the plate is positioned so that the footprint for the robot is properly oriented to the workcell 8 Using a spirit level verify that the top mounting surface of the plate is level The surface must be horizontal within 0 25 degrees If the plate is not level insert shims between the plate and the floor to bring the plate within specifications The shims should be at least 75 mm in diameter and have cutouts provided to fit around the anchor bolts 9 Insert a 1 2 13 x 4 inch bolt fitted with a lock washer a flat washer through the holes in the plate into each of the three plate to floor anchor holes Tighten the bolts to 54 Nm 40 ft Ib of torque 1 e Re check the robot mounting surface of the plate using the spirit level and re shim as required to bring the mounting surface horizontal within 0 25 degrees 28 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Installation Installing a Mounting Spool The following sequence details the installation of the robot mounting spool to the floor See Figure 2 6 NOTE You can substitute M12 bolts of correct length in place of 1 2 13 bolts to install mounting spool and robot 1 Drill and tap three 1 2 13 UNC 2B mounting holes through as shown in Figure 2 3 for robot to spool attachment 2 Prepare the opposite flange of th
113. cifications 183 AdeptThree MV specifications 183 description 182 hazards from expelling a part 7 High Power enable process description of 75 High Power On Off switch on External Front Panel 39 humidity required range power chassis 22 robot 19 HyperDrive robot cleaning fan air filter 107 operating environment specifications 19 Installation CleanRoom robot 146 installation AC power 54 62 External Front Panel 40 floor requirements 20 joining power chassis to controller 32 keyboard 37 MCP cradle 47 monitor 37 mounting surface 20 power chassis in rack or panel 34 power cord to controller 55 power cord to Security Panel 58 required tools 25 robot on base 30 Security Panel 41 system cable connections 42 J Joint 3 bellows replacement PackOne MV 106 Joint motion Joint1 127 Joint 2 127 Joint3 128 Joint4 128 Joint state with SCARA robot 96 K keyboard installation 37 L Lamp Test button on External Front Panel 40 Lefty configuration 127 limiting joint travel hardstops 182 softstops 182 Local key switch position 40 lubrication AdeptOne MV lower quill shaft 103 AdeptThree MV lower quill shaft 104 type of grease for AdeptOne AdeptThree 101 type of grease for PackOne MV 101 upper quill shaft 101 M maintenance checking VFP lamps 108 cleaning controller fan filter 108 cleaning power chassis fan filter 108 compressed air filter on PackOne MV 107 PackOne MV cleaning information 109 P
114. contacts must be closed to enable High Power Make sure that sufficient E Stop switches are provided in the workcell so they can be easily reached in an emergency Install a removable terminal block connector supplied in the accessory kit on 4 Then connect to appropriate Customer E Stops and other safeguards as described in this section WARNING Adept highly recommends using all of the provided additional Customer Emergency contacts to develop and operate a safe robot workcell that complies with the European Safety standards The robot system must comply with Category 3 per EN 954 which according to our risk assessment is the required category of safety for these Adept robot installations per EU Directives Table 3 1 Terminal Assignments on Terminal Block TBA for Customer Supplied E Stop switches Muda Signal Name TB4 1 Customer E Stop IN 1 TB4 2 Customer E Stop IN 1 TB4 3 Customer Safety Barrier 1 TB4 4 Customer Safety Barrier 1 TB4 5 Customer Safety Barrier Mute 1 4 6 Customer Safety Barrier Mute 1 4 7 Customer E Stop 2 4 8 Customer E Stop IN 2 4 9 Customer Safety Barrier 2 TB4 10 Customer Safety Barrier 2 TB4 11 Customer Safety Barrier Mute 2 TB4 12 Customer Safety Barrier Mute 2 NOTE If any of the signal pairs in the table above are not connected to customer safety devices the contacts must be closed with a jumper
115. ct circuitry should not fault out while performing this test The following will then be displayed Program controlled move xpect E S8top assert The default test locations are with Joint 3 at 50 mm from midrange and all other joints at midrange Do you want to use the default test locations Y N WARNING Responding Y may cause the robot to move Joints 3 and 4 to the positions described below If the robot is in its workcell it may contact other tooling and or fixtures causing extensive damage Responding N allows new test locations to be defined The test locations must be defined so that Joint 3 moves a minimum of 100 mm and Joint 4 moves a minimum of 180 degrees The robot will make a quick move causing the sensor to activate the E STOP The robot may overshoot slightly To ensure the robot does not crash it should be able to move slightly beyond the defined locations in both directions After the new test locations are defined Joint 3 is tested first The following is displayed 162 AdeptOne MV AdeptThree MV Robot Instruction Handbook Tests Performed at Time of Commissioning Testing Joint 3 Press the COMP PWR button Hold the SPEED BAR then press and release the STEP button While continuing to hold the SPEED BAR press and release the STEP button The B amp voltage restrict has tripped as expected I Joint 4 is tested in the same manner as Joint 3
116. d by the EMC Directive Table D 1 summarizes the test results of some of the most critical tests Table D 1 EMC Test Results Test Performed Status Fast Transient Burst FTB IEC61000 4 4 to level 3 2 kV power 1 kV I O Passed without qualification Electrostatic Discharge ESD IEC61000 4 2 to level 4 8 kV contact discharge Passed without qualification Radiated Immunity ENV50140 to level 3 10 V m 80 100 MHz 80 mod 1 kHz 80 200 MHz passed to 10V m 200 350 MHz passed to 3 V m 350 1000 MHz passed to 10 V m Conducted Immunity ENV50141 to level 3 10 V Passed without qualification Damped Oscillatory 255 4 1 kV Passed without qualification Gradual Shutdown and Start up 1131 2 Passed without qualification Surge IEC1000 4 5 to level 2 kV common mode on I Os only Passed without qualification Radiated Emissions EN55011 for group 1 ISM to Class A 2 dB Passed without qualification Conducted Emissions EN55011 for group 1 ISM to Class A 2 dB Passed without qualification In industrial environments with field strengths above 3 V m in the range of 200 to 350 MHz disturbance of normal robot operations may occur In these cases the robot may come to a stop but in a safe condition presenting no hazard to the operator Therefore it is recommended that active devices such as radios cellular telephones etc should no
117. d using the Brake Release button you must remove the Jumper and reconnect the User to Teach Restrict cable to enable the safety features of the Security Panel When the User Brake Release Jumper is installed and when system power is on pressing the Brake Release button releases the brakes which allows movement of the arm If this button is pressed while High Power is on High Power will automatically shut down CAUTION When the Brake Release button or Remote Brake Release switch is pressed the quill Joint 3 may drop to the bottom of its travel To prevent possible damage to the equipment make sure that the quill is supported while releasing the brake and verify that the end effector or other installed tooling is clear of all obstructions Remote Brake Release Connection The Brake Release can be operated remotely by connecting to the remote circuit located next to the Brake Release button see Figure 4 1 You can install a mini dual banana plug ITT Pomona part number 2224 1 or equivalent in the socket next to the Brake Release button Construct a circuit with a momentary contact switch and connect that to the banana plug This circuit will perform like the normal Brake Release button described in the previous section and the same cautions must be observed As stated in the Note above you must install the User Brake Release Jumper on the Arm Signal cable before using the Remote Brake Release feature CAUTION The Remote
118. e SIO module Plug the other end into the 26 pin D Sub connector on the back of the VFP Tighten the thumbscrews on both connectors 4 If you are not using an install the bypass plug in the connector of the VFP If you are using an MCP refer to page 46 5 Connect the cable between the VFP and the Security panel see page 49 2 14 Installation of the Adept Security Panel Enclosure Requirements See Table 2 2 for enclosure requirements Installation of the Security Panel ph Figure 2 15 Security Panel Adept recommends mounting the Security Panel in the enclosure of the Adept MV controller or in a separate protected enclosure that fulfills the requirements See Figure 6 11 on page 124 for the dimensions of Security Panel AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 41 Chapter 2 Installation of the Robots 2 15 Signal Interconnection Installation System Cable Connections VJl to Amp Cable
119. e bottom of its travel 2 Adept PackOne MV robot Remove the bellows by loosening the top and bottom clamps Slowly pull the bellows down over the Joint 4 seal assembly 3 The Joint 3 seal is a soft rubber lip seal located as shown in Figure 5 2 Gently insert the tip of the syringe applicator underneath the seal and apply grease around the entire circumference of the shaft 4 Apply three thin lines of grease vertically on the shaft with each line running from top to bottom and evenly spaced around the lower shaft 5 With a small brush spread the grease into a thin film covering the entire shaft surface including the V groove 6 Move Joint 3 slowly from the bottom to the top of its travel several times then leave it in the middle of its travel Use a cloth to wipe away any excess grease on the shaft or at the seal 7 Replace the quill cover Adept PackOne MV Be sure to reseal the bolts on the quill cover according to the resealing process listed in section 5 9 on page 111 Reinstall the bellows see the following procedure for details and torque specs Quill Shaft Figure 5 2 Lower Quill Shaft and Lip Seal Location AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 103 Chapter 5 Maintenance 104 Lubricating the Lower Quill Shaft AdeptThree MV Robot Turn High Power off Move the quill to its fully raised position CAUTION The quill MUST be in the fully raised position
120. e installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord or an incorrect installation can injure or kill anybody who touches the equipment in the robot workcell Connect each conductor of the power cord securely to your AC power source using the color code below You must provide a suitable plug or other facility connection in accordance with all applicable European and national codes See the section 2 16 on page 51 for important information on system grounding Table 2 6 Adept MV Controller Power Cord Specifications Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 10 amps Number and size of 3 x 1 00 mm conductors Color code line brown neutral blue ground green yellow AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 55 Chapter 2 Installation of the Robots Connecting AC Power to the Adept PA 4 Power Chassis through the Security Panel The Adept PA 4 power chassis provides amplified power signals to drive the robot motors in an Adept robot system The amplifier modules in the Adept PA 4 power chassis receive control signals from the Adept MV controller The amplifier modules then provide the necessary current to drive the various robot joint motors The Adept PA 4 power chassis is shipped from the factory configured for either 380 415 VAC or 200 240 VAC operation depending on your sales order A volta
121. e mounting spool by drilling three 16 mm 5 8 inch diameter through holes as shown in Figure 2 6 for spool to floor anchoring 3 Place the spool exactly where the robot is to be installed Ensure that the spool is positioned so that the footprint for the robot is properly oriented to the workcell Transfer the locations of the three spool to floor mounting holes directly to the floor 4 Set the spool aside and drill three holes 22 mm 7 8 inch in diameter by 90 mm 3 5 inch deep in the floor at the locations identified in step 3 5 Using a vacuum cleaner remove all chips and debris from the holes and surrounding area drilled in step 4 6 Insert an expansion bolt anchor into each of the three holes in the floor Ensure that the threaded end of each bolt anchor is toward the bottom of each hole as shown in Figure 2 6 7 Reposition the spool over the anchor holes in the floor taking care to align the three spool to floor holes with the anchor holes Ensure that the spool is positioned so that the footprint for the robot is properly oriented to the workcell 8 Using a spirit level verify that the top mounting surface of the spool is level The surface must be horizontal within 0 25 degrees If the spool is not level insert shims between the spool and the floor to bring the spool within specifications The shims should be at least 75 mm 3 inches in diameter and have cutouts provided to fit around the anchor bolts 9 I
122. e power to the power chassis and all related external power supplies Failure to observe this warning could cause injury or damage to your equipment Removing Amplifier Modules 1 Turn off the power chassis and the Adept MV controller 2 Note the location of any cables connected to the module then disconnect them 3 Loosen the captive screws at the top and bottom of the module AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 65 Chapter 2 Installation of the Robots 4 Using both the top handle and bottom handle pull the module straight out of the chassis Remove the module from the chassis and store it in a safe place CAUTION You must take precautions to prevent amplifier modules from being exposed to electro static discharge ESD while you are handling or storing them Adept recommends using an anti static ground strap on your wrist when handling modules Installing Amplifier Modules 1 2 Turn off the power chassis and the Adept MV controller If the slot has a blank panel installed loosen the captive screws at the top and bottom of the panel and remove it Verify that the intended slot for the module is ready to accept the module Align the module with the card guide slots at the top and bottom of the card cage Slide the module in slowly Apply straight forward pressure to the top and bottom handles until it is firmly seated in the rear power connector and the face of the module is flush with the
123. e robot program and 3 the high probability that an Operator could not avoid being hit by the robot in a high acceleration runaway failure condition EN 1050 specifies use of a Category 3 Control System per EN 954 EN 954 defines a Category 3 Control System as one in which 1 no single failure can cause a loss of the safety function and 2 any failure that does occur can be checked prior to enabling power The AdeptOne MV Control System Control System described in this Handbook employs a fully redundant Emergency Stop that incorporates proprietary Teach Restrict sensors and self checking hardware Through use of a thorough Failure Mode and Effect Analysis it has been determined that the AdeptOne MV Control System with the Manual Mode Safety Package as described in this Handbook meets the stringent requirements of the Category 3 level of safety specified in EN 954 The Control System also has been designed to meet relevant standards referenced in EN 954 including EN 775 15 10218 Manipulating robots safely See also the Manufacturer s Declaration at the front of this Handbook AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 5 Chapter 1 Safety 1 4 Precautions and Required Safeguards This manual must be read by all personnel who install operate or maintain Adept systems or who work within or near the workcell WARNING Adept Technology strictly prohibits installation commissioning or operation o
124. e robot tool performs a continuous path motion consisting of all straight line segments 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and returning along the same path The endpoints of the cycle are approached in COARSE mode AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 137 Chapter 6 Technical Specification Adept PackOne MV Robot Working Envelope Maximum Radial Reach Mimimun Intrusion Functional Area Contact Radius 800 mm 870 mm 33 8 Minimum Radial Reach Inaccessible Area 245 mm 965 Joint 2 Limit 1 T 145 N h Joint 1 Limit AGUAS Joint 1 Limit 150 150 Figure 6 19 Adept PackOne MV Robot Working Envelope 138 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Adept PA 4 Power Chassis Specifications 6 6 Adept PA 4 Power Chassis Specifications The following power consumption information is provided to allow customers to install adequate electrical wiring and power sources for worst case short duration demands of the Adept PA 4 power chassis The typical values are for calculating air conditioning requirements Table 6 4 Power Consumption for PA 4 Power Chassis with an AdeptOne MV System Line Voltage Typical Worst Case 380 415 VAC Current 5 8 5 amps phase 20 amps phase 50 60Hz 3 phase Watts 1 65 kW 3 kW 200 240 VAC Current RMS 7 2 amps phase
125. e the MCP E STOP button MCP E STOP test passes Press ENTER to continue If all MCP tests pass the next test is performed or the main menu is displayed Brake Holding Force Test The holding force of the brakes is tested to ensure that the robot cannot move when the brakes are engaged The following message is displayed Brake Holding Force test The default test point is with the arm straight out and the quill at midrange Do you want to define a non default test point Y N If the response is Y the system prompts the user to move the robot to the desired location If the response is N the system uses the default location The following will be displayed 166 AdeptOne MV AdeptThree MV Robot Instruction Handbook Tests Performed at Time of Commissioning Press ENT ER to enable power and move the robot to the test location High Power is switched on and Joint 1 attempts to move with the brakes released The system should not fault Joint 1 is then tested with the brakes engaged which induces a failure The following is displayed Testing Joint 1 Testing with brakes released Press the HIGH POWER button when it blinks Testing with brakes engaged Press the HIGH POWER button when it blinks Motor stalled Mtr 1 Testing with brakes released Press the HIGH POWER button when it blinks After the system faults as described above Joint 1 is tested again with the br
126. e wire in the power cord and use a heat gun to apply it See Figure 2 28 5 Fold the blue wire back and place the 19 mm shrink tubing over the end of the power cord Use a heat gun to apply the shrink tubing 6 Re install the power chassis power cord at the Security Panel according to the 200 240 VAC section in Table 2 8 See also Figure 2 27 power cord from 19 mm 3 4 inch power chassis shrink tubing 60 blue wire 7 mm 1 4 inch shrink tubing Figure 2 28 Insulating Blue Wire in Power Cord AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Connecting to AC Power Part 2 Moving Blue Wire on Security Panel 7 Locate the blue wire labeled Neutral that is installed on the neutral terminal on the Power Rail X2 N 8 Remove that wire from the neutral terminal and install it in the L2 position on contactor AP1 X2 AP1 L2 next to the wire that is already installed there Move blue wire to Blue wire labeled Neutral AP1 L2 from 24 VDC supply EN 55o AP1 AP2 Power Rail X2 eooo Figure 2 29 Moving Blue Wire From Neutral to AP1 L2 Part 3 Rotating Voltage Selector in Power Chassis 9 Open the front air intake grill on the power chassis by loosening two screws and swinging the grill out 10 Inspect the voltage setting it is marked on the front of the voltage selector plug
127. ector Locations 44 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Signal Interconnection Installation Installing Signal Cables Robot to MV Controller The cable between the robot and the module in the Adept MV controller is called the Arm Signal cable The robot end has a large rectangular connector The controller end has a 50 pin D sub connector and two smaller 15 pin D sub connectors See Figure 2 16 If you have an AdeptOne MV or AdeptThree MV start at step 1 On an Adept PackOne MV robot the Arm Signal cable is already connected with the robot Please start at step 2 1 Connect the large rectangular end of the arm signal cable to the Arm Signal connector on the back plate of the robot Tighten the thumb screw securely 2 Connect the 50 pin D sub connector to the Arm Signal connector lower on the module Tighten the two captive screws securely See Figure 2 19 3 The 15 pin D sub connectors are labeled User and Force The User connector is connected to the User to Security Panel cable see page 49 The Force connector is not used WARNING Verify that all connectors are fully inserted and screwed down Failure to do this could cause unexpected robot motion Also a connector could get pulled out or dislodged unexpectedly VJI Module in Adept MV Controller Install VJI to Amp cable here AMPLIFIER Install Arm Signal cable here ARM SIGNAL
128. ed use compressed air to clean the filter 4 Replace the cleaned air filter and secure the grill Adept MV Controller Fan Filter Inspection and Cleaning 5 7 The air filter located on the front of the chassis should be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must be inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or unusable for any reason you will need to order a new air filter the Adept part number is 40330 11190 1 Turn off the controller and protect it against an unauthorized return to service 2 Open the front grill by loosening two screws and swinging the grill out 3 Pull the air filter out and inspect for dust or dirt particles If cleaning is required use compressed air to clean the filter 4 Replace the cleaned air filter and secure the grill Check Lamps on VFP 108 Use the Lamp Test button on the external Front Panel to test the lamps once per month Replace any lamps that are not working Contact Adept Customer Service for replacement information AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Special Maintenance for Adept PackOne MV Robot 5 8 Special Maintenance for Adept PackOne MV Robot General Information Exterior Surface Coating The coatings used on the exterior surfaces of the Adept PackOne robot are USDA approved polymer powder coatings
129. ed To empty the trap use a rag to push up on the bottom of the air filter If you have to empty water from the filter housing frequently check the water content in your compressed air supply and consider using an air dryer Moisture inside the robot can cause damage to mechanical electrical and pneumatic components Maintaining Compressed Air Filter of Adept PackOne MV Robot Draining Moisture from the Air Filter Check the air filter housing on a daily basis for any buildup of water at the bottom of the housing Drain any accumulated water by opening the knob at the bottom of the filter If your air dryer is working properly very little water should accumulate in the air filter Replacing the Filter Cartridge The air filter housing contains a replaceable coalescent filter cartridge Replace the cartridge every six months Order the replacement coalescent cartridges from Master Pneumatic Detroit Inc 6701 Eighteen Mile Road Sterling Heights Michigan 48078 313 254 1000 e Filter Housing Model Number FC100 2 Replacement Cartridge Number A103 133 HyperDrive Robot Fan Filter Inspection and Cleaning The fan filter on a HyperDrive robot is located on the base see Figure 2 17 The fan filter must be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must be inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or u
130. ed Model Part or Version Number Standard AdeptOne robot Model Number 843 CleanRoom AdeptOne robot Model Number 843 with Class 10 CR Kit PackOne robot Model Number 848 AdeptThree robot Model Number 643 Adept MV 8 controller part number 30330 15000 Adept MV 19 controller part number 30330 25000 Adept PA 4 power chassis part number 30336 31000 A Power Amplifier part number 10337 15200 Manual Mode Safety Package consisting of Category 3 Security Panel Power Amplifier with voltage restrict External VME Front Panel VFP part number 30335 00000 part number 90338 51010 Category 3 part number 90335 00380 Manual Control Pendant MCP III part number 90332 48050 V Operating System software Version 11 3 or later Note Category 3 hardware cannot be used with earlier versions of V See Tables 1 and 2 in the Manufacturer s Declaration at the front of this handbook for information on approved plug in modules for Adept MV controllers P The new Category 3 has two keyswitches older versions have only one The label on the back of the new MCP III is Manual Control III Operator Also on the new the button in the lower right corner below T1 is labeled STEP Definition of a Manipulating Industrial Robot An automatically controlled reprogrammable multi purpose manipulative machine with several degrees of freedom which may be either fixed in a place or mobile for use in
131. ed according to EN 775 150 10218 sections 5 6 EN 292 1 3 71 and EN 60204 section 13 The safety distance to the robot depends relating to the standard EN 294 on the height of the safety fence The height and the distance of the safety fence must ensure that nobody can reach the danger zone of the robot see EN 294 Adept controller systems for AdeptOne MV AdeptThree MV and Adept PackOne robots have various control features which can aid the integrator or user in constructing system safeguards including Customer Emergency stop circuitry and digital input and output lines The emergency power off circuitry is capable of switching external power systems and can be interfaced to user supplied Category 3 compliant safeguards See Chapter 3 for information on safe and effective use of the robot 6 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Precautions and Required Safeguards Impact and Trapping Points Trapping Pinch gt Points Figure 1 4 Robot Impact and Trapping Point Hazards Adept robots are capable of moving at high speeds If a person is struck by a robot impacted or trapped pinched serious injury or death could occur Robot configuration joint speed joint orientation and attached payload all contribute to the total amount of energy available to cause injury Hazards from Expelling a Part or Attached Tooling The maximum joint and user flange tip speeds that can be achieved by the Adept
132. een yellow of the Adept PA 4 Power Chassis is internally connected to the accessible metal parts of the power chassis To ensure electrical shock protection this must be connected to a properly grounded power source via the Security Panel WARNING Ensure that a proper protective ground connection exists before turning on the power The Adept PA 4 power chassis and the Adept MV controller must be connected to the same earth ground Security Panel Grounding The Security Panel must be grounded using the M5 ground stud on the right side of the panel see Figure 2 21 The ground wire should be as short as possible Typically it would be grounded to the frame of the equipment cabinet Adept Robot Grounding The major structural parts of the robot are connected to the ground point on the base of the robot see Figure 2 23 See the next section for parts of the robot that are not grounded The user must install a ground wire at this point to ground the robot Make sure to remove all paint from the surface under the screw at the ground point and usea star washer to ensure a proper ground connection At the Adept PackOne robot ground point place the large diameter washer over the user supplied ground lug then tighten the bolt Apply a silicone based sealant to the area to protect from moisture AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 51 Chapter 2 Installation of the Robots Robot Mounted Equipment Grounding The
133. emove the two 3 16 inch long 4 40 screws from the bottom of the quill flange Using a 7 64 inch hex wrench turn the set screws 2 3 turns counter clockwise or until the bearing mount begins to drop Remove the bearing mount from the robot then remove the lower bellows clamp Pull the bellows off the bearing Installing the New Bellows Place the smaller end of the bellows over the outer race of the bearing Placing the bearing flat on a table should make the bellows cuff easier to slide over the bearing Fit the cuff so that it is roughly 1 32 inch beyond the bearing yet not so much as to contact the bearing mount Keeping the bellows even with the bearings helps to extend its life Clamp the bellows onto the bearing keeping wrinkles to a minimum If the bellows cuff is pushed down against the bearing mount it must be trimmed This allows air flow through the bearing and prevents rubbing If the bellows cuff must be trimmed use a new X acto knife blade Push the two sliding pins in until their flat surface contacts the O ring The O ring should be evenly seated around the groove with the bellows on the top slide the bearing mount over the robot s tool flange Slide both of the mount pins in until its tip is aligned with the through hole in the robot s tool flange Install one of the 3 16 inch long 4 40 screws into the bottom of the quill flange Using a 7 64 inch hex wrench tighten the set screws evenly from each side until they hold the
134. en it is not being held by an operator The cradle has a retaining clip that keeps the Hold to Run switch closed The MCP cradle must installed outside of the robot workcell See Figure 6 13 on page 126 for the dimensions of the cradle AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 47 Chapter 2 Installation of the Robots Connecting the Security Panel The Adept Security Panel consists of two DIN Rails see Figure 2 21 The upper DIN Rail X1 called the Control Rail contains the Category 3 Emergency Stop board and the Teach Restrict Interface board The lower DIN Rail X2 called the Power Rail contains the power supply contactors terminals and circuit breaker Cable Trays 000000000000 000000000000 00000000000 em BIB Control Rail X1 E Ground Category 3 E Stop Board Teach Restrict Interface Board Power Rail X2 a Circuit External 24 VDC Power Supply Contactors Terminals Beaker Cable Tie Anchor Figure 2 21 Connectors on the Security Panel Connecting the Security Panel to the SIO Module
135. enclosure power disconnect in the OFF position 2 3 Environmental and Facility Requirements for Power Chassis The Adept PA 4 power chassis is typically installed in the same enclosure as the controller See Table 2 2 for environmental requirements See Table 2 7 on page 56 for electrical requirements 2 4 Before Unpacking the Adept Equipment Carefully inspect all shipping crates for evidence of damage during transit Pay special attention to tilt and shock indication labels on the exteriors of the containers If any damage is indicated request that the carrier s agent be present at the time the container is unpacked 22 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Adept Shipment Specifications 2 5 Adept Shipment Specifications Adept ships the equipment in a number of boxes and shipping crates depending on the order The boxes have different dimensions and weights The following table gives an overview Table 2 3 Adept Shipping Crate Specifications Product in Crate Length Width Height Weight AdeptOne MV Robot 0 74 m 29 in 1 20 m 47 in 1 78 m 70 in 220 kg 484 Ib AdeptThree MV Robot 0 74 m 29 in 1 20 m 47 in 2 00 m 79 in 240 kg 528 Ib Adept PackOne MV 0 74 m 29 in 1 20 m 47 in 1 78 m 70 in 275 kg 605 Ib Robot Adept MV Controller 0 89 m 35 0 64m 25in 096m 38in 66 kg 145 Ib and PA 4 Power
136. ended use or not 1 6 Robot Modifications It is sometimes necessary to modify the robot in order to successfully integrate it into a workcell Unfortunately many seemingly simple modifications can either cause a robot failure or reduce the robot s performance reliability or lifetime The following informa tion is provided as a guideline to modifications Acceptable Modifications In general the following robot modifications will not cause problems but may affect robot performance Attaching tooling utility boxes solenoid packs vacuum pumps screwdrivers cameras lighting etc to the inner link outer link or column Attaching hoses pneumatic lines or cables to the robot These should be designed so they do not restrict joint motion or cause robot motion errors Unacceptable Modifications If not done properly the modifications listed below will damage the robot reduce system safety and reliability or shorten the life of the robot CAUTION Making any of the modifications outlined below will void the warranty of any components that Adept determines were damaged due to the modification You must contact Adept Customer Service if you are considering any of the following modifications Modifying any of the robot harnesses or robot to controller cables Modifying any robot access covers or drive system components Modifying including drilling or cutting any robot casting Modifying any robot electrical c
137. ent sub assemblies of a complete industrial automation system The controller and power chassis sub assemblies must be installed inside a suitable enclosure The controller and power chassis sub assemblies must not come into contact with liquids Additionally the AdeptOne MV and the AdeptThree MV robots must not come into contact with liquids The Adept equipment is not intended for use in any of the following situations e hazardous explosive atmospheres In mobile portable marine or aircraft systems In life support systems In residential installations In situations where the Adept equipment will be subject to extremes of heat humidity See specifications for allowable temperature and humidity ranges WARNING The given instructions about operation installation and maintenance in this Instruction Handbook must be strictly observed Non intended use of an AdeptOne MV an AdeptThree MV or a PackOne MV Robot can cause injury to the personnel damage the robot or other equipment reduce the system reliability and the performance of the system AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 9 Chapter 1 Safety persons that install commission operate or maintain the robot must have the necessary qualifications read and follow exactly the instructions in this Instruction Handbook If there is any doubt concerning the application ask Adept to determine if it is an int
138. eptThree MV Robot Instruction Handbook Rev B 153 Using the Safety Ulility C TI Introduction 4a nu RUE ee Eb RE LARGE 154 Category Robot COMPONENTS ens 154 AGGOletFormelet ee dott ew acp nee e 154 B Amplifier Voltage 5 154 Switches and Buttons 2 2 2 154 Hola To Run Switch liess es 154 Dual Brake Solenoid 155 Dual Dump Valves AdeptThree MV 155 Robot Brakes sos ace ae ac 155 C2 SAFEUTIE V2 ia narn anie retook cate itus Sayed 155 Commissioned vs Not Commissioned 155 Starting the SAFE_UTL V2 Utility csse 156 Tests Performed at Time of Commissioning 157 Accelerometer Test roe esce e RA al e e ce ph tr e fe at 158 Amp Voltage Restrict Test ne 160 VFP Switeh and Butter Tests teu ep EMEN EE Up 161 FUNCTIONS 43 erp aa ro Ua as e o hat 163 Brake Holding Forca Tehnos is 164 C 4 Tests Performed Periodically 166 REGUS A OOS c Sh ce d 166 Testing the Dual Brake 2 4 167 Testing the Dual Dump VAIV
139. er Assembly Port A Valves 1 amp 2 normally plugged Solenoid Assembly i Under Joint 2 Cover TZ Din 1 Outer Access v Link Card Cover at either end User Air Lines Port B Valves 1 amp 2 Access Hole Plug second plug on i opposite side of base o Figure E 1 User Connections in the AdeptOne MV Robot 180 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Compressed Air Lines In the Robot Spare Air Line A spare air line 5 32 is incorporated into the robot to allow for User options This line runs from the base of the robot up to the area near the outer link card in the outer link The line is not supplied with connection fittings at either end At the base the end of the air line can be routed through either one of the access holes capped with removable plastic plugs Figure E 1 To access the spare air line at the base remove eight cap head screws that secure the base top cover then lift and turn the cover out of the way Be careful not to disturb exposed parts and wiring when top cover is off At the outer link location you can access the air line by removing the outer link access cover NOTE This spare air line is not available on the PackOne MV robot AdeptThree MV Robot Solen
140. ervice Center in Paris France The phone numbers are 33 1 69 19 16 16 Monday to Friday 8 30 to 17 30 CET 33 1 69 32 04 62 FAX Italy For customers in Italy Adept Technology maintains a Customer Service Center in Arezzo Italy The phone numbers are 39 575 3986 11 Monday to Friday 8 30 to 17 30 CET 39 575 3986 20 FAX In the United States Adept Technology maintains a Customer Service Center at its headquarters in San Jose CA The phone numbers are Service Calls 800 232 3378 24 hours per day 7 days a week 408 433 9462 FAX Application Questions 800 232 3378 Monday to Friday 8 00 am to 5 00 pm Pacific time 408 434 6248 FAX Applications Internet E Mail Address If you have access to the Internet you can send applications questions by e mail to applications adept com Training Information For information regarding Adept Training Courses in the USA please call 408 434 5024 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 15 Chapter 1 Safety 16 Outside Continental United States or Europe For service calls application questions and training information call the Adept Customer Service Center in San Jose California USA 1 408 434 5000 1 408 433 9462 FAX service requests 1 408 434 6248 FAX application questions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installation of the Robots 2 1 Environmental and Facility Requi
141. ervice at the numbers listed in Chapter 1 Chassis and Amplifier Module Fuses Six chassis fuses are located inside the base of the power chassis on the power control board These fuses are not user replaceable If you suspect that a chassis fuse may have blown contact Customer Service In addition to the fuses in the power chassis there are additional fuses located inside the power amplifier modules The amplifier fuses are not user replaceable If you suspect that an amplifier fuse may have blown contact Customer Service CAUTION Failure of a chassis or an amplifier fuse indicates an internal circuit fault which must be corrected before the fuse is replaced Do not attempt to replace the fuse yourself contact Adept Customer Service at the numbers listed in Chapter 1 Removing and Installing Amplifier Modules The Adept PA 4 power chassis is shipped from the factory with the amplifier modules installed in the chassis Any unused slots are filled with blank covers Normally you will not need to remove the amplifier modules If you do need to remove and re install a module for some reason follow the instructions below The four slots in the chassis are not interchangeable some slots have special control signals The amplifier modules are factory installed in the correct slots Contact Adept Customer Service if you need to relocate any modules WARNING Do not attempt to install or remove any amplifier modules without first turning off th
142. es its state If the test fails the main menu is displayed If the test passes the HIGH POWER state test is performed and the following is displayed HIGH POWER state test Press and hold the HIGH POWER button Release the HIGH POWER button As the HIGH POWER button is pressed SAFE UTL verifies its state If the test fails the main menu is displayed If the test passes the HIGH POWER enable test is performed and the following is displayed HIGH POWER Enable test Press and release the HIGH POWER button while the button is flashing Press ENTER to begin the test After pressing ENTER the HIGH POWER button must be pressed If the test fails the main menu is displayed If the test passes the EMERGENCY STOP Button test is performed and the following is displayed EMERGENCY STOP Button test Press the EMERGENCY STOP Release the EMERGENCY STOP Press the EMERGENCY STOP button on the After releasing the EMERGENGY STOP button the test is complete If the test fails the main menu is displayed If the test passes the HIGH POWER Timeout test is performed and the following is displayed HIGH POWER Timeout test DO NOT press the HIGH POWER button at all After several seconds the enable power request faults and the test is complete If the test fails the main menu is displayed If the test passes the following is displayed VFP test passes
143. ety Robot Kinetic Stored Energy The AdeptOne MV and PackOne MV have a fail safe mechanical brake on Joints 1 2 and 3 only Joint 4 does not have a mechanical brake it is decelerated by friction and the regenerative capability of the amplifiers In the event of an emergency stop Joint 4 may continue to move due to its own stored kinetic energy inertia and that of the payload The mass of the Joint 4 flange and quill is approximately 3 5 kg 7 7 Ib The AdeptThree MV has a fail safe mechanical brake on axes 1 2 3 and 4 Additional Safety Information The standards and regulations listed in this handbook contain additional guidelines for robot system installation safeguarding maintenance testing start up and operator training The table below lists sources for the various standards Table 1 4 Sources for International Standards and Directives BSI British Standards Institute Sales Department Linford Wood Milton Keynes MK14 6 United Kingdom Phone 0181 996 7000 Fax 0181 996 7001 Beuth Verlag GmbH 10722 Berlin Germany Phone 030 26 01 22 60 Fax 030 26 01 12 60 IEC International Electrotechnical Commission Rue de Varembe 3 PO Box 131 CH 1211 Geneva 20 Switzerland Phone 41 22 919 0211 Fax 41 22 919 0300 American Electronics Association Europe 40 Rue des Drapiers 1050 Brussels Belgium Phone 322 502 7015 Fax 322 502 6734 American National Standards Institute 11 Wes
144. f an installation with an Adept robot without the adequate safeguards according to the standards EN 775 1SO 10218 sections 5 6 EN 292 1 and EN 60204 section 13 Robot Static Forces Adept robot systems include computer controlled mechanisms that are capable of exerting considerable force Like all robot and motion systems and most industrial equipment they must be treated with respect by the user and the operator The following table shows the forces that can be generated by an AdeptOne MV robot Table 1 2 Robot Torques and Forces Joint 1 maximum static torque 400 Nm 295 ft lb Joint 2 maximum static torque 280 Nm 207 ft Ib Maximum static force applied by the robotin 1250 N 280 Ib XY plane measured at user flange Safety Barriers Safety barriers must be an integral part of robot workcell design installation Operator training and operating procedures Adept systems are computer controlled and may activate remote devices under program control at times or along paths not anticipated by personnel It is critical that safeguards be in place to prevent personnel from entering the workcell whenever equipment power is present The AdeptOne MV AdeptThree MV and PackOne MV robots are not safe on their own The Robot System Integrator or end user must ensure that adequate safeguards safety barriers light curtains safety gates safety floor mats etc will be installed The robot workcell must be design
145. fety Barrier 1 and 2 connectors but in Manual mode they are not connected to the chain of E Stops In Manual mode these connectors are muted bypassed by the control system This allows you to open an access door to the robot workcell in Manual mode if these limit switches are installed to the Customer Safety Barrier 1 and 2 Mute contacts Voltage Free Contacts for Monitoring E Stop Circuitry Passive E Stop Adept provides voltage free contacts passive E Stop on TB5 for monitoring the emergency circuitry The Passive E Stop output uses positive drive electro mechanical relays that the customer can use to monitor the E Stop circuit Many safety standards do not permit electronic control of E Stop signals therefore the passive E Stop output is often required to ensure that the user s equipment is shut down if the E Stop circuit is activated The Passive E Stop output should also be used to control any other user devices in the workcell that need to be stopped in an emergency Such devices might include other moving equipment such as conveyor belts indexing or transfer devices pneumatic systems etc The specifications for the relays in the passive E Stop circuit are maximum switching power 250VA volt amps 5W maximum switching voltage 230 Volts AC 300 Volts DC maximum switching current 2A CAUTION The power through the relay must not exceed 250VA 5 W The user can monitor the condition of the E Stop circuitry wi
146. g external surface coating rotary seal assemblies and cleaning information Please refer to section 5 8 on page 109 for this maintenance information See Table 5 1 for a summary of the preventive maintenance procedures and guidelines on frequency Table 5 1 Recommended Preventive Maintenance Schedule Item Recommended Schedule hours Lubricate the upper and lower quill shaft Every 3 months or 1000 hours Check all screws in robot cover plates Monthly robot mounting stand Check all cable connections Monthly Drain robot compressed air filter moisture Monthly trap Check air filters on controller and power Monthly chassis Check lamps on VFP using Lamp Test Monthly button Run Safety Utility Every six months NOTE The frequency of these procedures will depend on the particular system its operating environment and amount of usage Use the times in Table 5 1 as guidelines and modify the schedule as needed WARNING The procedures and replacement of parts mentioned in this section should only be performed by skilled or instructed persons as defined in section 1 11 on page 12 The access covers on the robot are not interlocked turn off disconnect power if covers have to be removed 5 2 Using the Safety Utility Use the Safety Utility every six months to test the components of the Category 3 safety system See Appendix C for instructions 100 AdeptOne MV AdeptThree M
147. ge 125 for dimensions of the chassis and M4 x 10mm pan head screw mounting brackets Panel Mount M4 x 25mm pan head screw M4 x 25mm pan head screw 2 places 2 places ni M4 x 10mm pan head screw M4 x 10mm pan head screw Rack Mount Flush Rack Mount Set Back Figure 2 11 Installing Mounting Brackets on an Adept PA 4 Power Chassis 36 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installing the A Series Monitor and Keyboard 2 11 Installing the A Series Monitor and Keyboard NOTE The peripheral equipment such as the keyboard and monitor supplied by Adept are intended for use in light industrial conditions In more severe conditions they should be protected with a suitable enclosure Installation Procedure An A Series Adept MV controller can be configured with a color monitor and an extended keyboard with built in trackball Both of these devices connect to the VGB module The terminal monitor and or keyboard should be mounted at least 0 2 m 0 7 ft above the floor or other servicing level This is mandatory if the installation is in an EU or other country that requires compliance with EN 60204 See Figure 2 12 for details the steps are listed below 1 Make sure the controller is turned off before making any connections oJ A Series Color Monitor
148. ge setting label is located on the front of the chassis below the circuit breaker The voltage setting is also shown on the ID label on the side of the chassis Verify that the setting matches your facility power before installation This chassis is designed for 3 phase operation only If you need to change the AC voltage setting from 380 415 VAC to 200 240 VAC see page 60 WARNING Electrical hazard Verify the voltage settings are correct before turning on power Operating the Adept PA 4 power chassis with incorrect voltage settings can cause damage or injury AC Power Requirements for Power Chassis Table 2 7 Adept PA 4 Power Chassis Power Requirements NE Recommended Nominal Minimum Maximum Voltage Operating Operating Phasing Circuit Breaker Range Voltage Voltage user supplied 380 to 415 50 60Hz 342 VAC 424 VAC 20 amps VAC 3 phase with neutral 200 to 240 50 60Hz 180 VAC 245 VAC 20 amps VAC 3 phase Power to the Adept MV controller and PA 4 power chassis must come from a single source Specifications for the Power Chassis are based on an Adept PA 4 with two A and one amplifier modules and an AdeptOne MV an Adept PackOne MV or an AdeptThree MV robot Connecting the Power Cord of the Power Chassis to the Security Panel The 3 phase AC power cord of the PA 4 power chassis must be installed at the contacts on the Power Rail X2 See Figure 2 25 Adep
149. gory 3 E Stop Schematic __ AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 145 Appendix A Category 3 E Stop Circuit The following table gives the descriptions of the numbers in Figure A 1 Table A 1 Description of numbers in the Category 3 E Stop Drawing Description of Numbers in the schematic Front Panel MANUAL AUTOMATIC select key switch MANUAL Normally Open Customer Manual Mode 1 and 2 OUT Voltage Free Contacts V Manual Mode Input Contacts Customer E Stop IN 1 and 2 Contacts Customer Safety Barrier 1 and 2 Contacts Customer Safety Barrier Mute 1 and 2 Contacts Teach Restrict Cyclic Check Contacts J1 J2 Accelerometer Contacts Oo MINI oD OFF wl J3 B Amplifier Speed Cutoff Contacts A B Amplifier Speed Cutoff Contacts V User External E Stop Input Contacts A N Customer E Stop 1 OUT Voltage Free Contacts OA W Customer E Stop 2 OUT Voltage Free Contacts V High Power Enable Passive E Stop A O1 High Power On Off Push Button A Customer Safety Relay Feedback Contacts A PA4 Power Amplifier Chassis Contactors A Power Chassis Robot RSC Brake Release Enable Driver N e Robot Brake Release Enable Solenoids 146 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev
150. he normal motion range of the robot must be limited if other equipment is installed inside the envelope for example The softstops for each joint are set to their maximum value at the factory To limit any joint s motion range change the joint s softstop value using the SPEC utility program formerly CONFIG_R on the Adept Utility Disk supplied with the system Refer to the Instructions for Adept Utility Programs for information regarding this utility program When you are using the MCP to move the robot the robot will stop abruptly when it encounters a softstop This abruptness does not mean a hardstop has been contacted Hardstops In most cases the softstop will prevent joint travel from contacting a hardstop however contact is possible during high speed operation The hardstops are designed to withstand large forces without damaging the robot The hardstops for each joint are fixed mechanical stops The hardstops for Joints 1 3 and 4 are located inside the robot The hardstops for Joint 2 are mounted externally on the inner link they are the hard rubber cylinders that the large eyebolts pass through The hardstops for Joint 3 are mounted at the top and bottom of the quill The Joint 2 and 3 hardstops must not be modified in any way or damage to the robot could occur AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Limiting Joint Travel Table E 2 AdeptOne MV Robot Softstop and Hardstop Specs
151. hile working with the robot Press the positive speed bar until the robot starts moving When it moves in one direction stop pressing the speed bar Then press the minus speed bar and watch the robot It must now move into the opposite direction After you verified that the robot can move in both directions you can release the speedbar Selecting and Moving Joint 2 Press the Y2 button on the MCP to select Joint 2 After pressing the Y2 button the LED on it will turn on The robot is ready to move Joint 2 Press the positive speed bar until the robot starts moving Joint 2 When it moves stop pressing the speed bar Then press the negative speed bar and watch the robot It must move into the opposite direction After you verified that the robot can move in both directions you can release the speedbar Selecting and Moving Joint 3 Press the Z3 button on the MCP to select Joint 3 After pressing the Z3 button the LED on it will turn on The robot is ready to move Joint 3 Press the positive speed bar The robot quill must move in the direction of the floor If you verified that the robot follows the instruction then press the minus speed bar and check if the quill moves into the opposite direction Selecting and Moving Joint 4 Press the RX4 button on the MCP to select Joint 4 After pressing the RX4 button the LED on it will turn on The robot is ready to move Joint 4 Press the positive speed bar until the robot starts moving When it
152. ided for reference voltage sources are typically used to drive the inputs 2 ms response time minimum for fast inputs 1001 to 1003 depending on program task configuration when used with V INT EVENT instruction 80 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop and Teach Restrict Equipment Table 3 4 Digital Input Signal Assignments on Terminal Blocks and TB2 Terminal Block Terminal Signal Terminal Signal TB1 1 24 V 1 Amp 2 24 V return TB1 3 Input 1001 4 1001 return TB1 5 Input 1002 6 1002 return TB1 7 Input 1003 8 1008 return TB1 9 Input 1004 10 1004 return TB1 11 Input 1005 12 1005 return TB2 1 Input 1006 2 1006 return TB2 3 Input 1007 4 1007 return TB2 5 Input 1008 6 1008 return TB2 7 Input 1009 8 1009 return TB2 9 Input 1010 10 1010 return TB2 11 Input 1011 12 1011 return NOTE Digital Input signal 1012 is not available because it is used for the Category 3 safety system AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 81 Chapter 3 Preparation for Safe and Effective Use of the Robot 82 Output Signals The terminal block TB3 handles the digital output signals 0001 to 0005 Refer to Table 3 5 for output specifications The locations of the signals on the terminal block are given in Table 3 4 The SIO provides separate and connections for each channel no internal common con
153. ied equipment is connected and working correctly 4 2 Check Of Physical Connections Physical Connections Before turning on the controller and enabling High Power make sure that the following cables are installed correctly See Chapter 2 for installation instructions robot to power chassis robot to controller robot to Security Panel controller to power chassis controller to Security Panel power chassis to Security Panel VFP to controller Security Panel and MCP Make sure you have installed proper safeguards and E Stop circuits as described in Chapter 1 and Chapter 3 CAUTION Ensure that all screws holding the amp modules and blank panels in the power chassis are securely fastened If they are loose power to the robot cannot be enabled Make sure that the controller is connected to the correct AC power source See Chapter 2 for details about the power requirements of the devices 86 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B VFP Operating Modes 4 3 VFP Operating Modes Adept robots have two different operating modes The VFP incorporates a 2 position rotary keyswitch marked MANUAL and AUTO that controls whether the robot is operating in Manual or Automatic mode For safety reasons High Power is automatically disabled when the operating mode is changed Manual Operating Mode In the MANUAL position of the keyswitch robot motion can be initiated only from the Manual Co
154. ier design of 78 mute function 74 switch specifications 76 D Digital I O input signals on TB1 TB2 81 output signals on TB3 83 Digital I O from SIO inputspecifications 80 output specifications 82 dimensions Adept MV 19 controller 121 Adept MV 8 controller 120 AdeptOne MV robot 114 AdeptThree MV robot 115 calibration fixture 117 External Front Panel 123 MCP cradle 126 mounting brackets 125 PackOne MV robot 116 power chassis 122 Security Panel 124 E EMC test information 175 Emergency Stop circuit see circuit Emergency Stop switch on External Front Panel 39 Enable Power description of process 75 how to from MCP 92 end effector grounding 67 end effector installation clamp mounted 67 clamp mounted on PackOne 69 screw mounted 68 screw mounted on PackOne 70 envelope working AdeptOne MV 132 AdeptThree MV 135 PackOne MV 138 E Stop circuit 73 79 Customer Safety Barrier switch specifications 76 mute function in Customer Safety barrier 74 schematic 141 voltage free contacts 78 exterior surface coating maintenance on PackOne MV 109 External Front Panel 39 40 controls indicators 39 dimensions 123 installation 40 F fan filter cleaning in controller 108 fan filter cleaning in power chassis 108 fuses amplifier module 65 chassis 65 G grounding diagram 53 system information 51 188 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Index H hardstops AdeptOne MV spe
155. ime 12 in 305 mm No payload standard 0 70 sec with HyperDrive 0 60 sec 9 kg 20 Ib payload standard 0 92 sec with HyperDrive 0 79 sec Resolution Joint 1 0 00078 Joint 2 0 00312 Joint 3 vertical Z 0 0033 mm 0 00013 in Joint 4 tool rotation 0 047 130 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B AdeptOne MV Robot Specifications Table 6 1 AdeptOne MV Robot Performance Specifications Continued Repeatability X Y plane 10 025 mm 40 001 in Joint 3 vertical Z 0 050 mm 40 002 in Joint 4 rotational x 0 05 Accuracy in X Y Plane 3 F temperature variation With optional HPS hardware and software 0 076 mm 0 003 in over 17 x 17 area Joint Speed maximum Joint 1 540 sec Joint 2 540 sec Joint 3 500 mm sec 19 7 in Joint 4 3600 sec Weight Standard robot without options 180 kg 400 Ib Hyperdrive robot without options 190 kg 418 Ib Power chassis with 3 amplifier modules approximately 16 4 kg 36 Ib MV 8 controller with 030 SIO VGB approximately 14 5 kg 32 Ib Design Life 42 000 hours Maximum possible using modified servo gains and running at reduced speed P The robot tool performs a continuous path motion consisting of all straight line segments 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and returning along the same path The endpoints of the cycle are appr
156. in the following order NOTE The system integrator must add adequate strain relief for the Motor Power cable connectors at the amplifier modules a Install the plug labeled A Amp 1 in the connector marked Motor Power Output on the A Amp at the left side of the chassis b Install the plug labeled A Amp 2 in the connector marked Motor Power Output on the second A Amp to the right hand side of the first A Amp c Install the plug labeled B Amp 1 in the connector marked Motor Power Output on the Amp d The fourth connector on the motor power cable is used only for the Fifth Axis option which is not available for robots with the Category 3 package WARNING Verify that all connectors are secure and fully inserted Failure to do this could cause unexpected robot motion AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 43 Chapter 2 Installation of the Robots Robot Base Fan Filter Housing on HyperDrive Robots Arm Power Cable Connector Compressed Air b Inlet With Filter Brake Release Button Arm Signal Cable Connector Product Data Label Figure 2 17 AdeptOne MV or AdeptThree MV Robot Base Showing Air Filter and Cable Connector Locations Air Filter Arm Signal Cable gt Brake Release Button Arm Power Cable Product Data Label Figure 2 18 Adept PackOne MV Robot Base Showing Air Filter and Cable Conn
157. ing see Figure 2 7 Take up any slack but do not lift the robot at this time WARNING Impact Hazard Do not attempt to lift the robot at any points other than the eyebolts provided Failure to comply could result in the robot falling and causing either personnel injury or equipment damage 30 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Installation Lift robot only from two eyebolts Y Y OO Figure 2 7 Lifting Robot From Eyebolts Remove the three bolts securing the robot base to the pallet Retain these bolts for possible later relocation of the equipment WARNING Do not attempt to extend the inner or outer links of the robot until the robot has been secured in position Failure to comply could result in the robot falling and causing either personnel injury or equipment damage Lift the robot and position it directly over the floor plate or spool WARNING Impact Hazard The robot may swing free if not lifted straight up Stand clear of the robot at all times while it is supported by the lift Slowly lower the robot while aligning the base and the tapped mounting holes in the plate or spool Inserta 1 2 13 x 2 inch bolt 3 5 inch for PackOne fitted with both a lock washer and a flat washer through each of the three mounting holes in the robot base into the mounting plate or spool and torque to 88 Nm 65 ft Ib Adep
158. ing a bolt or unscrewing a bottle cap Refer to Figure 6 16 128 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Joint Motions E Joint 4 Rotation Figure 6 16 Joint 3 and Joint 4 Motions AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B C oo oL Joint 3 Stroke 129 Chapter 6 Technical Specification 6 3 AdeptOne MV Robot Specifications specifications subject to change without notice Table 6 1 AdeptOne MV Robot Performance Specifications Reach Maximum radial 800 mm 31 5 in Minimum radial 23 mm 9 1 in Vertical clearance bottom of base to end effector flange Standard 7 7 in stroke with maximum Joint 3 retraction 877 mm 34 52 in with maximum Joint 3 extension 679 mm 26 75 in Optional 11 6 in stroke with maximum Joint 3 retraction 775 mm 30 52 in with maximum Joint 3 extension 480 mm 18 91 in Vertical Stroke Z direction Standard Joint 3 195 mm 7 7 in Optional Joint 3 295 mm 11 6 in Joint Rotation Joint 1 300 Joint 2 294 Joint 4 554 Payload Including End Effector 9 09 kg 20 Ib Inertia Load Maximum About Joint 4 axis standard 281 kg cm 96 Ib in2 maximum 2926 kg cm 1000 Ib in Force Joint 3 downward force without payload 18 2 kg 40 Ib Cycle T
159. ion Handbook Rev B Environmental and Facility Requirements for Robots 21 Environmental and Facility Requirements for Robots The information in this chapter applies to the AdeptOne MV the AdeptThree MV and the Adept PackOne MV robots except where differences are specifically noted Facility Ambient Air Quality For Robots The following specifications apply to the AdeptOne MV AdeptThree MV and the Adept PackOne MV robots Table 2 1 Operating Environment Specifications for Adept Robots Temperature Relative Humidity IP Rating Standard Robot 5 to 40 C 5 to 9596 IP 20 41 to 104 F non condensing HyperDrive 5 to 50 C 5 to 9576 204 Robot 41 to 122 F non condensing Cleanroom Robot 5 to 40 C 5 to 95 IP 20 41 to 104 F non condensing Cleanroom 5 to 27 C 5 to 95 IP 20 HyperDrive 41 to 80 non condensing Robot PackOne MV 1 to 45 C 10 to 10096 IP 55 33 5 to 113 F condensing The IP rating includes the motors inside the robot P Standard HyperDrive robots have a cooling fan in the base The fan filter must be kept clean to ensure proper cooling See page 107 On the PackOne the motors inside the robot are IP 20 Compressed Air for the AdeptOne MV and AdepiThree MV Robot The AdeptOne MV and the AdeptThree MV robots require clean dry oil free compressed air at 5 5 7 6 bar 80 110 psi with a flow rate of 28 liters per minute 1
160. left most state World If MCP Manual mode is terminated and re entered without turning off system power the last active state is selected Joint Axis Control Buttons The buttons on the far right side are the Joint Axis control buttons see Figure 4 3 on page 91 When the controller is in Manual mode these buttons select which robot joint will move or the coordinate axis along which the robot will move Speed Bars The speed bars are used to control the robot s speed and direction The joint s that will move when the speed bars are pressed depends on the state selected with the MAN HALT button Press the speed bars with your left thumb Pressing the speed bars near the outer ends will move the robot faster pressing the speed bar near the center will move the robot slower The maximum speed of the robot in Manual mode is 250 mm per second 10 ips Fast Slow Fast Figure 4 6 Speed Bars AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 95 Chapter 4 Commissioning the System Selecting Joint State and Moving the Robot Figure 4 7 shows a typical Adept SCARA robot with three rotational joints Joints 1 2 and 4 and one translational joint Joint 3 Positive rotation of Joints 1 and 2 is counter clockwise as viewed from above Positive rotation of Joint 4 is clockwise as viewed from above Positive movement of Joint 3 is downward Before the speed bars will move joint the correct joint must be
161. lignment pin hole in the user flange then place the ring clamp over both flanges and tighten the clamp screw 6 Reconnect the compressed air supply Ring Clamp Flange Open and Close Air Lines Alignment Pin Figure 2 33 Clamp mounted End Effector Installation for Adept PackOne MV Robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 69 Chapter 2 Installation of the Robots Screw mounted End Effector The following procedure describes installing an end effector using four screws See Figure 2 34 1 Disconnect the air supply to the robot 2 Remove the plugs from the Open and Close air lines where they protrude from the user flange 3 Install the Open and Close air lines onto the appropriate fittings on the end effector 4 Anadhesive backed gasket is supplied with the robot to provide a hygienic seal between the user flange and end effector This gasket can be applied to either the user flange or the end effector flange Mate the end effector flange to the user flange Rotate the end effector until its alignment pin lines up with the alignment pin hole in the user flange 5 Insert four 8 32 screws through the mounting holes and tighten Recommended torque is 1 7 Nm 15 in Ib 6 Reconnect the compressed air supply Open and Close Air Lines Alignment Pin 8 32 4 places Figure 2 34 Screw mounted End Effector Installation for Adept PackOne MV Robot 70 AdeptOne MV Ade
162. llows Replacement The quill bellows should be visually inspected for wear every month Particular attention should be given to the area of the bellows in contact with the two clamps If any signs of wear are visible the bellows should be replaced The bellows should be replaced every three months The procedure below outlines the replacement of the bellows Required Materials and Tools To perform this procedure you will need the following tools parts and materials 1 Replacement Bellows Kit Adept part number 90842 99900 includes a One Bellows Cover used for both 7 7 inch and 11 6 inch AdeptOne robots b One3 1 2 inch bellows clamp bottom c One4 1 2 inch bellows clamp top d Two 3 4 long 4 40 hex head screws cap screws AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 151 Appendix B CleanRoom Option 2 Hex Wrenches 3 32 inch and 7 64 inch 3 X acto knife Removing the Bellows Move the robot to an area that will allow access to the outer link area and move Joint 3 midway between the hard stops Disable High Power to the robot Switch off the On Off power switch on the Adept MV Controller and the Adept PA 4 Power Chassis Refer to Figure B 2 while performing this procedure Loosen the top bellows clamp and slide it out of the way Pull the top of the bellows away from the housing Screw the two 3 4 inch long 4 40 cap screws provided into the tapped holes in the perimeter of the bearing mounts R
163. ly by skilled or instructed persons For a description of the level of qualification Adept uses the standard terms Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers which electricity may create engineers and technicians Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers which electricity may create operating and maintenance staff personnel must observe sound safety practices during the installation operation and testing of all electrically powered equipment To avoid injury or damage to equipment always remove power by disconnecting the AC power cord from the source before attempting any repair or upgrade activity WARNING The user is obligated to get confirmation from every entrusted person before they start working with the robot about the following subjects 1 The person has received the Instruction Handbook has read it has understood it and 2 The person will work in the described manner 1 12 Transport Always use adequate equipment to transport and lift Adept devices See Chapter 2 for more information on transporting lifting and installing WARNING Do not stay under the robot while it is transported 12 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Safety Equipment for Operators 1 13 Safety Equipment for Operators 1 14 Adept advises operators to wear ext
164. mer Service for further information Cleaning Information The Adept PackOne robot is designed to meet NEMA 4 and IP 55 requirements for low pressure water splashing The Adept PackOne is not designed to be sprayed from close proximity with high pressure water nozzles If high pressure water nozzles are used near the PackOne the protective cover supplied with the robot must be installed to protect against errant spraying In order to maintain compliance with the warranty follow the procedures listed below and pay close attention to the Caution messages Removing the End Effector for Cleaning The end effector can be removed for a separate cleaning procedure refer to the instructions that come from the manufacturer of the end effector When the end effector is removed you must plug the Open and Close air lines at the end of the quill so that no moisture can enter the robot through those lines AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 109 Chapter 5 Maintenance Washdown Procedure CAUTION The application of strong alkaline acidic or high chlorine cleaning chemicals may degrade the PackOne s surface finish Cleanup with high pressure sprays abrasive cleaning agents and scouring pads may damage the PackOne s seals and surface finish These practices are not recommended on the PackOne The PackOne is designed to withstand occasional errant exposure to high pressure sprays and caustic chemicals and no damage sh
165. moves stop pressing the speed bar Then press the minus speed bar and watch the robot It must move into the opposite direction After you verified that the robot can move in both directions you can release the speedbar AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 97 Maintenance 5 1 Introduction 15 0 000 cii no ER ia 100 5 2 Using the Safety 100 5 3 Robot Lubrication o kl EVER 101 Recommended Grease for AdeptOne MV AdeptThree MV Robot 101 Recommended Grease for Adept PackOne MV Robot 101 Lubricating the Upper QuillShaft sisse 101 Lubricating the Lower Quill Shaft AdeptOne MV Adept PackOne MV 2 2 2 2 222 2 103 Lubricating the Lower Quill Shaft AdeptThree MV Robot 104 5 4 Check Robot Mounting Bolt 106 5 5 Joint 3 Bellows Replacement Adept PackOne MV 106 5 6 Maintenance and Inspection of Air 107 Draining Moisture from AdeptOne MV AdeptThree MV Robot Compressed Air Filter csse en 107 Maintaining Compressed Air Filter of Adept PackOne MV Robot 107 Draining Moisture from the Air Filter 107 Replacing the Filter Cartridge eee
166. n an amp module Short Fault indicates that an over current in the motor leads has been detected d Amplifier Control connector the V I to Amp cable connec tors are installed here Teach Restrict connector the Teach Restrict to B Amp cable is installed here 4evico mmsov Motor Power Output connector the Arm Power cable is installed here 1 On B amplifier modules at revision level P2 or greater or revision A or greater the left hand LED when lit indicates that the fault was caused by a sag in voltage The right hand LED when lit indicates the fault was caused by an over temperature condition on the amplifier heat sink 64 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Additional Power Chassis Information Power Chassis Circuit Breaker and Fuse Information NOTE The SSER LVON HPON and ILMT labels on the lower right corner of the front of the power chassis are for diagnostic LEDs that can be viewed behind the front grill These LEDs are for Adept Field Service use only Chassis Circuit Breaker The power chassis circuit breaker is rated at 15A and is located on the lower left front of the chassis on the power entry module It also functions as an on off switch to isolate the chassis CAUTION If the circuit breaker trips due to current overload it indicates an internal fault Do not reset the circuit breaker yourself contact Adept Customer S
167. n of Category 3 operation As shown in Appendix A redundant connections are provided on the Security Panel for customer Emergency Stop safety barriers If one of these switches or contacts is open High Power will be turned off The Security Panel also supplies voltage free contacts that are closed when High Power is on and open when High Power is off These contacts can be used to switch on and off additional equipment depending on the status of the E Stop circuit The Security Panel also supplies voltage free contacts to signal that the robot is in Manual mode These contacts can be used by the customer to disconnect input devices or other external peripherals turn tables conveyors etc Description of Mute Capability There are two pairs of terminals see Table 3 1 on the Security Panel for customer safety barriers that can be muted in Manual mode Input to these terminals from a safety barrier is muted not active in Manual mode but the input is active in Automatic mode That means that an interlock switch on a workcell access door can be connected to these terminals and the door can be left open in Manual mode This is useful for a person who is teaching points in the workcell during program development There is a second pair of terminals for a second barrier This pair of inputs is always active even in Manual mode This feature can be used for an inner barrier safety mat or light curtain Power Relay E Stop with Cyclic
168. nd washers from accessories kit Repeat process for other side of controller If the controller is joined to an Adept PA 4 Power Chassis gt the position of the screws is different on the side of the controller See the drawing for the power chassis o o o Note See Figure 6 12 on page 125 for dimensions of the controller and M4 x 10mm pan head screw mounting brackets Panel Mount M4 x 25mm pan head screw M4 x 25mm pan head screw 2 places 2 places o o o o o M4 x 10mm pan head screw M4 x 10mm pan head screw Rack Mount Flush Rack Mount Set Back Figure 2 10 Installing Mounting Brackets on an Adept MV Controller AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 35 Chapter 2 Installation of the Robots M4 x 25mm pan head screw 2 places aoe To Install Mounting Brackets on Adept 4 Power Chassis Remove and discard 3 existing countersunk o o screws from side of chassis at locations shown in drawing Place bracket in desired position and secure with indicated M4 pan head screws and washers from e accessories kit Wa 0 0 Repeat process for other side of chassis If the power chassis is joined to an Adept MV controller the position of the screws is different on the side of the controller See the controller drawing o o o Note See Figure 6 12 on pa
169. nections This allows you the choice to wire for current sourcing or current sinking mode as required Each output channel circuit should be connected to only one output device Each output circuit is short circuit protected Table 3 5 DIO Output Specifications SIO module Operating voltage range 0 to 24 VDC Operational current range per channel Iout 100 mA across output in on condition 0 85 V at 100 mA Varop lt 0 80 V at 10 mA Output off leakage current Tout lt 600 pA Turn on response time hardware 3 psec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time Turn off response time hardware 200 usec maximum Software scan rate response time 16 ms scan cycle 32 ms max response time CAUTION The above specifications for the digital inputs and outputs on the SIO module are different than the specifications for a DIO module Specifically the SIO output current is limited via short circuit protection to 100 mA per channel whereas the DIO output is rated at 400 mA AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop and Teach Restrict Equipment Table 3 6 Digital Output Signal Assignments on Terminal Block TB3 4 Terminal Signal Terminal Signal TB3 1 24 V 1 Amp 2 24 V return TB3 3 Output 0001 4 Output 0001 TB3 5 Output 0002 6 Output 0002 TB3 7 Output 0003 8 Output
170. ng materials These items may become necessary to settle claims or at a later date to relocate equipment Repackaging For Relocation 24 If the robot or other equipment needs to be relocated reverse the steps in the installation procedures that follow this section Re use all original packing containers and materials and follow all safety notes used for installation Improper packaging for shipment will void your warranty Before unbolting the robot from the plate or spool fold the outer arm against the Joint 2 hardstops to help centralize the center of gravity The robot must always be shipped in an upright orientation specify this to the carrier if the robot has to be shipped AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Installation 2 9 Robot Installation Adept robots must always be installed on a base A base could be a mounting plate or a mounting spool It is not allowed to install a robot directly on the floor Tool and Equipment Requirements Common hand tools plus the following items are required to install the robot and any options or end effectors Drill motor 1 2 inch drive Masonry bit 7 8 inch 22 mm Ratchet handle 1 2 inch drive Socket 3 4 inch Spirit level Torque wrench 1 2 inch drive Vacuum cleaner Pallet jack or forklift Hydraulic lift with dual leg sling both rated for 320 kg 700 pounds minimum Mounting plate or spool WARNING The installation pr
171. ng the Security Panel to the SIO Module in the Adept Controller etra ede dre Ros ac cce 48 Connecting the Security Panel to the External Front Panel 49 Connecting the Security Panel to the Adept Robot 49 Connecting the Security Panel to the Adept PA 4 Power Chassis 50 2 16 Grounding 51 Adept MV Controller Grounding i n 51 Adept PA 4 Power Chassis Grounding 51 Security Panel 0 2 2 2 eene 51 Adept Robot Grounding 0 0 66 nn 51 Robot Mounted Equipment Grounding 52 2 17 Connecting to 54 Connecting AC Power to the MV 54 AC Power Requirements iiis n 54 Power Entry Modlule 3 2 oe es et feas 54 Connecting AC Power Cord eee ed 55 Connecting AC Power to the Adept 4 Power Chassis through the Security 2 4 4 56 AC Power Requirements for Power 5 56 Connecting the Power Cord of the Power Chassis to the SECURITY PONE c e eet Sd es 56 Connecting AC Power to the Security Panel 58 Typical AC Power Installation 59 Changing Voltage Setting for Power Chassis 60 2 18
172. nsert a 1 2 13 x 4 inch bolt fitted with a lock washer and a flat washer through the holes in the spool into each of the three spool to floor anchor holes Tighten the bolts to 54 Nm 40 ft Ib of torque 10 Re check the robot mounting surface of the spool using the spirit level and re shim as required to bring the mounting surface horizontal within 0 25 degrees AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 29 Chapter 2 Installation of the Robots 1 2 13 x 2 Hex Head Bolt With Lock and Flat Washers 3 Places Robot 2 Base 6 2 SSE Top Plate 1 2 13 Robot To Spool Tapped Hole 3 Places Center Column Bottom Plate NS 1 2 13 x 4 Hex Head Bolt With Lock and Flat Washers 8 Places 5 8 16 mm Spool To Floor Through Hole 3 Places Z5 40 0 e Expansion Bolt Anchor threaded o o3 0 uE end down 3 Places 2 Drawing to scale PZN 7 8 dia 22 mm Floor Holes 3 Places Figure 2 6 Mounting Spool to Floor Installation Detail Installing a Robot on a Base The following sequence describes the installation of the robot to the mounting plate or spool NOTE You can substitute M12 bolts of correct length in place of 1 2 13 bolts to install mounting spool and robot 1 Connect the hydraulic lift to the eyebolts at the top of the robot by means of the dual leg sl
173. nted and that electronic components on the back side of the panel are protected from contact by users or other equipment Mount the VFP in the same enclosure as the controller or in a separate protected enclosure See Table 2 2 for enclosure requirements Mount the VFP in a location giving clear view of the robot cell This will allow the operator to check that no personnel are inside the cell for example before enabling power in AUTO mode In particular the should be mounted between 0 4 m 1 3 ft and 2 0 m 6 ft above the floor or other servicing level This is mandatory if the installation is in an EU or other country that requires compliance with EN 60204 See Figure 2 14 as you perform the following procedure SIO Module 2 Meter Front Panel Cable E im 405 i f D Su External Front Panel VFP SYSTEM HIGH POWER cds gt LU PENDANT LOCAL NETWORK START RUNNING 9 6 3 S 9 Figure 2 14 External VME Front Panel Installation 40 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Installation of the Adept Security Panel 1 Turn off the Adept MV controller power switch 2 Remove the FP MCP bypass plug from the FP MCP connector on the SIO module 3 Locate the 2 meter Front Panel cable that comes with the VFP Plug one end into the FP MCP connector on th
174. nto the arm Vacuum requirements are defined in terms of a required level of vacuum at the base of the robot and corresponding flow required to create this level of vacuum These requirements are listed below Minimum input vacuum 20 inches of water column W C Maximum input vacuum 30 inches of water column W C Minimum air flow 25 SCFM AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Installation A practical requirement is that a minimum vacuum be maintained at the quill even during the fastest possible motions of Joint 3 and 4 It is possible to adjust the amount of vacuum being applied to the system provided the following minimum vacuum level is met when the robot is stationary Minimum arm vacuum 4 5 inches W C measured at the tool flange Maximum arm vacuum 8 5 inches W C measured at the tool flange These specifications result in sufficient vacuum to ensure that the installed functioning robot will be clean even at full speeds The plug covering the bottom of the tool flange has a 1 8 1 4 N P T tapped hole to facilitate measuring the vacuum Both of the above vacuum levels can be measured using a low pressure differential pressure meter Cover Seal Cover bu Y y EL Quill Bellows Vacuum Fitting
175. ntrol Pendant MCP In Manual mode it is not possible to initiate a motion with the system keyboard This protects the operator in the workcell from unexpected motions of the robot In Manual mode the maximum speed of the Tool Center Point and the joints of the robot is reduced to 250 mm per second 10 ips Also the motors run at reduced torque If the robot tries to move with a higher speed sensors in the robot and the power amplifiers will detect this fault and turn off High Power to the power chassis See section 1 13 on page 13 for a description of safety equipment for an operator who is working in the robot workcell In Manual mode the contacts of the Customer Safety Barrier Mute are muted and the safety function of these contacts are disabled This permits a skilled operator to enter the workcell while High Power is enabled Automatic Operating Mode The AUTO position of the operating keyswitch permits computer control of the robot A program that is currently running the robot or motion device may cause it to move at times or along paths you may not anticipate When the amber HIGH POWER light and the white PROGRAM RUNNING light on the are illuminated do not enter the workcell because the robot or motion device might move unexpectedly WARNING Impact Hazard In Automatic mode no personnel are allowed to stay in the workcell The robot can move at high speeds and exert considerable forces CAUTION The LAMP TEST button on
176. nusable for any reason you will need to order a new air filter The part number for the filter is 40320 20231 1 Turn off High Power to the robot 2 Liftthe filter up by the tabs on the top edge 3 Inspect the filter for dust or dirt particles If cleaning is required use compressed air to clean the filter 4 Replace the cleaned air filter AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 107 Chapter 5 Maintenance Adept PA 4 Fan Filter Inspection and Cleaning The air filter located on the front of the chassis should be inspected regularly and cleaned at the first sign of dust or dirt buildup The filter must be inspected and cleaned at least once per month Regular cleaning will prolong the life of the filter If the filter becomes clogged or unusable for any reason you will need to order a new air filter The part number for the filter is 40330 11200 WARNING Dangerous voltages are present inside the power chassis Turn off the power to the power chassis and protect it against an unauthorized return to service before opening the front grill to inspect the air filter Failure to observe this warning could cause injury or damage to your equipment 1 Turn off the power to the power chassis and protect it against an unauthorized return to service 2 Open the front grill by loosening two screws and swinging the grill out 3 Pull the air filter out and inspect for dust or dirt particles If cleaning is requir
177. oached in COARSE mode AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 131 Chapter 6 Technical Specification AdeptOne MV Robot Working Envelope Maximum Radial Reach Functional Area 800 mm 31 5 Maximum Intrusion Contact Radius 853 mm 33 6 mo Inner Link Radius 4a 425 mm 1 Minimum Radial Reach Inaccessible Area 231 mm 9 1 Joint 2 Limit 1 147 Joint 1 Limit 150 Joint 1 Limit 150 Figure 6 17 AdeptOne MV Robot Working Envelope 132 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B AdeptThree MV Robot Specifications 64 AdeptThree MV Robot Specifications specifications subject to change without notice Table 6 2 AdeptThree MV Robot Performance Specifications Reach Maximum radial 1067 mm 42 0 in Minimum radial 279 mm 11 0 in Vertical clearance bottom of base to end effector flange with maximum Joint 3 retraction 879 mm 34 6 in with maximum Joint 3 extension 547 mm 22 6 in Vertical Stroke Z direction Joint 3 305 mm 12 0 in Joint Rotation Joint 1 300 Joint 2 300 Joint 4 540 Payload Including End Effector 25 kg 55 Ib Inertia About Joint 4 axis standard 585 kg cm 200 Ib in maximum 7316 kg cm 2500 Ib in Force Joint 3 downwa
178. obot while other equipment is being cleaned Drying Time Before Operation Remove the protective cover after all high pressure spraying is complete Allow the Adept PackOne to dry for 15 minutes before returning to operation 110 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Bolt Removal Resealing Procedure PackOne MV Robot 5 9 Bolt Removal Resealing Procedure PackOne MV Robot The access cover bolts and screws on the Adept PackOne are hygienically sealed at the factory to prevent moisture entering the robot as well as to avoid a crevice which would be unhygienic If any bolts are loosened or removed they must be resealed according to the procedure listed below Loctite 518 Typical bolt Master Gasket and washer under bolt head and under washer Robot panel or cover x 7 Loctite 242 on threads to lock in place Figure 5 4 Bolt Resealing Detail 1 Clean off the old sealant from the bolt and the area around it 2 Apply a thin coat of Loctite 242 to the bolt threads 3 Apply a continuous bead of Loctite 518 Master Gasket to the under side of the washer and the bolt head 4 Tighten the bolt to a torque of e 50 in lb 5 7 Nm for 1 4 20 30 in lb 3 4 Nm for 10 24 15 in lb 1 7 Nm for 8 32 5 Wipe off any excess sealant after tightening NOTE If an Adept Field Service engineer performs repairs to a PackOne at the customer site prior
179. ocedures in this chapter should only be performed by skilled persons as defined in section 1 11 on page 12 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev 25 Chapter 2 Installation of the Robots Installing a Base for the Robot Adept recommends that you follow the given instructions for the installation of a mounting plate or a mounting spool see page 20 Figure 2 3 shows the mounting hole pattern of the robot for an installation on a mounting plate or mounting spool 305 Mounting noes in 12 0 plate or spool 1 2 13 thru 152 mm 3 places gt 6 0 2610 mm 24 0 108 mm 4 25 Figure 2 3 Mounting Hole Pattern Robot to Plate Spool 26 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Installation Installing a Mounting Plate The following sequence details the installation of a robot mounting plate to the floor See Figure 2 5 NOTE You can substitute M12 bolts of correct length in place of 1 2 13 bolts to install mounting plate and robot 1 Drill and tap three 1 2 13 UNC 2B mounting holes as shown in Figure 2 3 for robot to plate attachment 0559 mm T SOAM 22 0 610 mm 016 mm 5 8 3x Figure 2 4 Mounting Hole Pattern Plate Spool to Floor 2 Drill three 16 mm diameter through holes as shown in Figure 2 4 for plate to floor anchoring 3 Place the plate exactly where the rob
180. of pipe of a certain diameter The CleanRoom option provides a 1 1 4 inch male thread pipe fitting for the vacuum connection on the outside of the base of the robot see Figure B 1 This can be adapted to any vacuum supply pipe being used Adept recommends the connection include the following features Union at the robot which allows the robot to be removed from the workcell A tee with a threaded plug machined to accept a vacuum sensing switch This allows the vacuum to be tested gate valve in line with the vacuum piping and located near the robot This will allow regulation of the vacuum at the robot Keep in mind that gate valves have flow losses 10 to 12 times lower than that of globe or ball valves Union at the wall separating the vacuum pump and robot Union at the vacuum pump which allows the pump to be replaced Table B 1 Pipe fitting flow equivalents in feet of straight pipe Pipe Size Fitting 1 1 4 inch 1 1 2 inch 2inch 90 degree 7 feet 8 feet 10 feet 45 degree 1 5 feet 1 8 feet 2 3 feet 150 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Bellows Replacement Vacuum Switch Maintaining adequate levels of vacuum is critical for cleanroom environments The robot gives no external indication whether the vacuum is present or not Adept suggests vacuum switches be used as a method of assuring proper vacuum is present Such a switch could provide contact closure
181. off 2 Connect the male plug of the cable to the connector J3 on the Category 3 Emergency Stop board Tighten the two captive screws securely 3 Connect the female connector of the cable to the connector J5 on the board of the VFP Tighten the two captive screws securely TB1 TB2 TB3 eo TAS 12 1 1 1 TRS1 TRS3 5000000000089 00000600000 00000000003 IET a pe 55 1 4 5 6 J5 Figure 2 22 Connectors Control Rail Connecting the Security Panel to the Adept Robot For speed limiting of Joint 1 and 2 in Manual mode the User to E Stop Teach Restrict cable must be installed between the User connector on the Arm Signal cable and the Teach Restrict Interface board The robot can not be operated in Manual mode until this connection is made The User connector has a 15 pin standard male D Sub connector marked User On the Teach Restrict Interface PCB are two connectors a 9 pin female D Sub connector marked TRS1 and a rectangular 4 pin connector Installation procedure for the User to E Stop Teach Restrict cable see Figure 2 16 and Figure 2 21 1 Make sure that the power chassis and controller On Off switches are turned off 2 Remove the User Brake Release Jumper if it is installed from the User connector on the robot Arm
182. oid Valve Assembly The solenoid valve assembly in the Outer Link consists of two independent valves Valve 1 and Valve 2 on a common manifold The manifold supplies air at the user s line pressure 5 5 bar 80 psi minimum Each valve has two output ports A and B The output ports are arranged so that when Port A is pressurized Port B is not pressurized Conversely when Port B is pressurized Port A is not In the AdeptThree MV robot the air lines from Port A on each valve are plugged at the factory at the solenoid assembly and the lines from Port B are routed out to the flange and are used for the User Open and Close lines see the description of the user air lines in next section User Air Lines The User Open and Close air lines are the two 5 32 air lines that run between the solenoid valve assembly and the user flange at the lower end of the quill These lines are plugged at the flange end and are labeled OPEN and CLOSE They are controlled by the V instructions OPEN I CLOSE I and RELAX I or the software signals 3001 and 3002 see Table E 1 After initial installation it is a good idea to check the positive pressure on the open and close air lines to verify that they are installed as shown in Table E 1 Spare Air Line Two spare air lines 5 32 and 1 4 are incorporated into the robot to allow for User options These lines run from the base of the robot up to the area near the outer link card in the outer link The lines
183. ommunautaire relative aux machines 89 392 CEE Annexe II B Par la pr sente nous d clarons que la machine d crite ci dessous livr e en l tat est conforme la directive communautaire Annexe I sur les imp ratifs fondamentaux en mati re de sant et de s curit La machine ne pourra tre mise en service avant que la machine dans laquelle elle sera incorpor e ne soit d clar e compl tement conforme aux dispositions des directives en cours de validit Ceci comprend tout quipement compl mentaire et dispositif de protection Italiano Dichiarazione del Costruttore ai sensi della direttiva CE 89 392 relativa a macchinari Appendice Si dichiara che la macchina come da noi fornita soddisfa i requisiti fondamentali definiti nella direttiva CE Appendice fatto di sicurezza e sanit La messa in funzione della macchina resta vietata fintanto che l intero sistema nel quale questa incorporata sia stato dichiarato conforme alla versione vigente della suddetta normativa Il sistemasi intende comprensivo di tutte le parti accessorie e dispositivi di sicurezza P N 01840 00030 Rev P1 Table 1 VME Plug in Modules that meet all applicable Directives and that may be installed without additional EMC conformance testing in MV 8 and MV 19 Controllers Minimum Acceptable i Part Number Revision Description 10332 11150 P6 PCA VME 030 Processor 10332 00710 P1 PCA VME 040 Processor 30332 12350 P2 SYSIO
184. omponent or PC board Routing additional hoses air lines or wires through the robot 10 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Endangerment Through Additional Equipment 1 7 Endangerment Through Additional Equipment 1 8 Additional equipment for instance grippers conveyor belts etc are not allowed to reduce the safeguarding of the workcell Emergency Stop Switches must be always accessible If the robot is to be used in an EU or EEA member country all components in the robot workcell must comply with the safety requirements in the European Machine Directive 89 392 EEC and subsequent amendments and related harmonized European international and national standards In other countries Adept strongly recommends a similar level of safety be obtained in addition to complying with the applicable local and national regulations Sound Emissions 1 9 The sound level of the AdeptOne MV the AdeptThree MV and the Adept PackOne MV Robot exceeds 70dB Thermal Hazard 1 10 WARNING Thermal Hazard You can burn yourself Do not touch the robot base or outer link shortly after the robot has been running at high ambient temperatures 40 50 at fast cycle times over 60 cycles per minute The temperature at the robot can exceed 70 Working Areas Adept robots have both a Manual and an Automatic operating mode While in Automatic Mode no personnel are allowed
185. ontroller is the Wyse WY 60 You must also specify that you require the Wyse ANSI VT100 style keyboard Wyse p n 900127 02 or 900128 02 Note The WY 60 is also available with ASCII and IBM Enhanced PC Keyboards These are not Adept compatible You must make sure you order the correct keyboard The WY 60 is available in both 220V and 110V configurations Installation Procedure The terminal monitor and or keyboard should be mounted at least 0 2 m 0 7 ft above the floor or other servicing level This is mandatory if the installation is in an EU or other country that requires compliance with EN 60204 1 Make sure the controller is turned off before making any connections 2 Verify the voltage range marked on the terminal is compatible with your local voltage source Connect the AC power cord to the terminal then plug it into an appropriate voltage source 3 Connect a suitable serial cable between the terminal and the RS 232 TERM connector on the System Processor module 4 If the terminal is a Wyse 60 use the setup mode to set the personality to WY 75 If you are using terminal emulation software on a computer set the software to WY 75 emulation If WY 75 is not available try VT102 or VT100 but you will not be able to use all of the function keys 5 Setthe terminal baud rate to 9600 that is the default rate for the Adept system To change the baud rate refer to the information on CONFIG C in the Instructions for
186. or submitting your comments Copyright 1996 by Adept Technology Inc rights reserved The Adept logo is a registered trademark of Adept Technology Inc Adept AdeptOne AdeptOne MV AdeptThree AdeptThree MV PackOne PackOne MV HyperDrive Adept 550 Adept 550 CleanRoom Adept 1850 Adept 1850 A Series S Series Adept MC Adept CC Adept IC Adept OC Adept AdeptVision AIM VisionWare AdeptMotion MotionWare PalletWare AdeptNet AdeptFTP AdeptNFS AdeptTCP IP AdeptForce AdeptModules and V are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Printed in the United States of America MANUFACTURER S DECLARATION We Adept Technology with Corporate Headquarters at 150 Rose Orchard Way San Jose CA USA and European Technical Center at Otto Hahn Str 23 44227 Dortmund Germany herewith declare that the Robot comprised of 1 Controller MV 8 P N 30330 15000 MV 19 P N 30330 25000 5 P N 30340 10000 or MV 10 P N 30340 20000 4 Power Chassis P N 30336 31000 A Power Amplifiers P N 10337 15200 Power Amplifiers with voltage restrict P N 90338 51010 Manual Control Pendant MCP III P N 90332 48050 VME Front Panel Category 3 P N 90335 00380 Category 3 Security Panel P N 30335 00000 Accelerometer P N 30335 10000 Robot from the AdeptOne MV AdeptOne MV Model Num
187. ot is to be installed Ensure that the plate is positioned so that the footprint for the robot is properly oriented relative to the workcell Using the plate as a template transfer the locations of the three plate to floor mounting holes directly to the floor 4 Set the plate aside and drill three holes 22 mm 7 8 inch in diameter 90 mm 3 5 inches deep in the floor at the locations identified in step 3 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 27 Chapter 2 Installation of the Robots 1 2 13 x 2 Hex Head Bolt With Lock and Flat Washers 3 Places 3 Places Robot Base gt Mount ounting mae AOS Robot To Plate Q a 1 2 13 Tapped Hole d 0 3 Places Qo e ox wc 3 5 07 Q Q 90mm vue Concrete Floor e ad 2 Drawing not to scale 1 2 13 x 4 Hex Head Bolt With Lock and Flat Washers 5 8 16 mm Plate To Floor Through Hole 3 Places Expansion Bolt Anchor threaded end down 8 Places 7 8 dia 22 mm Floor Holes 3 Places Figure 2 5 Mounting Plate to Floor Installation Detail 5 Using a vacuum cleaner remove all chips and debris from the holes and surrounding area drilled in step 4 6 Insert an expansion bolt anchor into each of the three holes in the floor Ensure that the threaded end of each bolt anchor is toward the bottom of each hole as shown in Figure 2 5 7 Reposition the plate over the an
188. ot motors he system waits until the HIGH POWER ON OFF push button is pressed If the button has not been pressed in a selected time the system stops enabling power with an error message While in Manual mode the robot speed is limited to 250 mm per second 10 ips The motors also run at reduced torque This is to protect a person who is in the workcell teaching points with the MCP during program development It is important to remember that the robot speed is not limited when the robot is in Automatic mode AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 75 Chapter 3 Preparation for Safe and Effective Use of the Robot 3 2 Category 3 Emergency Stop and Teach Restrict Equipment The Category 3 Emergency Stop and Teach Restrict Equipment is located on the Control Rail on the Security Panel For the installation of Adept supplied equipment to the Security Panel see Chapter 2 Figure 3 4 shows the Category 3 E Stop board left side and the Teach Restrict board right side NOTE Removable terminal block connectors for TB1 to TB5 on the Category 3 Emergency Stop board are supplied in the accessory kit Use these connectors to install customer wiring Adept recommends using crimp on ferrules on all wires that are installed into terminal blocks TRS2 54 Figure 3 4 Category 3 E Stop Board and Teach Restrict Board Control Rail
189. ould result from accidental high pressure spraying or cleaning chemical exposure Adept warranty coverage is not extended to seal surface finish and consequential damage caused by failure to observe recommended cleaning procedures and cautions Regular cleanup procedures should follow the recommendations listed in this manual WARNING Personnel working in the robot workcell must always wear safety equipment see section 1 13 on page 13 1 With High Power turned on lower the quill to its fully extended position so the bellows folds are as open as possible 2 Turn off High Power to the robot 3 Make sure compressed air to the robot remains turned on so the internal air flow can work to dry out any internal condensation that may develop during cleaning 4 Adept recommends that the robot be washed by hand using sponges towels or soft brushes and mild detergents or sanitation chemicals 5 Rinse the robot with a low pressure 0 06 Bar 19 liters minute 1 psi 5 gpm water hose typical of a garden hose output 6 Inspect the bellows the outer exposed edges of all gaskets and the rotary seal areas after every cleaning to look for signs of wear chafing abrasion or other indications of problems Installing Protective Cover Install the supplied protective vinyl cover on the Adept PackOne before any high pressure spraying or strong chemical cleaning agents are applied to any equipment nearby This protective cover shields the r
190. page 117 for a drawing and dimensions of the calibration fixture Plate Using a flat steel plate is mandatory if the robot is to be mounted directly to the facility floor The mounting plate should conform to the following recommended specifications Material carbon steel Diameter 610 mm 24 0 inches Thickness 25 mm 1 0 inch Mounting surface flatness within 0 5 mm 0 02 inch Mounting hole pattern as shown in Figure 2 3 and Figure 2 4 Mounting surface level must be level to within 0 25 degrees 2 5 mm 0 1 in for a 610 mm 24 in spool WARNING The specification for leveling the mounting surface is critical on Category 3 systems because the Teach Restrict sensor in the outer link will not function otherwise 20 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Environmental and Facility Requirements for Robots Spool Another method of mounting uses a spool Refer to Figure 2 1 for the specification and dimensions of a robot spool All of the specifications for the mounting plate in the previous section apply to the top plate of the mounting spool The recommended design for a manufactured spool is a welded assembly consisting of three steel parts top and bottom plates welded to a center column as detailed in Figure 2 1 610 mm dia Top Plate Bottom Plate 10 0 40 min i 12 Schedule 40 IPS or equiv 3
191. primarily to move the robot when it is in MCP Manual mode NOTE The Step button on the lower right corner of the MCP is used to step through motions in a V program See the V 11 3 Release Notes for details AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 91 Chapter 4 Commissioning the System 4 6 How to Stop a Robot in Manual Mode There are several ways to stop the motion of a robot The fastest way to stop the motion of a robot is to press an Emergency Stop button The robot will stop its motion immediately Use a Emergency Stop button only in emergency situations The normal way is to press the DIS PWR button on the MCP or to release the speed bars on the MCP The robot will stop after the actual motion Ways to stop the motion of a robot Press the Emergency Stop button on the MCP or another Emergency Stop button but only in emergency situations Release the Hold to Run switch to shut off High Power Release the Speed Bars on the Press the DIS PWR Disable Power button on the Press the HIGH POWER ON OFF button on the NOTE If the robot or end effector are bumped or jarred in Manual mode while High Power is on an E Stop could be triggered because of the Teach Restrict sensor in the outer link CAUTION Press an Emergency Stop button or release the Hold to Run switch only in emergency situations In normal operations stop the robot by releasing the speed bars or pres
192. ptThree MV Robot Instruction Handbook Rev B Preparation for Safe and Effective Use of the Robot 3 1 Overview of Safety 72 IATOGUGTION D 73 Security Panel FUNCTIONS s 6 4 usb s ace fe efe 73 Description of Mute 74 Operating in Manual 75 3 2 Category 3 Emergency Stop and Teach Restrict Equipment 76 Terminal Assignments for Customer 5 77 Voltage Free Contacts for Monitoring E Stop Circuitry Passive E Stop 78 Digital Inputs and Outputs of the System Input Output SIO Module 80 oc 80 SIONS cso Pi entr p de m C ERR RE Tp RR RN 82 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 71 Chapter 3 Preparation for Safe and Effective Use of the Robot 3 Overview of Safety System 0008 Uf 200
193. r Rail X2 Figure 3 2 Security Panel Figure 3 2 shows the Security Panel with all its components On the left side of the Control Rail upper one is the Category 3 E Stop board with the terminals for the connections of customer supplied safety equipment and digital I O signals On the right side is the Teach Restrict Interface Board The lower DIN rail is the Power Rail X2 containing the external 24 VDC power supply the contactors and the circuit breaker for the power chassis Security Panel Functions It is the function of the Security Panel to check for faults in the safety systems prior to power up in Manual mode cyclic checking remove power from the robot if the Teach Restrict sensors in the robot and power chassis detect excessive speed and or acceleration while the robot is in Manual mode AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 73 Chapter 3 Preparation for Safe and Effective Use of the Robot interlock with Category B safety circuitry in the Adept MV controller indicate to the Adept MV controller the source of emergency stop conditions The Emergency Stop circuitry has two independent channels and is so constructed that no single failure can cause a loss of the safety function and that any latent failures can be detected before power is applied the definitio
194. ra safety equipment in the workcell For safety reasons the operators must wear safety glasses protective headgear and safety shoes when they are in the robot workcell Install warning signs around the workcell to make sure anyone working around the robot system knows they must wear safety equipment Protection Against Unauthorized Operation 1 15 The system must be protected against unauthorized use Restrict access to the keyboard and the Manual Control Pendant by locking them in a cabinet or use another adequate method to prevent access to them Operating Modes of Adept Robots The AdeptOne MV AdeptThree MV and Adept PackOne MV robot have two different operating modes Automatic Mode Adept Robot systems are computer controlled and the program that is currently running the robot may cause it to move at times or along paths you may not anticipate When the key switch for the operating mode is in the AUTO position and the HIGH POWER light or the PROGRAM RUNNING light on the external Front Panel VFP are illuminated do not enter the workcell because the robot or motion device might move unexpectedly The LAMP TEST button on the VFP allows these lights to be periodically checked WARNING During Automatic Mode operations no person is allowed to stay in the guarded space of the robot because serious injury or death can occur if a person is struck by the robot Manual Mode Adept robots can also be controlled
195. rack An internal proximity sensor will cause a V error condition and shutdown High Power to the robot if the braketrack area is entered AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 185 A A amplifier module connections indicators 63 AC power connecting power cord to controller 55 connecting power cord to Security Panel 58 connecting to controller 54 connecting to power chassis 56 installation diagram for 200 240VAC 59 installation diagram for 380 415VAC 59 requirements for controller 54 requirements for power chassis 56 voltage current ratings controller 54 power chassis 56 AdeptOne MV robot compressed air 177 dimensions 114 mounting holes on outerlink 181 operating environment specifications 19 specifications 130 user flange dimensions 118 working envelope 132 AdeptThree MV robot compressed air 179 dimensions 115 operating environment specifications 19 specifications 133 user flange dimensions 118 working envelope 135 air quality facility requirements for robot 19 amplifier module fuses 65 installing 66 interlock circuit 66 removing 65 Arm Power cable installation 43 Index Arm Signal cable installation 45 A Series controller installation 37 Auto keyswitch position 39 Automatic mode how to use 87 B amplifier module connections indicators 64 bellows replacement CleanRoom robot 149 bellows replacement PackOne MV 106 bolt resealing detail drawing on PackOne MV 111 pro
196. rd force without payload 36 3 kg 80 Ib Cycle Time 12 in 305 mm No payload standard 0 92 sec with HyperDrive 0 83 sec 9 kg 20 Ib payload standard 1 08 sec with HyperDrive 0 99 sec Resolution Joint 1 0 00078 Joint 2 0 00312 Joint 3 vertical Z 0 0066 mm 0 00026 in Joint 4 tool rotation 0 047 Repeatability X Y plane 0 05 mm 40 002 in Joint 3 vertical Z 0 05 mm 40 002 in Joint 4 rotational 0 05 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 133 Chapter 6 Technical Specification Table 6 2 AdeptThree MV Robot Performance Specifications Continued Accuracy in X Y Plane 3 F temperature variation With optional HPS hardware and software 0 076 mm 0 003 in over 17 x 17 area Joint Speed maximum Joint 1 540 sec Joint 2 540 sec Joint 3 500 mm sec 19 7 in sec Joint 4 3600 sec Weight Robot without options 205 kg 450 Ib Hyperdrive robot without options 213 kg 468 Ib Power chassis with 3 amplifier modules approximately 16 4 kg 36 Ib 8 controller with 030 SIO VGB approximately 14 5 kg 32 Ib Design Life 42 000 hours Maximum possible running at reduced speed P The robot tool performs a continuous path motion consisting of all straight line segments 25 mm 1 in up 305 mm 12 in over 25 mm 1 in down and returning along the same path The endpoints of the cycle are approached in
197. re to use sealant to create a water tight seal at pass through holes Replace the tube cap and secure with four plastic screws Install the flange assembly back into the quill apply Loctite 242 on the four 8 32 screws and torque to 15 in Ib 1 7 Nm Manually raise and lower the quill to ensure there is binding or excess air line length at the top of the quill Replace the quill cover and reseal the bolts per the instructions in section 5 9 on page 111 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Outer Link Mounting Holes on AdeptOne MV Robot E3 Outer Link Mounting Holes on AdeptOne MV Robot On the AdeptOne MV robot the mounting holes on the top side of the outer link can be used to mount user equipment See section 1 6 on page 10 for information on limitations for modifications Figure E 2 shows the dimensions of the mounting holes 3 8 8 32 threaded hole 4 places Figure E 2 Mounting Holes on Top Side of Outer Link on AdeptOne MV Robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 183 Appendix E Additional Robot Information E 4 Limiting Joint Travel The joint motion or travel is limited by both software and hardware limits The program mable software limits are known as softstops the fixed hardware limits are referred to as hardstops See Table E 2 Table E 2 and Table E 2 Softstops 184 Softstops are used when t
198. rements for Robots 19 Facility Ambient Air Quality For 19 Mounting Surface Specifications iiie 20 2 2 Environmental and Facility Requirements for Controller 22 2 3 Environmental and Facility Requirements for Power Chassis 22 2 4 Before Unpacking the 22 2 5 Adept Shipment 5 23 2 6 Transport and Storage 23 2 7 Unpacking and Inspecting the Adept Equipment 24 2 8 Repackaging For 24 2 9 Robot Installation ss osses eers nnee a a E meh 25 Tool and Equipment 1 25 Installing a Base for the 222 221 2 26 Installing Robot BASE es 30 2 10 Installation of the Adept MV Controller and the Adept PA 4 Power 32 Joining an Adept PA 4 Power Chassis to an Adept MV Controller 32 Space Around the 34 Installation in a Rack or Panel 34 2 11 Installing the A Series Monitor and 37 INSTONAT OM
199. ruction Handbook B Tests Performed Periodically Dual Solenoid test 5 Plug the second solenoid into 413 Press the brake release button on the RSC Do the brakes release Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Release the brake release button on the RSC Do the brakes engage Y N 6 Put the cover and or fan assembly back in place in the reverse order that was described in step 2 On PackOne MV robots the rear cover must be resealed See Chapter 5 for information on resealing covers The following message is displayed Dual brake solenoid test passes Replace th switch Remov rear cover and turn on the PA 4 power chassis the User jumper plug and connect the USER cable to the security panel Press ENTER to continue 7 Turn the amplifier chassis power switch on and press ENTER AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 171 Appendix C Using the Safety Utility Air Filter Remove screws 7 amp ooo nud foo Bu Fan Assembly Si BG of ooo 4 3o Figure C 3 Removing the HyperDrive Fan Assembly 172 AdeptOne MV AdeptThree MV Robot Instruction Handbook Tests Performed Periodically
200. s CURA e Rec d Mas 155 SAFE UTE V2 rate mal m ect as aua epp te NDE 155 Commissioned vs Not Commissioned 155 Starting the SAFE UTL V2 Utility cee tenes 156 Tests Performed at Time of 0 157 Accelerometer Test teen task sunl ede ns MN Ae te e 158 B Amp Voltage Restrict Test e 160 VFP Switeh arid Button Test nica tos mo EI ta eee ra tgs VER tae 161 MCP E SILOP FUNCTIONS Y real odit t eats 163 Broke Holding Eoree Tesr uy ike ure Re BE e oaa 164 C 4 Tests Performed 166 87 ait e ue dae Ne ule pte i i on 166 Testing the Dual Brake 167 Testing the Dual Dump VAIVES 172 D 175 Introduction culo RE Rex yn E EDD 175 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev xiii Table of Contents E Additional Robot Information 177 Compressed Air Lines In the Robot 177 AdeptOne MV and PackOne MV Robot 177 Solenoid Valve Assembly
201. s TRS2 and TRS3 Installation procedure for the Teach Restrict to B Amp cable see Figure 2 16 Figure 2 21 and Figure 2 22 1 21 Make sure that the power chassis and controller On Off switches are turned off Plug the 15 pin high density D Sub male connector at one end of the Teach Restrict to B Amp cable into the Teach Restrict socket on the Amplifier Module in the power chassis Tighten the two captive screws securely The other end of the cable with two plugs must be connected to the Teach Restrict Interface Board a Plug the 9 pin D Sub connector labeled TRS2 into the socket TRS2 on the Teach Restrict Interface Board Tighten the two captive screws securely b Plug the 9 pin D Sub connector labeled TRS3 into the socket TRS3 on the Teach Restrict Interface Board Tighten the two captive screws securely AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev Grounding Information 2 16 Grounding Information Adept MV Controller Grounding The detachable three wire power cord is used for connection to the power source and the protective ground The protective ground conductor colored green yellow in the power cord is internally connected to the exposed metal parts of the Adept MV Controller To ensure electrical shock protection the protective ground conductor must be connected to a properly grounded power source Adept PA 4 Power Chassis Grounding The protective ground conductor colored gr
202. s a 2 position rotary switch marked AUTO and MANUAL This switch determines which operating mode is selected The AUTO position permits control of the system from the controller The MANUAL position makes the MCP the single point of control The lamp flashes for a predetermined time 10 seconds If the button is not pressed the request is canceled and High Power is not enabled The time out duration can be changed using the CONFIG utility AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 39 Chapter 2 Installation of the Robots Control Keyswitch The keyswitch is a 2 position rotary switch marked LOCAL and NETWORK This switch determines which device is able to start robot motions The LOCAL position makes the Manual Control Pendant MCP or the connected Terminal the single point of control The NETWORK position is used with host supervisory control software LAMP TEST switch When the button is pressed all the indicator lamps should light If an indicator does not light check it before continuing operation PENDANT connector for attaching the Manual Control Pendant MCP to the front panel In order to enable High Power either the MCP or the supplied pendant jumper plug must be connected Installing the External Front Panel VFP The VFP can be mounted in a standard 19 inch equipment rack See Figure 6 10 on page 123 for dimensions Since the back of the VFP is open make sure that it is securely mou
203. s described on the screen Press the brake release button on the RSC Do the brakes release Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed Release the brake release button Do both dump valves exhaust Y N If the response is N the test fails and an error message is displayed If the response is Y the following message is displayed AdeptThree Dump Valve test passes Put the Joint 1 cover back in place and turn on the PA 4 power chassis power switch Remove the User jumper plug and connect the USER cable to the security panel Press ENTER to continue 5 Lower the Joint 1 cover and secure the eight screws then turn on the PA 4 amplifier chassis power switch 174 AdeptOne MV AdeptThree MV Robot Instruction Handbook Tests Performed Periodically Joint 1 Cover X Dump Valve 2 N Dump Valve 1 Brake Release Button Figure C 6 Testing the AdeptThree MV Dump Valves AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B 175 EMC Test Information D 1 Introduction The AdeptOne MV AdeptThree MV and Adept PackOne MV robot systems meet all applicable requirements as mandate
204. shaft area will have to be replaced about every six months Replacement bellows kits should be purchased from Adept call Customer Service to order CAUTION Inspect the bellows daily for cracks splits or any other signs of wear Replace the bellows sooner than six months if you see any indications that moisture could get inside to the quill area 1 Remove the existing bellows by loosening and removing the upper and lower clamps then slowly pull the bellows down over the Joint 4 seal assembly 2 Remove the upper and lower rubber band gaskets that sit under the clamps and bellows 3 Install the new gaskets that come with the kit Place the gaskets in the recessed grooves located on both clamping diameters 4 Carefully install the new bellows checking to see that both rubber band gaskets are centered in their respective grooves 5 Install the clamps and tighten the screws to a torque of 3 39 Nm 30 in Ib minimum AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Maintenance and Inspection of Air Filters 5 6 Maintenance and Inspection of Air Filters Draining Moisture from AdeptOne MV AdeptThree MV Robot Compressed Air Filter The air filter on the compressed air inlet at the AdeptOne MV and AdeptThree MV robot base has a moisture trap that should be emptied periodically depending on the quality of the air supply and the frequency of usage The procedure to empty the trap is done with the air supply connect
205. sing the Disable Power button 47 How to Start the Robot Before a robot motion can be initiated High Power must be turned on and the robot must be calibrated Enable High Power with the MCP In Automatic Mode Follow the steps to enable High Power in Automatic mode with the MCP NOTE If High Power is on and you release the Hold to Run switch on the MCP the system recognizes an emergency stop signal and will turn off High Power immediately 1 Turn on the power switches on the controller and the power chassis 2 Set the VFP System Power switch into the position I to turn on system power 3 Verify that all Emergency Stop switches are pulled out and all access doors to the workcell are closed WARNING Impact Hazard In Automatic mode no personnel are allowed to enter or stay in the workcell The robot can move at high speeds and exert considerable force 92 AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B How to Start the Robot 4 Setoperating keyswitch to AUTO and the other keyswitch to LOCAL 5 Press the COMP PWR button on the MCP 6 Press the blinking HIGH POWER ON OFF button on the within 10 seconds NOTE In Automatic mode the V operating system may take approximately 8 seconds to complete the High Power sequence In Manual Mode Follow the steps to enable High Power in Manual mode with the MCP NOTE If High Power is on and you release the Hold to Run switch on the MCP the sy
206. st be pressed If the button is not pressed within 10 seconds it will stop flashing and High Power will not be turned on Tests are also performed on the LAMP TEST button PROGRAM START button and the key switches MCP Hold To Run Switch The Hold To Run switch on the Manual Control Pendant must be pressed for High Power to remain on If the Hold To Run switch is released for any reason High Power is disabled If the MANUAL AUTO key switch is in the manual position the Hold To Run switch must be cycled when the user requests High Power to be enabled This is to confirm before enabling High Power that the Hold To Run switch is operational The following instructions are displayed on the screen and must be followed Release then press the Hold To Run button Press the HIGH POWER button when it blinks The Manual Control Pendant displays the following messages The time out value can be changed using the CONFIG C V2 utility 156 AdeptOne MV AdeptThree MV Robot Instruction Handbook B SAFE UTL V2 C 2 Release then press the Hold To Run button Press the HIGH POWER button to enable power The Hold To Run switch must be released then pressed The system will then attempt to turn on High Power flashing the HIGH POWER lamp The HIGH POWER button must be pressed and High Power will switch on The above procedure must be performed several times while running SAFE UTL Dual Brake Solenoid Valves Two br
207. stallation 42 AdeptOne MV or AdeptThree MV Robot Base Showing Air Filter and Cable Connector LOCATIONS 2 2 44 Adept PackOne MV Robot Base Showing Air Filter and Cable Connector nns 44 Robot to VJI Cable Installation ees 45 COMESCO oct OR Rant 47 Connectors on the Security Panel 48 Connectors on the Control ien 49 Robot System Grounding 2 2 2 2 2 22 2 2 53 Adept MV Controller Power Entry 55 Gonriectors ori Power Ralls ase Sis erbe bina e ea 57 Typical 380 415 V AC Connection for Category 5 59 Typical 3 Phase 200 240 V AC Connection for Category 3 System 59 Insulating Blue Wire in Power 60 Moving Blue Wire From Neutral to 1 12 61 Changing Voltage in Power 62 Clamp mounted End Effector 67 Screw mounted End Effector Installation 6 eee 68 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B XV Table of Contents Figure 2 33 Figure 2 34 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5
208. stem recognizes an emergency stop signal and will turn off High Power immediately 1 Turn on the power switches on the controller and the power chassis 2 Setthe VFP System Power switch into the position I to turn on system power 3 Verify that all Emergency Stop switches are pulled out and all access doors to the workcell are closed 4 Set operating keyswitch to MANUAL and the other keyswitch to LOCAL For added safety remove the keys from the keyswitches 5 Press the COMP PWR button on the MCP 6 Release the Hold to Run switch as instructed by a message on the MCP display and then close the switch again This step is done to check for proper operation of the Hold to Run switch This step is not required in Automatic mode 7 Press the blinking HIGH POWER ON OFF button on the VFP within 10 seconds NOTE In Manual mode the V operating system may take approximately 20 seconds to complete the High Power sequence To re enable High Power after pressing the MCP emergency stop button turn the emergency stop button to the right clockwise The switch is spring loaded and will return to its normal position Depress the Hold to Run switch High Power can now be re enabled by pressing the COMP PWR button mode control group and the HIGH POWER ON OFF push button on the Calibration of the Robot with the MCP The robot can be calibrated only when High Power is enabled and Automatic mode is selected If the robot is in M
209. structions OPEN I CLOSE I and RELAX D or the software signals 3001 and 3002 see Table E 1 There are two extra user air lines that run from the solenoid valve assembly to the outer link tower assembly they are labeled Port A Valve 1 and Port A Valve 2 These extra lines are plugged at the factory but can be used if you need two lines from each valve instead of one see Figure E 1 After initial installation it is a good idea to check the positive pressure on the open and close air lines to verify that they are installed as shown in Table E 1 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 179 Appendix E Additional Robot Information Table E 1 User Air Line Command Summary Pneumatic Action State on Port B V Command MCP Procedure Open Pressure at Valve 1 on DO OPENI In World Tool or Port B or Joint state press T1 no pressure at Valve 2 SIGNAL 3001 3002 and plus speed bar on Port B Closed Pressure at Valve 2 on DO CLOSEI In World Tool or Port B or Joint state press T1 no pressure at Valve 1 SIGNAL 3001 3002 and minus speed bar on Port B Relaxed No pressure at either DO RELAXI In Free state press T1 Valve 1 or 2 or Port B SIGNAL 3001 3002 Pneumatic action on Port A will be the opposite of Port B No pressure indicates that the valve is connected to the return exhaust User Connector T A Extra User Air Lines on Tow
210. t 42nd Street 13th Floor New York NY 10036 Phone 212 642 4900 Fax 212 398 0023 Document Center Inc 1504 Industrial Way Unit 9 Belmont CA 94002 Phone 415 591 7600 8 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Intended Use of the Robots 1 5 Intended Use of the Robots The installation and usage of Adept products must comply with all safety instructions and warnings in this manual Installation and usage must also comply with all applicable European international or local requirements and safety standards The AdeptOne MV robot is intended for use in small parts assembly and material handling for payloads typically less than 8kg 17 6 Ib The AdeptThree MV robot is intended for use in parts assembly and material handling for payloads typically less than 25kg 55 Ib and for those applications that require a longer reach than the AdeptOne MV or the Adept PackOne MV Robot The Adept PackOne MV robot is intended for use in applications that require washdown environments with payloads typically less than 7 7 kg 17 Ib A HyperDrive Option is available for these robots that delivers higher power to the Joint 1 and 2 motors This option is used for applications that require faster throughput WARNING For safety reasons it is prohibited to make certain modifications to Adept robots see section 1 6 The Adept MV controller and the Adept PA 4 power chassis are intended for use as compon
211. t be operated within 10 m of the equipment AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 177 Additional Robot Information 1 Compressed Air Lines In the Robot AdeptOne MV and PackOne MV Robot Solenoid Valve Assembly The solenoid valve assembly under the Joint 2 cover consists of two independent valves Valve 1 and Valve 2 on a common manifold The manifold supplies air at the user s line pressure 5 5 bar 80 psi minimum Each valve has two output ports A and B The output ports are arranged so that when Port A is pressurized Port B is not pressurized Conversely when Port B is pressurized Port A is not In the AdeptOne MV robot the air lines from Port A on each valve are plugged at the factory at the tower assembly see Figure E 1 and the lines from Port B are routed out to the flange and are used for the User Open and Close lines see the description of the user air lines in next section Mounting holes are provided to install a four position manifold in place of the existing two position manifold under the Joint 2 upper cover Contact Adept Customer Service for information on this installation User Air Lines The User Open and Close air lines are the two 5 32 air lines that run between the solenoid valve assembly and the user flange at the lower end of the quill These lines are plugged at the flange end and are labeled Port B Valve 1 and Port B Valve 2 They are controlled by the V in
212. tOne MV AdeptThree MV Robot Instruction Handbook Rev B Connecting to AC Power WARNING Flectrical hazard The installation of the power cord must be done by a skilled person The power supply can injure or kill the person who installs the cord or an incorrect installation can injure or kill anybody who touches the equipment in the robot workcell The user end of the cord is unterminated Connect each conductor of the power cord securely to the contacts of the contactor AP2 and terminals for protective ground and the neutral Use Table 2 8 for the information about the terminal numbers and the color code for the connections The installation must meet all applicable European international and national standards and regulations Table 2 8 Connecting Power Cord of the Power Chassis to the Terminals on Power Rail X2 Wire Description Wire Color Terminal Number Color code 30 380 415VAC line 1 black X2 AP2 T1 line 2 black X2 AP2 T2 line 3 brown X2 AP2 T3 neutral blue X2 N ground green yellow X2 PE Color code 30 200 240VAC line 1 black X2 AP2 T1 line 2 black X2 AP2 T2 line 3 brown X2 AP2 T3 no connection blue must be insulated see page 60 ground green yellow X2 PE Power Rail X2 Contactors Terminals 3j N blue PE green yellow Circuit Breaker oo 0 000 H 1 2 I i F1 91 3 m A
213. tOne MV AdeptThree MV Robot Instruction Handbook Rev B 31 Chapter 2 Installation of the Robots 2 10 Installation of the Adept MV Controller and the Adept PA 4 Power Chassis Joining an Adept PA 4 Power Chassis to an Adept MV Controller The Adept PA 4 power chassis can be joined to the Adept MV 8 or MV 19 controller using the brackets supplied in the accessory kit They must be joined at the top and bottom as described in the following paragraphs Top view with covers removed Adept MV 8 Controller Adept PA 4 Power Chassis NN lo o 1et lo o 4et Q Q 1 Install four M4 x 8 flat head Phillips screws to secure bracket Figure 2 8 Joining the Power Chassis and Controller at the Top 32 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Installation of the Adept MV Controller and the Adept PA 4 Power Chassis Joining at the Top 1 Turn off power to each unit and disconnect the power cord Place the two units next to each other Remove the top cover from both See Figure 2 8 Locate the C shaped bracket in the accessory kit Slip the bracket under the lip of the top edge of the unit on the right hand side and into the two slots in the edge of the chassis Install two M4 x 8 flat head screws into the lip and down into the bracket Install the other two x
214. th separate pairs of voltage free contacts The names of these two pairs of contacts are Customer Estop 1 OUT and Customer Estop 2 OUT These contacts are closed if the E Stop loop is closed and open if the E Stop loop is open AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Category 3 Emergency Stop and Teach Restrict Equipment The Customer System Power voltage free contacts are especially for monitoring the condition of AC power at the controller The contacts are located in the VFP System Power switch The terminals for the Customer Manual Mode 1 and Customer Manual Mode 2 voltage free contacts are two switches that are open in Automatic mode and closed in Manual mode These contacts can be used to shut off workcell peripherals conveyors feeders PLCs network interfaces when programing the robot in Manual mode When used in this fashion the MCP becomes the single point of control for the robot The Customer Safety Relay IN N C normally closed Feedback Contacts must be closed with a jumper if they are not used These contacts must be used to check user supplied relays in the E Stop circuit for example if there is relay contact in the Emergency Circuit instead of a E Stop switch The terminals for the passive E Stop and related signals are on terminal block TB5 The following table gives the terminal assignments and the signal names Table 3 2 Terminal Assignment On Terminal Block TB5 for Passive E Stop Contacts
215. the VFP allows you to check the HIGH POWER light and the PROGRAM RUNNING light on the VFP Adept recommends checking the two lights periodically prior to entry into the workcell NOTE The MCP can be used in Automatic and in Manual MAN mode For example it is possible to calibrate the robot or to enable High Power with the MCP in Automatic mode AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 87 Chapter 4 Commissioning the System 4 4 Using the Brake Release Button Brakes The robots have fail safe spring actuated air release brakes on Joints 1 2 and 3 The AdeptThree MV also has a brake on Joint 4 These brakes are on whenever High Power is off The brakes are intended primarily to restrict arm movement when high power is off but they also assist in stopping robot motion when the Emergency Stop circuitry is activated or when there is a robot motion error These brakes are not designed to be used as a routine method of stopping robot motion Brake Release Button Under some circumstances you may want to manually position the arm without turning on High Power For such instances a Brake Release button is located on the rear of the base see Figure 4 1 NOTE To use the Brake Release button you must disconnect the User to E Stop Teach Restrict cable at the User connector on the Arm Signal cable Then you must install the User Brake Release Jumper on the Arm Signal cable When you are finishe
216. the rear of the base to release the brake allowing manual quill movement See section 4 4 on page 88 for instructions on using the Brake Release button CAUTION When the brake release button is pressed the quill could drop to the bottom of its travel To prevent possible damage to the equipment make sure that the quill is supported while releasing the brake and verify that installed tooling is clear of all obstructions 1 Turn off HIGH POWER to the robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 101 Chapter 5 Maintenance 2 Remove the quill cover see Figure 5 1 3 Press the brake release button and move the quill to its fully raised position Inspect the upper quill shaft and remove any excess or accumulated grease 4 Use a grease syringe to apply five lines of grease vertically on the exposed quill shaft Each line should run from top to bottom and they should be evenly spaced around the shaft Tower Assembly User 4 Connector Upper Quill Shaft Figure 5 1 Upper Quill Shaft CAUTION When reinstalling the quill cover of a Adept PackOne MV robot you must reseal the bolts that secure the cover Refer to the procedure in section 5 9 on page 111 for complete details 102 AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Robot Lubrication Lubricating the Lower Quill Shaft AdeptOne MV Adept PackOne MV Robot 1 Move Joint 3 to th
217. to stay in the workcell In Manual Mode operators with additional safety equipment see section 1 13 on page 13 are allowed to work in the robot workcell For safety reasons the operator should whenever possible stay outside of the working envelope of the robot to prevent injury The maximum speed and power of the robot is reduced but it could still cause injury to the operator Before performing maintenance in the working envelope of the robot High Power must be switched off and the power supply of the robot must be disconnected After these precautions a skilled person is allowed to maintain the robot See section 1 11 on page 12 for the specifications of the personnel The AdeptOne MV PackOne MV and AdeptThree MV robots can work in Automatic Mode with high speeds and accelerations and can trap persons or can crush them The impact of a robot can kill a person AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B 11 Chapter 1 Safety WARNING Electrical Hazard Impact Hazard Never remove any safeguarding and never make changes in the system that will de commission a safeguard 1 11 Qualification of Personnel This manual assumes that the personnel have attended an Adept training course and have a working knowledge of the system The user must provide the necessary additional training for all personnel who will be working with the system As noted in this handbook certain procedures should be performed on
218. to stop in Manual mode 92 installation on base 30 intended uses 9 jointlocations 3 lubrication 101 105 modifications 10 moving with MCP 94 shipment specifications 23 speed limited in Manual mode 75 staticforces 6 transport and storage 23 unpacking and inspection 24 workingarea 11 robot mounted equipment grounding 52 rotary seal assemblies on PackOne MV 109 S safety 5 14 during maintenance 14 equipment for operators 13 expelling apart 7 impact and trapping points 7 qualification of personnel 12 required safeguards 6 sources for information 8 safety barriers 74 79 requirements 6 Safety Utility how to use 154 173 using during commissioning 94 using during maintenance 100 166 Security Panel components 73 connecting to power chassis 50 connecting to robot 49 connecting to SIO 48 connecting to 49 dimensions 124 drawing of components 48 enclosure requirements 41 grounding 51 installation 41 list of functions 73 softstops AdeptOne MV specifications 183 AdeptThree MV specifications 183 description 182 solenoid valve assembly AdeptOne MV robot 177 AdeptThree MV robot 179 SPEC utility program to set softstops 182 speed bars on 95 S series controller installation 38 system cable connections 42 system grounding diagram 53 information 51 System Power switch on External Front Panel 39 T TB1 TB2 terminal assignments 81 TB3 terminal assignments 83 TB4 terminal assignments 77 TB5 terminal
219. ty Utility has been run and all tests have passed See Appendix C for instructions The Safety Utility requires you to define test locations for robot motions Refer to section 4 9 for instructions on moving the robot Moving the Robot with the MCP 4 9 94 This section describes how to use the MCP to move the robot You will need to use the MCP to perform some portions of the Safety Utility Follow the steps on page 92 to enable High Power and to calibrate the robot Do riot enter the workcell Leave the operating keyswitch in the AUTO position Make sure that all access doors are closed and no person is in the workcell Press the MAN HALT button on the MCP to select the MCP Manual mode then see the following descriptions WARNING Impact Hazard Only a robot operator with the qualifications and safety equipment given in section 1 11 on page 12 is allowed to work with the robot AdeptOne MV AdeptThree MV Robot Instruction Handbook Hev B Moving the Robot with the MCP MAN HALT Button for Selecting Joint State The MAN HALT button changes the state being used to move the robot Figure 4 5 Mode Control Buttons The system will remain in MCP Manual mode until High Power is turned off or the COMP PWR button is pressed When the MAN HALT button is pressed the first time the MCP will be in World state Pressing the MAN HALT button again selects the next state to the right Tool Joint or Free eventually wrapping back to the
220. uae Vieh Roe at anos e e ee Ks 37 2 12 Installing a Terminal in an S Series System 38 Viii AdeptOne MV AdeptThree MV Robot Instruction Handbook Rev B Table of Contents Recommended Terminal for S Series Systems 38 Installation PrecSdute ses ag tto tg RR ee 38 2 13 Installing the External Front 39 Gonirols anc IndicdtOorssc i dedo eoo Fa ee Ug i e OP Dd 39 Installing the External Front 40 2 14 Installation of the Adept Security Panel 41 Ericlosure Redulrements s CELA debere 4 Installation of the Security 41 2 15 Signal Interconnection Installation 42 System Cable Connections 2 2 2 2 22 21 42 system Cable mes Ra e ni cs 43 Connecting the Robot the Power 55 43 Installing Signal Cables Robot to MV 45 Installing Signal Cables MV Controller to Power Chassis 46 Connecting the to the 46 cT 47 Connecting the Security 48 Connecti
221. ul note of the error message and try again If the error occurs a second time contact Adept Customer Service If no error occurs the following is then displayed Program controlled move xpect E Stop assert The default test locations are with Joint 1 at 30 degrees Do you WARNING from midrange and all other joints at midrange want to use the default test locations Y N Responding Y causes the robot to move Joint 1 to the positions shown in Figure C 1 If the robot is in its workcell it may contact other tooling and or fixtures causing extensive damage AdeptOne MV AdeptThree MV Robot Instruction Handbook B Tests Performed at Time of Commissioning Default Test Locations Example Test Locations Figure C 1 Test Locations Responding N allows new test locations to be defined The test locations must be defined so that Joint 1 is driven at least 30 degrees see Figure C 1 The robot will make a quick move causing the accelerometer to activate the E STOP The robot may overshoot slightly To ensure the robot does not crash it should be able to move 10 degrees beyond the defined locations in both directions After the new test locations are defined the following is displayed Testing Joint 1 Press the COMP PWR button Hold t While ne SPEED BAR then press and release the STEP button continuing to hold the SPEED BAR press and release the STI
222. ut SIO Module in the Adept MV controller are wired to the terminal blocks TB1 and TB2 on the Security Panel see Figure 3 4 Eleven input and five output channels are available The SIO module supports 12 input and 8 output channels however 1 input and 3 outputs are used by the Category 3 safety system and are not available to users Input Signals The terminal blocks TB1 and TB2 handle the digital input signals 1001 to 1011 Each channel has an input and a corresponding return line Refer to Table 3 3 for input specifications The locations of the signals on the terminal blocks are given in Table 3 4 Table 3 3 DIO Input Specifications SIO module on the Security Panel Operational voltage range 0 to 24 VDC Off state voltage range 0 to 3 VDC state voltage range 10 to 24 VDC Typical threshold voltage Vin 8 VDC Operational current range 0 to 20 mA state current range 0 to 1 2 mA state current range 7 to 20 mA Typical threshold current per channel 10 mA Impedance Vin lin 1 3 KO minimum Current at Vi 424 VDC Iin lt 20 in Turn on response time hardware Software scan rate response time 5 psec maximum 16 ms scan cycle 32 ms max response time Turn off response time hardware Software scan rate response time 5 psec maximum 16 ms scan cycle 32 ms max response time the input current specifications are prov
223. ware Compatibility for Category Systems 4 Robot Torques and Forces isses 6 Maximum Robot Joint Velocities in Runaway 5 7 Sources for International Standards and 8 Operating Environment Specifications for Adept 1 19 Operating Environment Requirements 22 Adept Shipping Crate Specifications 22 2 23 System Cable tes 43 Adept MV Controller Power Requirements 54 Adept MV Controller Power Cord 5 55 Adept PA 4 Power Chassis Power 56 Connecting Power Cord of the Power Chassis to the Terminals on Ine Powerthail X2 5 iore pem aree 57 Customer Supplied AC Power Cord Specifications for Security Panel 58 Connection of Main AC Power Cord to the Circuit Breaker on the Power Gb tao e patito Or qi Nai dec tal 58 Terminal Assignments on Terminal Block TBA for Customer Supplied E Stop 5 77 Terminal Assignment On Terminal Block TB5 for Passive E Stop Contacts 79 DIO Input Specifications SIO module on the Security Panel 80 Digital Input Signal Assignments on Terminal Blocks TB and 2 81
224. while the vacuum is within the appropriate range The switch can be used in series with any other external E stop devices This method will allow High Power to be turned on only if vacuum is present The user would see an External E stop error message on the system monitor terminal if the vacuum fails NOTE To comply with the requirement for redundant E Stop loops use two independent switches if an E Stop is needed to sense the presence of a vacuum Testing the Vacuum B 3 Setting the vacuum switch requires that all parts of the robot and vacuum systems be installed High Power need not be enabled but the Arm Power and Arm Signal cables connecting the robot to the Adept MV Controller and Adept PA 4 Power Chassis must be connected with their seals Connect a vacuum gauge to the pipe tee just outside the robot s vacuum supply fitting Turn the vacuum system on and wait a few moments for the system to stabilize Adjust the vacuum to within the limits mentioned in Vacuum Requirements on page 148 plus roughly 1 1 2 inches W C of vacuum Adjust the switch so that this is the vacuum falling setpoint That is set the switch for this point apply for more vacuum then gradually reduce the amount of vacuum until the switch trips This helps compensate for switch hystereses The extra 1 1 2 inches of vacuum allows for the normal swing of vacuum roughly 1 inch as Joint 3 is moved up and down Reset the vacuum supply to the normal setting Be
225. ys and menus shown in sections C 3 and C 4 are presented to help you understand how the SAFE UTL program works We do not attempt to show all of the messages that actually occur when using the program The utility program displays the following menu and prompts the user to select an option Adept CE Category 3 Test Program Version 11 3 Copyright c 1996 by Adept Technology Inc Robot 1 Not Commissioned gt EXIT gt All Tests gt Accelerometer B Amp Voltage Restrict gt Switches and Buttons gt MCP E STOP Functions gt Brake Holding Force ll V Enter Selection In order for the robot to be marked as commissioned option 1 must be selected It is however strongly recommended that the individual options be tested first starting with option 2 This will allow the user to become familiar with the tests and procedures before attempting to commission the robot The other options can also be selected individually to test a component that has failed a test After testing the individual component option 1 must be selected again The system is marked commissioned only after all tests pass AdeptOne MV AdeptThree MV Robot Instruction Handbook 159 Appendix C Using the Safety Utility 160 In some tests the system recognizes the result of the test on its own Other tests require the operator to type a N or Y to indicate the result of

AdeptOne-MV/AdeptThree-MV Robot Instruction Handbook

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