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Adept 550 Robot Instruction Handbook

1. mm mmm a El Wl Figure 6 5 Adept MV 19 Dimensions 86 Adept 550 Robot Instruction Handbook Rev A Dimensions Dimensions for Adept PA 4 Power Chassis Top View lt 216 mm 290 mm gt A e e e e a e e e e e e e A A A A 479 mm 136 mm l 18 Front View mm Side View Figure 6 6 Adept PA 4 Power Chassis Dimensions Adept 550 Robot Instruction Handbook Rev A 87 Chapter 6 Technical Specification Dimensions of the Extemal Front Panel 482 6 mm 19 in 6 35 mm 0 25 in D LAMP SYSTEM HIGH POWER A TEST MANUAL AUTO o POWER I ON OFF C 4 EMERGENCY STOP 57 41 mm cde Q Q 132 6 mm 2 26 in 5 22 in PENDANT LOCAL NETWORK START RUNNING O Q KO 14 3 mm 0 56 in 90 mm 3 5 in i 81 3 mm 3 2 in 48 3 mm 1 9 in Y Figure 6 7 Adept Ext
2. All dimensions in mm Figure 6 2 User Range Dimensions for Adept 550 Robot Adept 550 Robot Instruction Handbook Rev A 83 Chapter 6 Technical Specification 21 221 00 000 14 1 15_ 99 ETS All dimensions in mm 50 X 45 CHAMFER Figure 6 3 User Hange Close up Dimensions 84 Adept 550 Robot Instruction Handbook Rev A Dimensions Dimensions for Adept MV 8 Controller 290 mm L 216 mm Y Top View lt 2l6mm _ 52 mm 290 mm gt A e Iesele elexlenienienuis CI 7 Hi i Eet q ost UI 136 mm INI Y e 18 Front View mm Side View Figure 6 4 Adept MV 8 Dimensions Adept 550 Robot Instruction Handbook Rev A 85 Chapter 6 Technical Specification Dimensions for Adept MV 19 Controller 4 290 mm
3. 69 Selecting and Moving Joint1 70 Selecting and Moving Joint2 70 Selecting and Moving Joint 3 70 Selecting and Moving Joint4 70 4 9 Limiting Joint Tavel ee essere ern hh hh nnn hn 71 POPS ill 4e E A a Exi Dor RE DIE RES 71 Hard TOP S uuu sl a sha ul BE EE SE a EM du E 71 Adept 550 Robot Instruction Handbook Rev A 59 Chapter 4 Commissioning the System 41 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 MCP 42 Check Of Physical Connections Physical Connections Before turning on the controller and enabling High Power make sure that all cables from robot to power chassis robot to controller controller to power chassis VFP to controller and MCP are installed correctly See Chapter 2 for installation instructions 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 Also make sure you have installed proper safeguards an
4. 27 Installatiori Procedure Lu oe A de 27 2 12 Installing a Terminal in an S Series System 28 Recommended Terminal for S Series Systems 28 Installation Procedure 28 2 13 Installing the Extemal Front Panel e esee nnn nnn nnn 29 Controlsand Indicators 29 Installing the Extemal Front Panel VER 30 2 14 Signal Interconnection Installation eee eee 31 System Cable Connection 31 Connecting the Robot to the Power Chassis 32 Installing Signal Cables Robotto MV Controller 33 Installing Signal Cables MV Controllerto PowerChassis 34 Connecting the MCP to the VFP 35 2 15 Grounding Information lere seen nnn nnn 36 Adept 550 Robot Instruction Handbook Rev A 15 Chapter 2 Installation 16 Adept MV ControllerGrounding 1 36 Adept PA 4 Power Chassis Gmoundimg aaaea 36 Adept Robot Grounding 0 0 cece ete 36 Robot Mounted Equipment Grounding 36 2 16 Connecting to AC Power ococcccccc eee 37 Connecting AC Powerto the MV Controller 37 Connecting AC Powerto the Adept PA 4 Power Chassis 39 2 17 Additional Power Chassis Information esee 44 Overview of B Amplifier Module 1 44
5. 4 X 99 7 mm e 0 38 201 mm 7 9 221 mm 8 70 Figure 6 9 MCP Cradle Dimensions 90 Adept 550 Robot Instruction Handbook Rev A Joint Motions 6 2 Joint Motions Joint 1 Joint 1 also referred to as the shoulder provides rotation of the inner link Joint 1 motion is limited to 100 See Figure 6 10 Figure 6 10 J oint 1 Motion Joint 2 Joint 2 also referred to as the elbow provides rotation of the outer link Joint 2 motion is limited to x140 Joint 2 s motion is similar to an elbow capable of acting in both left and right hand configurations see Figure 6 11 When you teach a robot location the robot elbow when viewed from the back of the robot will be pointing either to the left or right These arm orientations are referred to as Lefty and Righty In Figure 6 11 the dotted outline is in a lefty configuration and the solid outline is in a righty configuration Under program control the robot will always move to the next location in its current configuration lefty or righty unless the location is a precision point or the LEFIY or RIGHTY program instruction is used Back of Robot Figure 6 11 J oint 2 Motion and LEFTY RIGHTY Configurations Adept 550 Robot Instruction Handbook Rev A 91 Chapter 6 Technical Specification Joint 3 Joint 3 provides vertical translation of the quill Joint 3 drives the quill to up and down
6. lt gt lt gt lt gt All dimensions in mm 140 300 250 730 gt lt 17 CT A A A 242 250 I Y 43 A 60 78 Y 46 r 867 13 70 832 y Y 215 7 X 57 X Y Y 411 5 E 317 E 297 J 137 Y Y Y Y Y Y These dimensions may vary slightly due to manufacturing tolerances Figure A 1 Adept 550 CleanRoom Robot bp and Side Dimensions Adept 550 Robot Instruction Handbook Rev A 99 Dual Adept550 Robots BL Inttoduction Xu cece eee 102 Dual Adept 550 Robot System Description 102 B2 Installation EE a 102 VMEbusAddressforV IModule 102 AdeptPA 4PowerChassis nen 102 Cable Insallation a a 1 103 B 3 Operation with the Manual Control Pendant MCP 103 BA Programming Information coccoocccoc mnn mmn 103 V c Language Programming ren 103 V MonitorCOMMAndS o ccocccocc er 103 B 5 Emergency Stop Circuit Shuts Off Both Robots 104 Adept 550 Robot Instruction Handbook Rev A 101 Appendix B Dual Adept 550 Robots B 1 Introduction All of the information in this instruction handbook is applicable to the Dual Adept 550 robot configuration This appendix describes some additional considerations when working with this product Dual Adept550 Robot System Description A
7. rn 90 62 Joint MOHONS hh hr hrs 91 Jont AS 91 SOME mem RE eg mmm m xxm EO E m RR OR a 91 Joint EE 92 JOY aa RR s CE WER Was em Ware cue eee We aea coii te E RT Re QR s 92 6 3 Adept 550 Robot SpecificationS 93 Adept 550 Robot Working Envelope 95 6 4 Adept PA 4 Power Chassis Specifications se sanaaa 96 A Adept550 CleanRoom Robot 97 Al ntmduchon suuyk aya kak awas uya skua hh 98 Vacuum Specifications oooooooocerrnrar rr 98 A 2 INStAN ATION EE 98 A 3 Adept550CleanRoom Robot Dimensions 99 B Dual Adept550 Robots 101 BL Introductions 3 2244 eevee red Seve ede be mk eee eee LEGGE Ed 102 Dual Adept 550 Robot System Description 102 B 2 Installation EN EIN EELER Eds m km ee Ree EEE EG mE EEG 102 VMEbusAddressforVJI Module 102 Adept PA 4 Power hass nesenenenersrsrsrrenener erene 102 Cable Installation esser ntanu anaa utaa eee eee eens 103 B 3 Operation with the Manual Control Pendant MCP 103 B 4 Programming Information 0 0 c ee tae 103 V Language Programming eren 103 VtMontorCommandes cece cect E AEREA k A 103 B 5 Emergency Stop Circuit Shuts Off Both Robots 104 C EMC Testinformation nn LOD CL Electromagnetic Compatibility Testing
8. 31 Adept 550 RoborbRearbanel 32 Robot to VJI Cable Installation 33 PowerChassisto VJI Cable Insallation 34 MEP ee nei el EE 35 Adept MV Controller Power Entry Module 38 Typical 380 415 V AC Connection for Category 1 System 41 Typical 3 Phase 200 240 V AC Connection for Category 1 System 41 Insulating Blue Wire in PowerConl Be 42 Changing Voltage in Power Chassis 43 User Flange Removal Details 47 Digital VO Connector Pin Locations on SIO Module 56 E Stop Diagram with VFP and MCR eee 57 E Sto p Circuitry with Additional Safety Equipment 58 Holding the MEP ue eet s e wba ee e anp s Fa REGES e 63 MEP Ee TEEN 64 Command CMD Function Button 67 Mode Control Buttons 68 Speed Bas roc e auc mone OEC He ee ey Sa RN ED DD 68 Tont State SCARA sve EWu A EXE URAN ATI ERROR MAURUS des 69 Lubrication of Joint 3BallScreW 75 Location of Access Coveron Underside of Outerlink 76 Location of Joint 3 and Joint 4 Drive Belts 77 Close up View of Joint 3 Brake Assembly 78 Adept 550 Robot Top and Side Dimensons 82 User Flange Dimensions for Adept 550 Robot
9. 70 4 9 limiting oint Travel zuo du RR REX ERG X ERG ER RENE AE 71 SOTESEO PSs Yawa ades dm tot ee i m OR ale wee MAR Roe lentus Tn Siet ec a es ce 71 Hard TODS u pees ear ea Dee HER eS eA Su evt seg 71 5 Malnte alic nia a l 3 5 L Introduction cs eser mimin REDE eed eee Li he eee A 74 5 2 Checking Robot Mounting Bolts and Leveling 74 5 3 Lubricate Joint 3 Ball Screw eens 75 5 4 Check Tension and WearOnJ 3and J4 Drive Belts 76 5 5 Maintenance and Inspection of AirFilters 79 Adept PA 4 Fan Filter Inspection and Cleaning 79 Adept MV Controller Fan Filter Inspection and Cleaning 79 5 6 CheckLampson VFP pei Hrita e e a e n e eaa a n 79 6 Technical Specification i OL OL DIMENSIONS voir eerie ok eT Dt ln editio imi wer eret 82 Dimenaions for Adept 550 Robot eese 82 User Flange Dimensions for Adept 550 Robot 83 Dimensions for Adept MV 8 Controller 85 Dimensions for Adept MV 19 Controller 86 x Adept 550 Robot Instruction Handbook Rev A Table of Contents Dimensions for Adept PA 4 Power Chassis 87 Dimensions of the ExtemalFrontPanel 88 Dimensions of the Mounting Brackets 89 MCP Cradle Dimensions
10. Operating voltage range 0 to 24 VDC Operational current range per channel Luz 100 mA Varop across output in on condition Varop 0 85 V at 100 mA Varop lt 0 80 V at 10 mA Output off leakage current Laut 600 HA Turn on response time hardware Software scan rate response time 3 psec maximum 16 ms scan cycle 32 ms max response time Turn off response time hardware Software scan rate response time 200 usec maximum 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 to 100 mA per channel whereas the DIO output is rated at 400 mA Adept 550 Robot Instruction Handbook Rev A Overview of Safety System Digital I O Connector Pinouts Table 3 4 Digital I O Connector Pin Assignments on SO Module Pin Signal Name Pin Signal Pin Signal Pin Signal 1 Input 1001 2 1001 return 27 Output 0002 28 Output 0002 3 Input 1002 4 1002 return 29 Output 0003 30 Output 0003 5 Input 1003 6 1003 return 31 Output 0004 32 Output 0004 7 Input 1004 8 1004 return 33 Output 00054 34 Output 0005 9 Input 1005 10 1005 return 35 Output 0006 36 Output 0006 11 Input 1006 12 1006 return 37 Output 0007 38 Output 0007
11. Mounting Surface The Adept 550 robot is designed to be mounted on a smooth flat level tabletop The mounting structure must be rigid enough to prevent vibration and flexing during robot operation Excessive vibration or mounting flexure will degrade robot performance Figure 2 2 shows the mounting hole pattern for the Adept 550 4 x 14 dia thru 200 160 125 Q DS amp 39 amp ii 80 80 All dimensions in mm 140 40 p lt 200 Figure 2 2 Mounting Hole Pattem Robot to Mounting Surface Tool and Equipment Requirements Common hand tools plus the following items are required to install the robot Hydraulic lift Mounting structure such as a tabletop or mounting spool Torque wrench WARNING The installation procedures in this chapter should only be performed by skilled persons as defined in section 1 9 on page 10 Mounting Proc edure 1 Using the dimensions shown in Figure 2 2 drill and tap the mounting surface for four M12 1 75 x 36mm or 7 16 14 UNC x 1 50 inch machine bolts bolts not provided See Table 2 4 for bolt and torque specifications 2 While the robot is still bolted to the transportation pallet connect the hydraulic lift to the eyebolt at the top of the robot see Figure 2 1 Take up any slack but do not lift the robot at this time 20 Adept 550 Robot Instruction Handbook Rev A Robol Installation
12. 83 Adept 550 Robot Instruction Handbook Rev A Table of Contents 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 A 1 Xiii User Flange Close up Dimensions 84 Adept MV 8 Dimensions nn 85 Adept MV 19 Dimensions ooooococcoc en 86 Adept PA 4 Power ChassisDimensions 87 Adept Extemal Front Panel Dimensions 88 Adept MV 8 and PA 4 With Mounting Brackets Installed 89 MCP Cradle Dimensions l cc nh 90 Jemp Mettet S a aes AE tana a eee ERR eT E ERRARE ee Ree 91 J oint 2 Motion and LEFTY RIGHTY Configurations 91 Joint 3 and Joint 4 Motions a 92 Adept 550 Robot Working Envelope 1 95 Adept 550 CleanRoom Robot Top and Side Dimensions 99 Adept 550 Robot Instruction Handbook Rev A 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 3 1 Table 3 2 Table 3 3 Table 3 4 Table 4 1 Table 5 1 Table 6 1 Table 6 2 Table A 1 Table B 1 Table C 1 xiv List of Tables Adept Hardware and Software Compatibility for Category 1 Systems 3 Robot Torquesand Forces 5 Maximum Robot Joint Veloc
13. Check the leveling of the base every 6 months 74 Adept 550 Robot Instruction Handbook Rev A Lubricate Joint 3 Ball Screw 5 3 Lubricate J oint 3 Ball Screw Use Marutemp SRL grease Adept part number 60554 00070 to lubricate the Joint 3 ball screw Procedure 1 Turn off main power to the controller and power chassis 2 Remove the Joint 3 cover by removing two nuts using an 8 mm socket on the top of the cover and lifting the cover up and off See Figure 5 1 3 Move Joint 3 to the top of its travel Remove any existing grease with a soft cloth 4 Apply a thin film of grease to the surface of the length of the ball screw 5 Move Joint 3 to the bottom of its travel Remove any existing grease with a clean lint free soft cloth 6 Apply a thin film of grease to any surface of the ball screw that you did not reach in step 4 7 Move Joint 3 up and down several times to spread the grease evenly 8 Replace the Joint 3 cover Adept 550 Robot with Joint 3 cover Joint 3 Ball Screw removed Figure 5 1 Lubrication of J oint 3 Ball Screw Adept 550 Robot Instruction Handbook Rev A 75 Chapter 5 Maintenance 5 4 Check Tension and Wear On J3 and J4 Drive Belts Check the tension and wear on the Joint 3 and Joint 4 drive belts every 3 months 1 Turn off main power to the controller 2 Remove the access cover by loosening four screws using 2 5 mm hex wrench
14. Off state current range 0 to 1 2 mA On state current range 7to20mA Typical threshold current per channel 10mA Impedance Vin Lin 1 3 KO minimum Current at Vi 24 VDC lin lt 20 mA Turn on response time hardware Software scan rate response time 5 usec 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 provided for reference voltage sources are typically used to drive the inputs b 2 ms response time minimum for fast inputs 1001 to 1003 depending on program task configuration when used with V INT EVENT instruction Adept 550 Robot Instruction Handbook Rev A 53 Chapter 3 Preparation for Safe and Effective Use of the Robot 54 Output Signals The digital I O connector handles output signals 0001 to 0008 Refer to Table 3 3 for output specifications The locations of the signals on the connector are shown in Table 3 4 The SIO provides separate and connections for each channel no internal common connections 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 3 DIO Output Specifications SIO module
15. 13 Input 1007 14 1007 return 39 Output 0008 40 Output 0008 15 Input 1008 16 1008 return 41 Auxiliary 42 External E Stop input E Stop input 17 Input 1009 18 1009 return 43 Auxiliary 44 External E Stop input E Stop input 19 Input 1010 20 1010 return 45 Passive 46 Passive E Stop E Stop output output 21 Input 1011 22 1011 return 47 Not used 48 Not used 23 Input 1012 24 1012 return 49 Not used 50 Not used 25 Output 0001 26 Output 0001 Pins 41 42 43 and 44 see Figure 3 2 and Figure 3 3 for more information Adept 550 Robot Instruction Handbook Rev A 55 Chapter 3 Preparation for Safe and Effective Use of the Robot Pin 17 Pin 50 Pin 33 O000000000000000 oo0oo00000000000000 oo0oo00000000000000 EY Pin 18 in Figure 3 1 Digital I O Connector Pin Locations on SIO Module 56 Adept 550 Robot Instruction Handbook Rev A Overview of Safety System Typical Emergency Stop Circuitry The following drawings show two examples of different types of connections to the Emergency Stop circuitry Digital Return SIO Module Adept External Front Panel MEME Dur High Power dd Push Button Manual Auto TS Keyswitch System Power VFP Switch System Power i Analog Return lt o O To Power Relay To user E Stop Signal 3 i equipment
16. PE na Im P ee WE EC a b i PE N LG Figure 3 3 E Stop Circuitry with Additional Safety Equipment Adept 550 Robot Instruction Handbook Rev A Commissioning the System 4 1 Introduction oocccoccc ees 60 4 2 Check Of Physical COMMectiONS ccooccccccc nn n n n nnn 60 Physical Connections nnn 60 4 3 VFP Operating Modes liess eee eee nnn EE 60 ManualOperating Mode 60 Automatic Operating Mode 61 4 4 Using the Brake Release Don ENEE ENEE n n n n nnn 62 Brake Sia nA 62 Brake Release Button 62 4 5 Description ofthe Manual Control Pendant MCP 63 How to Hold the MCP i ecien naa aba aea e nne 63 Description of Buttons on the MCL 64 Mode Control and Joint Axis Control Buttons 64 Speed Bars ia Strokes a ER ee eh 64 4 6 How to Stop a Robotin Manual Mode 000eee eee ee eens 65 4 7 How to Startthe Robot EE een ahhh 65 Enable High Power with the MCP nn 65 In Automatic Mode senken kE E eee 65 In Manual Mode eee 66 Calibration of the Robot with the MCP 66 4 8 Moving the Robot with the MCP seen nnnm 67 MAN HALT Button for Selecting Joint State 68 Joint Axis Control Buttons 68 Speed BS u u yoga edad nee wee E B ERE uswa Wu w sy 68 Selecting J oint State and Moving the Robot
17. WARNING Impact Hazard Do not attempt to lift the robot at any points other than the eyebolt provided 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 Remove the four bolts securing the robot base to the pallet Retain these bolts for possible later relocation of the equipment Lift the robot and position it directly over the mounting surface 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 mounting surface Install the customer supplied mounting bolts Tighten bolts to torque specified in Table 2 4 NOTE Check the tightness of the mounting bolts one week after initial installation and then recheck every 6 months See Chapter 5 for periodic maintenance Table 2 4 Mounting Bolt Specific ations Standard Size Specification Torque Metric M12xP1 75 ISO Property Class 8 8 85 Nm SAE 7 16 14 UNC SAE Grade 5 50 ft Ib Adept 550 Robot Instruction Handbook Rev A 21 Chapter 2 Installation 2 10 Installation ofthe Adept MV Controller and the Adept PA 4 Power Chassis Joining an Adept PA 4 Power Chassis to an Adept MV Controller The
18. 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 two 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 Blue Wire in Power Cord 1 Make sure the power chassis and controller are turned off 2 Disconnect the 5 wire power chassis power cord from the AC power source 3 Locate the two pieces of shrink tubing in the accessories 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 blue wire in the power cord and use a heat gun to apply it See Figure 2 18 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 power cord from 19 mm 3 4 inch diameter power chassis shrink tubing blue wire 7 mm 1 4 inch diameter shrink tubing Figure 2 18 Insulating Blue Wire in Power Cord Adept 550 Robot Instruction Handbook Rev A Connecting to AC Power Part 2 Rotating Voltage Selector in Power Chassis 1 Make sure the power chassis and controller are turned off 2 Open the front air intake grill by loo
19. CleanRoom robot Adept 550 98 99 dimensions 99 vacuum specifications 98 compatibility for Category 1 equipment 3 Control keyswitch on External Front Panel 29 controller connecting to power chassis 34 connecting to robot 33 dimensions MV 19 86 dimensions MV 8 85 grounding 36 joining to power chassis 22 panel mounting 24 rack mounting 24 current voltage ratings controller 37 power chassis 39 Customer E Stops 50 58 Customer Safety Barrier switch specifications 50 Customer Service contact information 13 cycle time specification 93 D Digital I O on SIO connector pinouts 55 input specifications 53 output specifications 54 dimensions Adept 550 robot 82 Adept MV 19 controller 86 Adept 550 Robot Instruction Handbook Rev A 107 Index Adept MV 8 controller 85 CleanRoom robot 99 External Front Panel 88 MCP cradle 90 mounting brackets 89 power chassis 87 dowel pin for keying on end effectors 46 drive belts checking tension 76 dual 550 robot system 102 104 cable installation 103 E stop circuit 104 installation 102 programming 103 using MCP with 103 E electrical lines user inrobot 48 EMC test information 105 Emergency Stop circuit see E Stop circuit Emergency Stop switch on External Front Panel 29 Enable Power how to from MCP 65 end effector dowelpin 46 grounding 46 envelope working 95 E Stop circuit 50 58 Customer Safety Barrier switch specifications 50 drawings 57 dual 550 robot system 104 exter
20. E ee Lum Su _ Mie D _ NS Figure 6 13 Adept 550 Robot Working Envelope Adept 550 Robot Instruction Handbook Rev A 95 Chapter 6 Technical Specification 6 4 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 2 Power Consumption for PA 4 Power Chassis with an Adept 550 System Line Voltage Typical Worst Case 380 415 VAC Current RMS 3 5 amps phase 8 2 amps phase 50 60Hz 3 phase Watts 0 72 kW 1 3 kW 200 240 VAC Current RMS 3 0 amps phase 7 0 amps phase 50 60Hz 3 phase Watts 0 72 kW 1 3 kW a In the 380 415 VAC configuration the Adept system draws current for a short duration during the positive peak voltage only 96 Adept 550 Robot Instruction Handbook Rev A Adept550 CleanRoom Robot A 1 Introduction EE A 98 Vacuum Specifications 0 eee 98 A2 Installation sa s sua mwa uwa s a a hh hh hh 98 A 3 Adept550 CleanRoom Robot Dimensions 99 Adept 550 Robot Instruction Handbook Rev A 97 Appendix A Adept 550 CleanRoom Robot A 1 Introduction The Adept 550 Class 10 CleanRoom robot meets or exceeds specifications for Class 10 cleanroom products The
21. brake which allows movement of Joint 3 If this button is pressed while High Power is on High Power will automatically shut down CAUTION When the Brake Release button is pressed Joint 3 may drop to the bottom of its travel To prevent possible damage to the equipment make sure that Joint 3 is supported while releasing the brake and verify that the end effector or other installed tooling is clear of all obstructions Adept 550 Robot Instruction Handbook Rev A Description of the Manual Control Pendant MCP 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 These routines 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 basic operations with the MCP such 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 Hold toRun switch that is connected to the emergency stop circuitry Whenever this switch is released High Power is turned off To operate the MCP 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
22. ee 11 1 12 Protection Against Unauthorized Operation 11 1 13 Operating Modesof Adept Robots 1 11 Automatic Mode 11 Manuel Mode musicos bbs a a ie 11 1 14 Safety Aspects While Performing Maintenance 12 1 15 Risks That Cannot Be Avoided 0 cee 1 12 1 16 What to Do in an Emergency Gtuation sussa saaa 12 Ly H0W t0 Get Help c4 eee us Bey E E ay are ae eS 13 In EUNO PGs corr EE ei te et a teehee ea eee ee Se Swa 13 Europe Gemmany 13 CHE 13 Italy o ronem E a die SERGE d RM RE wid 13 In the Uriited St tes salue xe ex RR ERE howe Wee A ae Was 13 Service Call u x ER Wai ck he ed xx RR EXTR xx 13 Application Questions isses 13 Applications Intemet E MailAddress 13 Training Information eh 13 Outside Continental United StatesorEurope 14 Adept 550 Robot Instruction Handbook Rev A vii Table of Contents 2 Ile NIE BEE E viii 2 1 Environmental and Facility RequiementsforRobot 17 Facility Ambient Air Quality For Robots 17 Robot Workcell Free Gpoace eee 17 2 2 Environmental and Facility Requirements for Controller 17 2 3 Environmental and Facility RequirementsPowerChassis 18 2 4 Before Unpacking Adept Equipment sasssa aaaea aaa 18 2 5 Adept Shipment Specifications 0 cee
23. on the under side of the outer link See Figure 5 2 Note the path of the cable that runs along the side of the opening so that you can route it the same way at the end of this procedure 3 Drop the Joint 3 brake assembly out of the way by removing 4 M3 x 8 screws using 2 5 mm hex wrench and lowering the assembly This makes it much easier to access the drive belts NOTE Be careful not to lose the four spacers that are between the brake assembly and the outer link assembly See Figure 5 4 These spacers are necessary to ensure that the brake is aligned properly with the Joint 3 drive pulley 4 Check the tension of the Joint 3 and Joint 4 drive belts with your fingers See Figure 5 3 The belts should feel tight to the touch If there is any noticeable loose ness call Adept Customer Service 5 Inspect up in the drive belt area with a flashlight to look for signs of excess wear from the drive belts A small amount of residue or dust from the belts is normal Any larger particles that may indicate worn or broken teeth on the drive belts could be a problem Call Adept Customer Service if you discover anything that looks unusual View of Underside of Adept 550 Outer Link Access Cover Joint 3 Brake Assembly Figure 5 2 Location of Access Cover on Underside of O uter Link 76 Adept 550 Robot Instruction Handbook Rev A Check Tension and Wear On J3 and J4 Drive Belts Joint 3 Motor Joint 4 Motor Joint
24. with a maximum stroke of 200 mm 7 9 See Figure 6 12 The Adept 550 Cleanroom robot has a maximum Joint 3 stroke of 180 mm see Appendix A Joint 3 Stroke AL CD Joint 4 Rotation Figure 6 12 Joint 3 and J oint 4 Motions Joint 4 Joint 4 also referred to as the wrist provides for rotation of the quill Joint 4 does not have hardstops but software limits its motion to 360 see Figure 6 12 92 Adept 550 Robot Instruction Handbook Rev A Adept 550 Robot Specifications 6 33 Adept550 Robot Specifications All specifications subject to change without notice Table 6 1 Adept 550 Robot Specific ations Adept 550 Robot Specifications Reach Maximum radial 550 mm 21 7 Minimum radial 194 mm 7 6 Vertical clearance bottom of base to end of quill with maximum joint 3 retraction 336 mm 13 2 with maximum joint 3 extension 136 mm 5 3 Vertical Stroke Joint 3 Z direction 200 mm 7 9 Joint Rotation Joint 1 3 100 Joint 2 140 Joint 4 360 Maximum Payload including end effector and arm mounted tooling During operation 5 5 kg 12 1 Ib Inertia Load About Joint 4 axis maximum 450 kgcm 150 Ib in Force Joint 3 downward force minimum without payload 12 1 kg 26 6 Ib Cycle Time 2 kg 4 4 Ib 0 8 seconds Resolution Joint 1 0 0008 per encoder count Joint 2 0 0012 per
25. 25 amps Number and size of 5x2 5 mm conductor size Color code 380 415 VAC line 1 black line 2 black line 3 brown neutral blue ground green yellow Color code 200 240 VAC line 1 black line 2 black line 3 brown no connection blue must be insulated see page 42 ground green yellow VARNING 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 40 Adept 550 Robot Instruction Handbook Rev A Connecting to AC Power Typical AC Power Installation Diagrams 30 380 415V 20A 380 415V 200 240V PE N L3 L2 L1 Adept PA 4 3 380 415V F4 10A PE N L1 19 200 240V Adept MV 8 MV 19 Note F4 is user supplied Figure 2 16 Typical 380 415 V AC Connection for Category 1 System 30 L2 F 200 240V 200 240V E 20A PE L3 Adept PA 4 3 200 240V Adept MV 8 MV 19 14 200 240V Note F4 and F5 are user supplied Figure 2 17 Typical 3 Phase 200 240 V AC Connection for Category 1 System Adept 550 Robot Instruction Handbook Rev A 41 Chapter 2 Installation 42 Changing Voltage Setting for Power Chassis
26. 550 Robot 4 x 14 dia thru 126 100 E 200 160 125 70 lt 40 80 80 40 gt gt 200 2 lt gt lt gt lt gt All dimensions in mm 140 300 250 730 gt lt 117 LT A A A A SS a s 242 250 U Y Y 43 Y I A y 60 Y x 78 f UH rea 46 10 8 867 51 5 eso 215 n a 57 X X Y i 411 5 209 I 336 a 297 Y 136 Y Y Y 1 Y Y Y These dimensions may vary slightly due to manufacturing tolerances Figure 6 1 Adept 550 Robot p and Side Dimensions 82 Adept 550 Robot Instruction Handbook Rev A Dimensions User Range Dimensions for Adept 550 Robot 482 50 X 45 CHAMFER 13 7 41 00 047 00 See Close up View on next page 42 0 31 5 Z 1 025 A 033 220 000 000 rj e 48 00 o 52 00 Cl Y N Y 241 15 ES 4 025 000 s 6 25 13 00 24 00 259 94 262 99 000 051 4X M6 Helicoil Insert Thru ON 350 000 BC 2 10 MAM B cQ
27. Adept 550 CleanRoom robot product specifications are the same as the standard Adept 550 robot listed in Table 6 1 except the Vertical Stroke Joint 3 Z direction is 180 mm 7 1 The working envelope dimensions for the Adept 550 CleanRoom robot are the same as those shown in Figure 6 13 Vacuum Specifications Table A 1 Adept 550 CleanRoom Robot Vac uum Specifications Vacuum Fitting on 550 50 5 mm external diameter 45 mm internal diameter Air pressure minimum 800 mm of water column Air flow rate minimum 1 2 cubic meter minute Vacuum source Spiral Blowers Model SL5A60F or equivalent In the U S contact Japanese Products Corp at 203 840 1601 for information In Europe contact Japan Servo Europe in the Netherlands at 599 31 3414 27575 A 2 Installation The robot installation procedures are the same as those listed in Chapter 2 with the additional step of connecting a user supplied vacuum source as described above 98 Adept 550 Robot Instruction Handbook Rev A Adept 550 CleanRoom Robot Dimensions A 3 Adept550 CleanRoom Robot Dimensions 4 x 14 dia thru 126 100 O y 200 160 125 gl 748 so 1 an gt Lao gt 200
28. 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 O Install four M4 x 8 flat head Phillips screws to secure bracket Figure 2 3 J oining the Power Chassis and Controller atthe Top 22 Adept 550 Robot Instruction Handbook Rev A Installation of the Adept MV Controller and the Adept PA 4 Power Chassis Joining atthe Top 1 Place the two units next to each other Turn off power to each unit and disconnect the power cord Remove the top cover from both See Figure 2 3 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 M4 x 8 flat head screws into the chassis on the left hand side Replace the cover on each unit Joining atthe Bottom 1 2 3 4 Turn the two units over so you have access to the bottom side Locate the cutout bracket in the accessory kit Place the bracket over the feet of the units as shown in Figure 2 4 Install the four M4 x 8 flat head screws in the holes i
29. Dual Adept 550 robot system consists of the following components two standard Adept 550 robots no modifications required an Adept MV 8 or 19 controller with two VJI modules installed two PA 4 power chassis with two amplifier modules in each chassis e a Dual Adept SCARA Kinematics License and a V Extensions License B 2 Installation The installation process for the system is the same as described in Chapter 2 except that there are two VJI modules in the Adept MV controller and four amplifier modules in two PA 4 power chassis VMEbus Address for VJ Module If you purchased both Adept 550 robots at the same time as part of a Dual Adept 550 robot system then the two VJI modules will be configured at the factory for the correct VMEbus address If you are upgrading or installing a 2nd VJI as a replacement part then you should check the VJI address setting to make sure it is configured correctly it should be set as Servo Board 3 See the VJI chapter in the Adept MV Controller User s Guide for the correct switch setting Adept PA 4 Power Chassis Each Adept 550 robot requires two B amplifier modules resulting in a total of four amplifier modules per Dual Adept 550 robot system You must purchase two power chassis and install two amplifier modules in each power chassis 102 Adept 550 Robot Instruction Handbook Rev A Operation with the Manual Control Pendant MCP Cable Installation The extra VJI module
30. 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 Service Center in Paris France The phone numbers are 83 1 69 19 16 16 Monday to Friday 8 30 to 17 30 CET 83 1 69 32 04 62 FAX ltaly For customers in Italy Adept Technology maintains a Customer Service Center in Arezzo Italy The phone numbers are 89 575 3986 11 Monday to Friday 8 30 to 17 30 CET 89 575 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 Intemet 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 Adept 550 Robot Instruction Handbook Rev A 13 Chapter 1 Safety Outside Continental United States or Europe For service calls application questions and training information call the Adept Customer Service Cente
31. Results 105 xi Adept 550 Robot Instruction Handbook Rev A Table of Contents Figure 1 1 Figure 1 2 Figure 1 3 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 3 1 Figure 3 2 Figure 3 3 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 6 1 Figure 6 2 Xii List of Figures Adept 550 Robot with Joint Locations 2 Adept MV 8 Controllerand PA 4 Power Chassis 2 Robot Impactand Trapping Point Hazards 6 Adept 550 Roboton a Transportation Pallet 19 Mounting Hole Pattem Robot to Mounting Surface 20 Joining the Power Chassisand Controleratthe Top 22 Joining the Power Chassisand Controleratthe Bottom 23 Installing Mounting Brackets on an Adept MV Controller 25 Installing Mounting Brackets on an Adept PA 4 PowerChassis 26 Connecting the A Series Monitor and Keyboard 27 Extemal Front Panel VER 29 Extemal VME Front Panellnstaallation 30 Adept 550 Robot System Cable Installation
32. The three smaller connectors are 4 mm diameter Thread size of connectors is M5 User Electrical Lines There is a 25 pin male connector on the back panel of the robot for user electrical lines This connector is wired directly to a 25 pin female connector on the top of the outer link These connectors can be used to run user electrical signals from the back panel through the robot and up to the outer link Wire size 0 1 mm2 Maximum current per line 1 Amp Adept 550 Robot Instruction Handbook Rev A Preparation for Safe and Effective Use of the Robot 3 1 Overview of Safety Gym EE hh hh nhan 50 Introd uction iic s suysusqa suyuq uq IIIS uem us 50 Operating in Manual Mode oococccccoc eee 50 User Supplied E Stop Switches 1 50 Terminal Block On Extemal Front Panel 51 ExtemalE Stop Input 52 Passive E Stop OUtpUt oococcocoo asa 52 Digital Inputs and Outputs of the System Input Output SIO Module 53 Input Signals sss id dt 53 Output Signals aun u a A ad REA 54 Digital I O ConnectorPinouts 1 55 Typical Emergency Stop Cum 57 Adept 550 Robot Instruction Handbook Rev A 49 Chapter 3 Preparation for Safe and Effective Use of the Robot 3 1 Overview of Safety System Introduction Adept Technology highly recommends the use of workcell safety features such as light curtains safety gates or safety floor mats to prevent access t
33. WARNING Adept Technology strictly prohibits installation commissioning or operation of an installation with an Adept robot without the adequate safeguards according to the standards ISO 10218 sections 5 6 EN292 1 and EN60204 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 Adept 550 robot Table 1 2 Robot Torques and Forces Joint 1 maximum static torque 160 Nm 118 ft Ib Joint 2 maximum static torque 79 Nm 58 ft Ib Maximum static force applied by the robotin 608 N 137 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 Adept 550 robot is not safe on its 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 insta
34. bars NOTE The operator must keep pressing the Hold to Run button to retain High Power while 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 J oint 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 J oint 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 J oint 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
35. 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 Herstellererkl rung 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 den einschl gigen grundlegenden Sicherheits und 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 in die Maschine zu installierenden Erg nzungen und Schutzeinrichtungen ein Francaise D claration du Constructeur selon la Directive Communautaire 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
36. 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 Table 1 1 Adept Hardware and Software Compatibility for Category 1 Systems Product Required Model Part or Version Number Standard Adept 550 robot CleanRoom Adept 550 robot 550A Mechanism Model Number 556 550A Mechanism Model Number 557 Adept MV 8 controller Adept MV 19 controller part number 30330 15000 part number 30330 25000 Adept PA 4 power chassis part number 30336 31000 B amplifier module part number 10338 51000 External VME Front Panel VFP Category 1 part number 90332 00380 Manual Control Pendant MCP III part number 90332 48050P V Operating System software Version 11 3 or later Note Category 1 hardware cannot be used with earlier versions of V The new Category 1 VFP has two keyswitches older versions have only one P The label on the back of the new MCP III is Manual Control III Operator Also on the new MCP 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 sever
37. encoder count Joint 3 vertical Z 0 0022 mm per encoder count Joint 4 tool rotation 0 0012 per encoder count Repeatability at constant temperature X Y plane 0 025 mm 0 001 Joint 3 vertical Z 0 03 mm 0 001 Joint 4 rotational 0 05 Adept 550 Robot Instruction Handbook Rev A 93 Chapter 6 Technical Specification Table 6 1 Adept 550 Robot Specifications Continued Adept 550 Robot Specifications Maximum Joint Speed with 2 kg 4 4 Ib payload Joint 1 270 sec Joint 2 430 sec Joint 3 1000 mm sec 40 sec Joint 4 480 sec Weight Robot without options approximately 40 kg 90 Ib Power chassis with two amplifier modules approximately 14 5 kg 32 lb MV 8 controller with 030 SIO VGB approximately 14 5 kg 32 lb The robot tool performs continuous path straight line motions 25 mm 1 up 305 mm 12 over 25 mm 1 down and back along the same path COARSE is enabled and BREAKs are used at each end location Not achievable over all paths 94 Adept 550 Robot Instruction Handbook Rev A Adept 550 Robot Specifications Adept 550 Robot Working Envelope Maximum Intrusion Contact Radius 590 mm 23 3 Maximum Radial Reach Functional Area 550 mm 21 7 Minimum Radial Reach i 194 mm 7 6 p ee SS koX 140 Eds 140 ra s u GS _ Ss Robot lt
38. es 18 2 6 Transport and Storage eects 18 2 7 Unpacking and Inspecting the Adept Equipment 19 2 8 Repackaging For Relocation ere 19 2 9 Robot Installation I n 20 Mounting Surface yia a ne a nne 20 Tool and Equipment Requirements 20 Mounting Procedure a prira mare nne 20 2 10 Installation of the Adept MV Controller a nd the Adept PA 4 Power hass 22 Joining an Adept PA 4 Power Chassis to an Adept MV Controller 22 Joining atthe jop 23 Joining atthe Bottom tee 23 Space Around the Chassis scu ER DOES Dew QUOS E eee eds 24 Installation in a RackorPanelMount 24 Panel Mounting a i e a ee ai ta aa e ee 24 Rack Mounting zu aaa aa u eal a 24 2 11 Installing the A Series Monitorand Keyboard 27 Installation Procedure 1 e RII Ih 27 2 12 Installing a Terminal in an S Series System 28 Recommended Terminal for S SeriesSystems 28 Installation Procedure enne 28 2 13 Installing the Extemal Front Panel 29 Controlsiand Indicato i us eae key EDUC ea Reed 29 Installing the Extemal Front Panel VER 30 2 14 Signal Interconnection Installation 0 0c cece ee 31 System Cable Connections 0 0 00 cee eee 31 Connecting the Robot to the PowerChassis 32 Installing Signal Cables Robotto MV Controller 33 Insta
39. power of the Adept PA 4 power chassis and the Adept MV 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 Risks That Cannot Be Avoided 1 16 The Adept 550 Robot Control system implementation has devices that 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 Take precautions to ensure that these situations do not occur Whatto Do in an Emergency Situation 12 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 Adept 550 Robot Instruction Handbook Rev A How to Get Help 1 17 How to GetHelp 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
40. 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 This is to protect a person who is in the workcell teaching points with the MCP during program development Also the motors run at reduced torque It is important to remember that the robot speed is not limited when the robot is in Automatic mode User Supplied E Stop Switc hes The specifications for user supplied E Stop and safety barrier switches are switches with positive driven contacts per EN60204 Section 10 73N1992 minimum switching power 24 VA minimum switching voltage 24 VDC minimum switching current 1 0 A DC 50 Adept 550 Robot Instruction Handbook Rev A Overview of Safety System WARNING Do not use switches in the E Stop circuit that do not comply with Category 1 requirements See Table 3 1 for the terminal assignments of the terminal block on the external Front Panel for the monitoring of the Emergency Stop switches on the Manual Control Pendant and the external Front Panel and the Hold to Run button on the MCP Teminal Block On External Front Panel Adept provides voltage free contacts on the terminal block on the back of the external Front Panel for monitoring the emergency circuitry components and other switches It is a vital part of your safety system You have access to voltage free contacts of the Emergency Stop switches on the Manual Control Pendant and t
41. the Joint 3 brake 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 is 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 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 Adept 550 Robot Instruction Handbook Rev A 29 Chapter 2 Installation PENDANT connector for attaching the Manual Control Pendant MCP to the front panel In order to enable High Power eithe
42. 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 42 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 Nominal Minimum Maximum Recommended Voltage Fiequencyr Operatin Operating Externa Ran 5 Phasing vel Ge 8 vel laa Circuit Breaker ange 8 8 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 Adept 550 Robot Instruction Handbook Rev A 39 Chapter 2 Installation Connecting the Power C hassis AC Power Cord The user end of the cord is unterminated Connect each conductor of the power cord securely to your AC power source using the color code shown in Table 2 8 The installation must meet all applicable European international and national standards and regulations Table 2 8 AC Power Cord Specific ations for Power Chassis Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating
43. the operating environment requirements shown in Table 2 2 See Table 2 5 on page 37 for electrical requirements Table 2 2 Operating Environment Requirements Ambient temperature controller while accessing floppy or hard drive 5 C to 40 C 32 to 104 F 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 chassis 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 and be rated at IP54 Also enclosure must provide a method of locking the enclosure power disconnect in the OFF position Adept 550 Robot Instruction Handbook Rev A 17 Chapter 2 Installation 2 3 Environmental and Facility Requirements Power C hassis 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 39 for electrical requirements 2 4 Before Unpacking Adept Equipment Carefully inspect all shipping crates for evidence of damage during transit Pay special att
44. 0 4A at 24 Vdc This rating must not be exceeded The specifications for the relay in the passive E Stop circuit are maximum switching power 10 VA volt amps maximum switching voltage 100 Volts DC 70 Volts AC rms maximum switching current 0 5 Amps DC 0 3 Amps AC rms CAUTION The power through the relay must not exceed 10 VA Adept 550 Robot Instruction Handbook Rev A Overview of Safety System Digital Inputs and Outputs of the System Input Output SIO Module The Digital I O connector on the SIO is a 50 pin high density D Sub female connector for digital I O communication There are 12 input channels and 8 output channels All channels are opto isolated The same connector also provides access to the Emergency Stop circuit E Stop input and Passive E Stop output To access this connector you will need a cable with a male 50 pin D Sub connector at one end not supplied with the system Input Signals The digital I O connector handles input signals 1001 to 1012 Each channel has an input and a corresponding return line Refer to Table 3 2 for input specifications The locations of the signals on the connector are shown in Table 3 4 Table 3 2 DIO Input Specifications SIO module Operational voltage range 0 to 24 VDC Off state voltage range 0 to 3 VDC On state voltage range 10 to 24 VDC Typical threshold voltage Vin 8 VDC Operational current range 0 to 20 mA
45. 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 4 Set operating keyswitch to AUTO and the other keyswitch to LOCAL Adept 550 Robot Instruction Handbook Rev A 65 Chapter 4 Commissioning the System 5 Press the COMP PWR button on the MCP 6 Press the blinking HIGH POWER ON OFF button on the VFP 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 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 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 Press the blinking HIGH POWER O
46. 3 Preparation for Safe and Effective Use of the Robot 52 Extemal E Stop Input Pins 42 and 44 on the Digital I O connector on the SIO module must be connected through a user provided normally closed NC safety circuit Multiple external emergency stop switches can be connected in series See Figure 3 2 The E Stop circuit should also be used to monitor other safety critical items including but not limited to safety barriers and encoder power supplies Pins 41 and 43 also comprise part of the E Stop circuit for most applications connect pin 41 to pin 43 Passive E Stop Output The passive E Stop output from the SIO module consists of a normally open voltage free relay contact Itis controlled by signals received from the external E Stop devices and the MCP and Front Panel E Stops See Figure 3 2 The passive E Stop output uses only electro mechanical relays to monitor the E Stop circuits Many safety codes 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 passive E Stop output is rated at 10 VA for example 0 8A at 12Vdc or
47. 3 Drive Belt Drive Belt Joint 3 Brake Assembly Figure 5 3 Location of J oint 3 and J oint 4 Drive Belts 6 Re install the Joint 3 brake assembly making sure the spacers are in place see Figure 5 4 and that the brake assembly fits correctly You may have to move Joint 3 up or down slightly to ensure the brake assembly meshes correctly with the mechanism on Joint 3 Secure the brake assembly with the 4 screws 7 Install the access cover using the 4 screws you removed earlier Make sure the cable ruming along the inside of the opening is not pinched when you install the access cover Adept 550 Robot Instruction Handbook Rev A 77 Chapter 5 Maintenance Joint 3 Motor INN s Im Spacer M3x8 screw IT a Joint 3 Drive Belt Joint 3 Brake Assembly Figure 5 4 Close up View of J oint 3 Brake Assembly 78 Adept 550 Robot Instruction Handbook Rev A Maintenance and Inspection of Air Filters 5 5 Maintenance and Inspection of Air Filters 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 n
48. Adept550 Robot Instruction Handbook Including Adept550 CleanRoom Robot ear Adept550 Robot Instruction Handbook Including Adept550 CleanRoom Robot 00556 00100 Rev A February 1996 Le weert 150 Rose Orchard Way San Jose CA 95134 USA Phone 408 432 0888 Fax 408 432 8707 AN s Otto Hahn Strasse 23 44227 Dortmund Germany Phone 0231 75 89 40 Fax 0231 75 89 450 ca 11 Voie la Cardon 91126 Palaiseau France Phone 1 69 19 16 16 Fax 1 69 32 04 62 Via don Luigi Sturzo 39 41 52100 Arezzo Italy e 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 for submitting your comments Copyright 1996 by Adept Technology Inc All rights reserved The Adept logo is a registered trad
49. Circuit Breakerand Fuse Infomation sass saua naaa 45 Removing and Installing AmplifierModules 45 2 18 Installing End Effectors on an Adept 550 Robot 46 2 19 Removing and Installing the User Hange een nnn 47 Removing De Fange s uu u suu ua URW aka eee 47 Installing the Flange r a 47 2 20 User Connections on Robot ccccccoccccn sen nnn nan 48 UserAIE Les sui sua A a ES WAKE wea was S ewes ES 48 User ElectricalLines i s IA 48 Adept 550 Robot Instruction Handbook Rev A Environmental and Facility Requirements for Robot 2 1 Environmental and Facility Requirements for Robot Facility Ambient Air Quality For Robots Table 2 1 Operating Environment Specific ations for Adept Robots Temperature Relative Humidity IP Rating 5 to 40 C 5 to 95 IP 20 Standard Rokot 41 to 104 F non condensing CleanRoom 5 to 40 C 5 to 95 IP 20 Robot 41 to 104 F non condensing a The IP rating also applies to the motors inside the robot Robot Workcell Free Space The workcell design should allow the Adept 550 freedom of movement within the area specified in Figure 6 13 on page 95 Additional allowances maybe required to accommo date any installed end of arm tooling 2 2 Environmental and Facility Requirements for Controller The Adept MV controller installation must meet
50. GH POWER light or the PROGRAM RUNNING light on the external Front Panel VEP 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 injury can occur if a person is struck by the robot Manual Mode Adept robots can also be controlled manually when the operating mode key switch is in the MANUAL position and the HIGH POWER light on the VFP is illuminated When Manual mode is selected motion can be only initiated from the Manual Control Pendant MCP Per 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 Adept 550 Robot Instruction Handbook Rev A 11 Chapter 1 Safety 1 14 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 Safety Aspects While Performing Maintenance 1 15 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
51. M6 x 12 mm dowel pin is also supplied in the accessories kit This dowel pin fits in the through hole in the user flange and can be used as a keying or anti rotation device in a user designed end effector 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 15 on page 36 Also see Chapter 6 for dimensions of the user flange 46 Adept 550 Robot Instruction Handbook Rev A Removing and Installing the User Flange 2 19 Removing and Installing the User Hange The user flange can be removed and reinstalled if this is required for a specific reason If the flange is removed it must be reinstalled in exactly the same position to avoid losing the calibration for the system There is a setscrew on the flange that holds the rotational position of the flange on the quill shaft A ball bearing behind the setscrew contacts the shaft in one of the vertical spline grooves in the shaft Follow the procedures below to remove and replace the flange assembly Removing the Range 1 Turn off High Power and system power to the robot 2 Remove any attached end effectors or other tooling from the flange 3 Use a 2 5 mm Allen driver to loosen the setscrew see Figure 2 20 Note the vertical spline groove that is in line with the setscrew You must replace the flange in the same position 4 Use a Torx 25 driver to loosen the two M5 To
52. N OFF button on the VFP NOTE In Manual mode the V operating system may take approximately 8 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 VFP 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 Manual 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 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 forces Calibration involves limited robot motion Observe all safety precautions 66 Adept 550 Robot Instruction Handbook Rev A Moving the Robot with the MCP 4 8 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 Figure 4 3 Command CMD Functi
53. Saa hka dd AEDE di 45 Amplifier Module Fuses Ih 45 Removing and Installing AmplifierModules 45 Removing Amplifier Modules aaua a aaa 45 Installing AmplifierModules 46 2 18 Installing End Effectorson an Adept 550 Robot 46 2 19 Removing and Installing the User Flange 47 Removing the Flange 47 Installing the Fonge 47 2 20 UserConnectionson Robot ooooccocco tees 48 UserAirlies i5 leniccikelekeeiER a a mri Rex 48 UserElectricallines i itune tt sen ia a e kuupa Qua k ia A 48 3 Preparation for Safe and Effective Use ofthe Robot 49 3 1 Overview of Safety System 1 a 50 Introduction its ese dd ada dde 50 Operating in Manual Mode eee 50 User Supplied E Stop Switches 50 Terminal Block On Extemal Front Panel 51 ExtemabE Stop INDUE sic uyu ns ae eed 52 Passive E Stop Outputs copii a a a a eee ee 52 Digital Inputs and Outputs of the System Input Output SIO Module 53 det Dee ele 53 Output Signals si rara ata RE TN 54 Digital I O Connector Pinouts uasa ae 55 Typical Emergency Stop Cum 57 4 Commissioning the System 9 41 IntroductiOrn xax a E IS ERR dn hs BAG eR RR e ee EROS 60 4 2 Check Of Physical Connections eere 60 Phy
54. ables Robotto MV Controller The 8 meter cable between the robot and the VJI module in the Adept MV controller is called the Arm Signal cable It is permanently attached at the robot and the controller end has a 50 pin D sub connector See Figure 2 10 1 Connect the 50 pin D sub connector to the Arm Signal connector lower on the VJI module See Figure 2 12 2 Tighten the two captive screws securely VJI Module in 6 Adept MV Controller vui es O OHE 1002 s00 sQOs TL Install VJl to Amp cable here AVPUFER SIGNAL ENCODER ss Install Arm Signal cable here SIGNAL Figure 2 12 Robot to VJI Cable Installation Adept 550 Robot Instruction Handbook Rev A 33 Chapter 2 Installation 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 Installing Signal Cables MV Controller to Power Chassis The VJI to Amp cable must be installed between the controller and the power chassis This cable assembly has a single plug on one end for the VJI and four plugs on the other end for the amplifiers 1 Connect the cable end with the single connector to the connector marked Ampli fier Signal upper on the VJI module Tighten the screws See Figure 2 10 2 The other end of the cable with four plugs mus
55. al Shutdown and Start up Passed without qualification IEC1131 2 Surge Passed without qualification IEC1000 4 5 to level 3 2 kV common mode on I Os only Radiated Emissions Passed without qualification EN55011 for group 1 ISM to Class A 2 dB Conducted Emissions Passed without qualification EN55011 for group 1 ISM to Class A 2 dB Adept 550 Robot Instruction Handbook Rev A 105 A AC power connecting power cord to controller 38 connecting to controller 37 connecting to power chassis 39 installation diagram for 200 240VAC 41 installation diagram for 380 415VAC 41 requirements for controller 37 requirements for power chassis 39 voltage current ratings controller 37 power chassis 39 Adept 550 robot specifications 93 working envelope 95 air lines user inrobot 48 air quality facility requirements for robot 17 amplifier module connections indicators 44 fuses 45 installing 46 interlock circuit 46 removing 45 Arm Signal cable installation 33 A Series controller installation 27 Auto keyswitch position 29 Automatic mode how to use 61 B B amplifier module connections indicators 44 Brake Release button 62 brakes description 62 releasing for manual movement 62 releasing J3 for manual movement 62 Index C cable connections system 31 calibration how to perform 66 Category 1 risk assessment 4 circuit breaker on power chassis 45 CleanRoom robot operating environment specifications 17
56. al degrees of freedom which may be either fixed in a place or mobile for use in industrial automation applications is called a manipulating robot ISO 10218 1992 E Adept 550 Robot Instruction Handbook Rev A Chapter 1 Safety 1 2 Notes Cautions and Wamings 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 WARNING If in a WARNING the actions are indicated with a 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 1 System 1 3 Provided that instructed personnel who enter Adept 550 robot work envelope are wearing protective headgear eyeglasses and safety shoes it is highly unlikely that the Adept 550 Robot could cause permanent injury Further due to its small size light payload capacity and limited reach it is highly likely that such pers
57. and two amplifier modules require additional cables that are shipped with the system It is important to keep the cables organized and prevent cables from being interchanged by mistake The table below shows a typical arrangement for cable assignments Table BL Typical Robot VJ I Amplifier Assignments in Dual Adept 550 Robot System Robot Number VJI Module Power Chassis Amplifier Module 1 1 Left 1 1 2 2 2 Right 2 12 Make sure to clearly label or mark the cables so it will be obvious which robot they belong to in case the cables have to be disconnected and re installed B 3 Operation with the Manual Control Pendant MCP The optional MCP can be used to control either robot in a Dual Adept 550 robot system By default the MCP controls robot 1 To switch to robot 2 press the DEV F3 button on the MCP The DEV LED turns on in this condition To switch back to robot 1 press the DEV F3 button again The DEV LED turns off See Section 4 5 for more information on using the MCP B 4 Programming Information V Language Programming By default Task 0 is used to control robot 1 Task 1 is normally recommended for robot 2 Use the SELECT ROBOT 2 and ATTACH instructions in your program to select robot 2 See the V Language User s Guide and the V Language Reference Guide for more information on these instructions V Monitor Commands By default monitor commands such as HERE and WHERE apply to r
58. andards EN 55011 1991 Class A EN 50082 2 1992 EN 292 1992 EN 60204 1 1992 IP20 EN 954 Category 1 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 Robot 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 instructions specified in Adept Instruction Handbook for Category 1 Operation per EN 954 3 The Robot 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 This Declaration is based upon extensive tests and evaluation by TUV Rheinland a Notified Body in their Project Number E9572254 The complete File is available at the California address Place San Jose California USA Signed Date 1 February 1996 Full Name Richard J Casler Jr Position Vice President Engineering P N 01554 00000 Rev P1 English Manufacturer s Declaration as defined in Machinery Directive 89 392EEC Appendix IIB We herewith declare that the machine as delivered by us complies with the relevant and fundamental safety and health requirements
59. bars Use your right hand for all the other function buttons O Depress the palm activated Hold to Run switch Figure 4 1 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 Adept 550 Robot Instruction Handbook Rev A 63 Chapter 4 Commissioning the System Description of Buttons on the MCP Liquid Crystal Display LCD Soft k 1 _ Buttons predefined lt Function Manual State LEDs Speed Bars Emergency Stop Switch Mode Control Buttons Joint Axis Control Buttons Hold to Run AN Switch Bur Power Figure 4 2 MCP 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 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 64 Adept 550 Robot Instruction Handbook Rev A How to Stop a Robot in Manual Mode 46 How to Sto
60. 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 36 Adept 550 Robot Instruction Handbook Rev A Connecting to AC Power 2 16 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 16 and Figure 2 17 Connecting AC Powerto the MV Controller The Adept MV controller can operate at two different voltage settings On the identification 1D 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 All 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 z Mis Recommended Nominal Minimum Maxim
61. ctive 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 C hassis Grounding The protective ground conductor colored green 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 Adept Robot Grounding The major parts of the robot are connected to the ground point on the base of the robot see Figure 2 11 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 Robot Mounted Equipment G rounding The following parts of an Adept 550 robot are not grounded to protective earth the Joint 3 quill the user 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 see Figure 2 11 Hazardous voltages can
62. cts 1 The person has received the instruction handbook has read it has understood it and 2 will work in the described manner 1 10 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 10 Adept 550 Robot Instruction Handbook Rev A Safety Equipment for Operators 1 11 Safety Equipment for Operators 1 12 Adept advises operators to wear extra 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 13 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 Adept 550 robot has 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 HI
63. cution and one to select the operating mode Before itis possible to use the MCP in the workcell the operating keyswitch 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 than 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 External Front Panel VFP SYSTEM HIGH POWER O e AUTO g POWER ON OFF er O O NETWORK START RUNNING d i MCP Bypass Plug Install if no MCP Manual Control Pendant Figure 2 14 MCP Connection MCP Cradle The MCP is stored in the MCP cradle when 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 be installed outside of the robot workcell See Figure 6 9 on page 90 for the dimensions of the cradle Adept 550 Robot Instruction Handbook Rev A 35 Chapter 2 Installation 2 15 Grounding Information AdeptMV Controller Grounding The detachable three wire power cord is used for connection to the power source and the protective ground The prote
64. d E Stop circuits as described in Chapter 1 and Chapter 3 43 VFPOperating 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 Control Pendant MCP In Manual mode it is not possible to initiate a motion with the system keyboard This protects the operator in the workcell for 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 60 Adept 550 Robot Instruction Handbook Rev A VFP Operating Modes See section 1 11 on page 11 for a description of safety equipment to be worn by an operator who is working in the robot workcell 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 VFP are illuminated do not enter the workcell because the robot or motion device might move unexpected
65. 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 EEC relativa a macchinari Appendice IIB Si dichiara che la macchina come da noi fornita soddisfa i requisiti fondamentali definiti nella direttiva CE Appendice Lin 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 01554 00000 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 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 V JI III Table 2 Plug in Modules and Accessories that may be installed in MV 8 and MV 19 Controllers but mu
66. e 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 Set the 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 Adept Utility Programs 28 Adept 550 Robot Instruction Handbook Rev A Installing the External Front Panel 2 13 Installing the Extemal Front Panel SYSTEM HIGH POWER gt MANUAL AUTO POWER I ON OFF EMERGENCY STOP Le wee LSZ PROGRAM PROGRAM PENDANT LOCAL NETWORK START RUNNING OO Ns Figure 2 8 Extemal 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 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 disables High Power and engages
67. e 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 15 on page 36 for important information on system grounding Table 2 6 Adept MV Controller Power C ord Specific ations Cord length 3 meters 40 1 m 9 ft 10 in 4 in Cord rating 10 amps Number and size of 3x1 00 mm conductors Color code line brown neutral blue ground green yellow 38 Adept 550 Robot Instruction Handbook Rev A Connecting to AC Power Connecting AC Powerto the Adept PA 4 Power Chassis 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 voltage 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
68. ead screw M4 x 25mm pan head screw 2 places 2 places o o 5 o o o o o o o o i o o 1 M4 x 10mm pan head screw M4 x 10mm pan head screw Rack Mount Flush Rack Mount Set Back Figure 2 5 Installing Mounting Brackets on an Adept MV Controller Adept 550 Robot Instruction Handbook Rev A 25 Chapter 2 Installation M4 x 25mm pan head screw 2 places o o o To Install Mounting Brackets on Adept PA 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 S o accessories kit Repeat process for other side of chassis If the S s 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 8 on page 89 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 4 o o o o T o o M4 x 10mm pan head screw M4 x 10mm pan head screw Rack Mount Flush Rack Mount Set Back Figure 2 6 Installing Mounting Brackets on an Adept PA 4 Power Chassis 26 Adept 550 Robot Instruction Handbo
69. eed 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 required 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 6 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 com
70. eft hand side called Module 1 drives motors 1 and 3 The amplifier module on the right hand side called Module 2 drives motors 2 and 4 Connectors and Indicators DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY EXTINGUISHED O O nien vours on OO Pwmon O O towvoLrson O O oPen ckr enr O O tv sacioven Teme O O snort rautt B1 B2 A BEE EE E d 4ev4co Imgov oos 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 PWM On indicates that current servo is on It does not go on until calibration is complete 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 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 on an amplifier module Short Fault indicates that an over current in the motor leads has been detected Amplifier Control connector the VJI to Amp cable connectors are installed here Note the Teach Restrict connector is not used on an Adept 550 robot system Motor Power Output connector the Motor Po
71. emal Front Panel Dimensions 88 Adept 550 Robot Instruction Handbook Rev A Dimensions Dimensions of the Mounting Brackets 3 2 mm AN CAN CAN CAN 22 2 mm mu 133 35 mm e a o e ele ele ello e ele ele ele e 7 IIIa o O 479 mm a 146 05 mm P P P P E o 133 35 mm er eletet etete 6 8 mm 4x o e elo ole ole ely e ele ele ele e Oo Y EE e H tj D E E E o III WORD eco MU xd ie Controller and Power Chassis with mounting Ax brackets installed Figure 6 8 Adept MV 8 and PA 4 With Mounting Brackets Installed Adept 550 Robot Instruction Handbook Rev A 89 Chapter 6 Technical Specification MCP Cradle Dimensions 4 X 10 2 mm 0 4 2x f J EN 28 7 mm 1 13 271 5mm 10 69 lt 4 X 4 8 mm 0 188 A 49 7 mm 2 0 38
72. emark of Adept Technology Inc Adept AdeptOne AdeptOne MV AdeptThree AdeptThree MV PackOne PackOne MV HyperDrive Adept 550 Adept 550 CleanRoom Adept 1850 Adept 1850XP A Series S Series Adept MC Adept CC Adept IC Adept OC Adept MV 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 MV 5 P N 30340 10000 or MV 10 P N 30340 20000 PA 4 Power Chassis P N 30336 31000 B Power Amplifiers P N 10338 51000 Manual Control Pendant MCP III P N 90332 48050 VME Front Panel Category 1 P N 90332 00380 550A Mechanism Model Number 556 for standard Model Number 557 for cleanroom covered under a Declaration of Incorperation 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 st
73. ention to tilt and shock indication labels if they are present 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 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 Adept 550 Robot 0 64 m 25 in 0 64 m 25 in 1 14 m 45 in 50 kg 110 lb Adept MV Controller 0 89 m 35 in 0 64 m 25 in 0 96 m 38 in 66 kg 145 lb and PA 4 Power 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 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 1 WARNING Heavy load Do not attempt to transport the robot boxes by hand Always use a pallet jack fork lift etc Adept 550 Robot Instruction Handbook Rev A Unpacking and Inspecting the Adept Equipment 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 sta
74. finition of industrial 3 dimensions 82 dual 550 system 102 104 grounding 36 how to start 65 how to stop in Manual mode 65 intended uses 7 jointlocations 2 maintenance 74 78 mounting bolt specifications 21 mounting procedure 20 mounting surface 20 moving with MCP 67 Adept 550 Robot Instruction Handbook Rev A 109 Index operating environment specifications 17 shipment specifications 18 specifications 93 speed limited in Manual mode 50 static forces 5 transport and storage 18 unpacking and inspection 19 user flange dimensions 83 working area 9 working envelope 95 robot modifications acceptable 8 unacceptable 9 robot mounted equipment grounding 36 S safety 4 12 during maintenance 12 equipment for operators 11 expelling a part 6 impact and trapping points 6 qualification of personnel 10 required safeguards 5 sources for information 7 safety barriers requirements 5 SCARA 2 softstops description 71 SPEC utility program tosetsoftstops 71 speed bars on MCP 68 S series controller installation 28 system cable connections 31 system grounding information 36 System Power switch on External Front Panel 29 T technical support contact information 13 temperature required range power chassis 18 robot 17 U user air lines in robot 48 electrical lines in robot 48 user flange dimensions 83 V vertical stroke specification 93 VFP see External Front Panel VJI to Amp cable installation 34 VMEbus addres
75. g 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 to resist being expelled from the robot Table 1 3 Maximum Robot oint Velocities in Runaway Situations Joint 1 maximum angular velocity 660 degrees second Joint 1 maximum linear velocity 4 2 meters second Joint 2 maximum angular velocity 1375 degrees second Joint 2 maximum linear velocity measured at 12 3 meters second user flange These velocities can only occur in a runaway or mechanical failure situation These are 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 Example 2 kg payload mounted at user flange maximum possible projectile energy 1 2 2kg 20 8m s 432 J 318 ft Ib 6 Adept 550 Robot Instruction Handbook Rev A Intended Use of the Robots 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
76. he external Front Panel Additionally there are contacts for monitoring the Hold to Run switch on the MCP the position of the System Power and Operating Mode switch on the external Front Panel See Table 3 1 for assignment of the terminals The voltage free contacts can be used to create additional safety circuitry or to monitor the existing one For instance you can control additional contactors with the voltage free contacts that turn on and off the power supply to the PA 4 power chassis Then it is only possible to enable High Power to the motors of the robot if the E Stop circuitry is closed See Figure 3 3 for an example of additional safety equipment that uses the voltage free contacts on the external Front Panel and the external E Stop Inputs on the SIO Module in the Adept MV Controller Table 3 1 Terminal Assignment of the Terminal Block on the Back ofthe VFP Number Description QA System Power switch on the external Front Panel contacts are closed when power is turned on Operating Keyswitch on the external Front Panel contacts are closed in Manual mode Emergency Stop switch on the external Front Panel N C Emergency Stop switch on the Manual Control Pendant N C N MINI DY SH AI O 9 Hold to Run switch on the Manual Control Pendant N O o HE m not used A N not used Adept 550 Robot Instruction Handbook Rev A 51 Chapter
77. ion eee ences 12 117 Howto GetHelp o cococococnc rh nnn nhanh 13 In Europeu sep E Rus ee E a ERE este tee ka jn tee Re hee Wine 13 In the United Gates 13 Outside Continental United StatesorEurope 14 Adept 550 Robot Instruction Handbook Rev A 1 Chapter 1 Safety 1 1 Introduction The Adept 550 robot is a four axis SCARA Selective Compliance Assembly Robot Arm robot Joints 1 2 and 4 are rotational and Joint 3 is translational See Figure 1 1 for a description of the robot joint locations The Adept 550 robot is 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 Joint 3 Joint 1 Shoulder Inner Link b TN re c Be gt ER 5 B RIT 7 ENE Adept MV 8 Controller Adept PA 4 Power Chassis Figure 1 2 Adept MV 8 Controller and PA 4 Power Chassis Adept 550 Robot Instruction Handbook Rev A Introduction Adept Equipment Compatibility The Adept 550 Category 1 robot system 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
78. ion tii A A 2 Adept Equipment Compatibility o oooooooommmmmo oo 3 Definition of a Manipulating Industrial Robot 3 1 2 Notes Cautions and Wamings iieesseeee nr mmn 4 1 3 Risk Assessment Category 1 System ccccccocccc nnn n nnn 4 1 4 Precautions and Required Safeguards esee rn 5 Robot Static Forces eee eee REV UY A EN ARENS 5 Safety Barmes ota uo E ota eed MCA SE M fede e Qe See iR ie Sod dt 5 Additional Safety Information liiis 7 1 5 Intended Use ofthe Robots 0cococcocco een nnn ann 7 1 6 Robot Modifications 0oococcooccc eser h hh nh hn 8 Acceptable Mod ificationSs mh 8 Unacceptable Mod atons uaaa 9 1 7 Endangement Through Additional Equipment 9 1 8 Working ATeaS coocccccn heh hh hh ahhh nha khan 9 1 9 Qualification of Personnel 0cccccccc rrr hmmm mme 10 1 10 Ranspott 2 oa REY AA WQ QK eR n a n Rc R Aa W RR RR AE R 10 1 11 Safety EquipmentforOperatolS ococccoococccc n m nn nnn 11 1 12 Protection Against Unauthorized Operation 11 1 13 Operating Modes of AdeptRoboORS 0oooocoooooco oo 11 Automatic Mode 11 ManualMode ooccoccocoo ees 11 1 14 Safety Aspects While Performing Maintenance 12 1 15 Risks That Cannot Be Avoided 0ocooccooocococo n nn nnn 12 1 16 Whatto Do in an Emergency Situat
79. is 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 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 18 Installing End Effectors on an Adept 550 Robot The user is responsible for providing and installing any end effector or other end of arm tooling End effectors can be attached to the user flange using either four M6 screws or a ring clamp hardware for both are supplied in the accessories kit An
80. is ready to move Joint 4 Press the positive speed bar until the robot starts moving When it 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 If every joint the robot moved correctly in both directions the installation of the hardware is correct Then press the DIS PWR button on the MCP to disable High Power Adept 550 Robot Instruction Handbook Rev A Limiting Joint Travel 4 9 Limiting J oint Tavel The joint motion range or travel is limited by both software and hardware The program mable software limits are known as softstops The fixed mechanical stops are called hardstops Softstops Softstops are used when the 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 Joi
81. ith 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 minal for S Series Systems The recommended terminal for use with the Adept MV controller 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 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 th
82. ities in Runaway Situations 6 Sources for Intemational Standardsand Directives 7 Operating Environment Specifications for Adept Robots 17 Operating Environment Requirements 17 Adept Shipping Crate Specifications 18 Mounting Bolt Specifications 21 Adept MV Controller Power Requirements 37 Adept MV Controller Power Cord Specifications 38 Adept PA 4 Power Chassis Power Requirements 39 AC Power Cord Spec ificationsforPower Chassis 40 Terminal Assignment of the Terminal Block on the Back of the VFP 51 DIO Input Specifications SIO module on the Security Panel 53 DIO Output Specifications SIO module 54 Digital I O Connector Pin Assignmentson SIO Module 55 Softstop and Hardstop SpecificationS 71 Inspection and Maintenance 1 74 Adept 550 Robot Specifications 93 Power Consumption for PA 4 Power Chassis with an Adept 550 System 96 Adept 550 CleanRoom Robot Vacuum Specifications 98 Typical Robot VJ l Amplifier Assignments in Dual Adept 550 Robot System 103 EMG Test Results 2 aoe Sse reus avere me ee Sea Race AA 105 Adept 550 Robot Instruction Handbook Rev A LI Intoductl
83. l Adept 550 Robot Instruction Handbook Rev A 9 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 9 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 only by skilled or instructed persons For a description of the level of qualification Adept uses the standard terms Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers 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 All 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 subje
84. l Installation 30 Adept 550 Robot Instruction Handbook Rev A Signal Interconnection Installation 2 14 Signal Interconnection Installation System Cable Connections Controller Module 1 ES Module 2 YT VJl to Amp Cable J HE o Fret Power Chassis v O C O O m 0 o iN H 4 JI fal I III i 1 phase ha Power Cord Front Panel Cable v E O O O S 3 Arm Signal Cable 8 meter Motor Power Nu e meis Adept 550 Robot Figure 2 10 Adept 550 Robot System Cable Installation Adept 550 Robot Instruction Handbook Rev A 31 Chapter 2 Installation Product Data Label Arm Signal Cable Brake Release f f Button User Electrical Lines User Air Lines Motor Power Cable O Robot Ground Figure 2 11 Adept 550 Robot Rear Panel Connecting the Robotto the Power Chassis The 8 meter cable between
85. lled The robot workcell must be designed according to ISO 10218 sections 5 6 EN292 1 3 71 and EN60204 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 the Adept 550 robot are Category 1 systems that 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 as well as detecting intrusion signals from safety barriers See Chapter 3 for information on safe and effective use of the robot Adept 550 Robot Instruction Handbook Rev A 5 Chapter 1 Safety Impact and Tapping Points Figure 1 3 Robotimpactand 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 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 Partor Attac hed Tooling The maximum joint and user flange tip speeds that can be obtained on the Adept 550 robot in a runaway situation are listed in Table 1 3 Any toolin
86. lling Signal Cables MV Controllerto PowerChassis 34 Connecting the MCP to the VFP 35 MGCP Cradley yu eee serenade terete EE 35 2 15 Grounding Infomation nnn 36 Adept MV ControllerGrounding a 36 Adept PA 4 Power ChassisGrounding 36 Adept Robot Grounding 0 0 c eee ete 36 Robot Mounted Equipment Grounding 36 2 16 Connecting to AC POWOT u vesci Q bee 14 been REENEN ied 37 Connecting AC Powerto the MV Controller 37 Adept 550 Robot Instruction Handbook Rev A Table of Contents AC Power Requirements a 1 1 37 Power Entry Module nnn 37 Connecting AC PowerCord a 38 Connecting AC Powerto the Adept PA 4PowerChassis 39 AC Power Requirements for Power Chassis 39 Connecting the Power Chassis AC Power Cord 40 Typical AC Power Installation Diagrams 41 Changing Voltage Setting forPowerChassis 42 2 17 Additional Power Chassis Infomation sausas 44 Overview of B AmplifierModule 44 Connectorsand Indicators o coccocococorcr 44 Circuit Breakerand Fuse Information auauua a 45 Chassis Circuit Breaker osn taae ebam ataa EOM aiai m EA M AAA e a A EN 45 Chassis USES aldea poa ae AWA
87. ly 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 CAUIION The LAMP TEST button on 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 COMP 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 Adept 550 Robot Instruction Handbook Rev A 61 Chapter 4 Commissioning the System 4 4 Using the Brake Release Button 62 Brakes Joints 1 2 and 4 have dynamic brakes that are used only to stop the robot in an emergency condition such as when the emergency stop circuit is open or a robot joint passes its soft stop These brakes will not prevent you from moving the robot manually once the robot has stopped and High Power has been removed Joint 3 has an electric brake The brake is off when high power is enabled When High Power is turned off the brake actuates and holds the position of Joint 3 Brake Release Button Under some circumstances you may want to manually position Joint 3 without turning on High Power For such instances a Brake Release button is located on the robot backplate see Figure 2 11 on page 32 When system power is on pressing the button releases the
88. mblies must be installed inside a suitable enclosure The controller and power chassis sub assemblies must not come into contact with liquids The Adept equipment is not intended for use in any of the following situations Adept 550 Robot Instruction Handbook Rev A 7 Chapter 1 Safety In hazardous explosive atmospheres In mobile portable marine or aircraft systems In life support systems n residential installations In situations where the Adept equipment will be subject to extremes of heat or humidity See specifications for allowable temperature and humidity ranges WARNING Impact Hazard It is prohibited to stay in the workcell while the robot is in Automatic Mode The robot can trap you with high speed The impact can hurt you WARNING The given instructions about operation installation and maintenance in this Instruction Handbook must be strictly observed Non intended use of an Adept 550 Robot can cause injury to the personnel damage the robot or other equipment reduce the system reliability and the performance of the system All persons that are involved in installation commissioning operation and maintenance of 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 intended use or not 1 6 RobotModifications It is of
89. n selects the next state to the right Tool Joint or Free eventually wrapping back to the 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 2 on page 64 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 1 4d Fast Figure 4 5 Speed Bars 68 Adept 550 Robot Instruction Handbook Rev A Moving the Robot with the MCP Selecting J oint State and Moving the Robot Figure 4 6 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 downwa
90. nal input 52 External E Stop input 52 External Front Panel 29 30 controls indicators 29 dimensions 88 installation 30 F fan filter cleaning in controller 79 fan filter cleaning in power chassis 79 force specification 93 fuses amplifier module 45 chassis 45 G grounding system information 36 H hardstops description 71 specifications 71 hazards from expelling a part 6 High Power enable process description of 50 High Power On Off switch on External Front Panel 29 humidity required range power chassis 18 robot 17 I installation AC power 37 43 dual550 robotsystem 102 External Front Panel 30 joining power chassis to controller 22 keyboard 27 monitor 27 power chassis in rack or panel 24 power cord to controller 38 required tools 20 system cable connections 31 J Joint motion Joint1 91 Joint2 91 Joint3 92 Joint4 92 joint resolution specification 93 joint rotation specification 93 joint speed specification 94 Joint state with SCARA robot 69 K keyboard installation 27 L Lamp Test button on External Front Panel 29 Lefty configuration 91 108 Adept 550 Robot Instruction Handbook Rev A Index Local keyswitch position 29 lubrication Joint3 75 M maintenance check mounting bolts 74 check robot leveling 74 checking drive belts 76 checking VFP lamps 79 cleaning controller fan filter 79 cleaning power chassis fan filter 79 recommended schedule 74 Manual Control Pendant calibrating robo
91. ndicated in Figure 2 4 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 9 9 OO dE Bracket OO OO OO OO OO Adept MV 8 Adept PA 4 Controller Power Chassis Figure 2 4 Joining the Power Chassis and Controller atthe Bottom Adept 550 Robot Instruction Handbook Rev A 23 Chapter 2 Installation 24 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 CAUIION It is important to keep the air filters clean so the forced air cooling system can work efficiently See section 5 5 on page 79 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 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 accesso
92. nding on the robot base could damage the robot Eyebolt for lifting robot after robot has been unbolted from the transportation pallet Place forklift or pallet jack here Figure 2 1 Adept 550 Robot on a Transportation Pallet Unpacking and Inspecting the Adept Equipment 2 7 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 packaging materials These items may become necessary to settle claims or at a later date to relocate equipment Repackaging For Relocation 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 mounting base 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 Adept 550 Robot Instruction Handbook Rev A 19 Chapter 2 Installation 2 9 Robot installation
93. nts 1 2 and 3 have hardstops at each end of the joint s travel Joint 4 does not have hardstops However its motion is limited by software and its soft stops can be set to further limit Joint 4 motion see above NOTE Joint 4 can be rotated an infinite number of turns To avoid wind up of harnesses going to end of arm tooling Joint 4 should always be left at 90 degrees in joint coordinates when powering down the controller This ensures that when the system is next powered on and the robot is recalibrated it calibrates in the same Joint 4 orientation without winding up user harnesses ble 4 1 Softstop and Hardstop Specifications Softstop RE Joint 1 2100 3108 Joint 2 140 149 Joint 3 0 to 200 mm 13 to 213 mm CleanRoom 0 to 180 mm 13 to 195 mm Joint 3 Joint 4 3360 max None Adept 550 Robot Instruction Handbook Rev A 71 Maintenance 5 1 IMIOAUCHON ooccc rr rh hh hh hh hah 74 5 2 Checking Robot Mounting Bolts and Leveling 74 5 3 Lubricate Joint 3 Ball Screw 2 eee rn m m nnn 75 5 4 Check Tension and WearOnJ3 and J 4 Drive Belts 76 5 5 Maintenance and Inspection of AirFilters 79 Adept PA 4 Fan Filter Inspection and Cleaning 79 Adept MV Controller Fan Filter Inspection and Cleaning 79 5 6 Check Lamps on VPP suseesera sehn hanh nhan ann 79 Ade
94. o the workcell while power is present These devices would open the E Stop circuit and shut down High Power when activated Make sure sufficient E Stop switches are provided in the workcell so they can be easily reached in an emergency It is possible to control different safety features in relation to the AUTO MANUAL operating mode keyswitch and the terminal block on the external Front Panel Together with the Adept Controller system you have various control features to construct indi vidual system safeguards including e Terminal block on the external Front Panel Emergency stop circuitry Digital input and output lines Operating in Manual Mode An important function of the Emergency Stop system is to protect the operator in Manual mode To work in Manual mode the operator switches the lower keyswitch on the VFP to the LOCAL position and the operating mode keyswitch upper one 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 MCP The system starts the process to enable High Power The steps are outlined in the following list High Power enable process in Manual mode takes about 8 seconds VFP HIGH POWER ON OFF push button starts blinking operator presses the VFP HIGH POWER ON OFF button The system waits until the HIGH POWER ON OFF push button is pressed If the button has not been pressed in a
95. obot 1 Use the monitor command SELECT ROBOT 2 first when you need to display the location of robot 2 NOTE The DISABLE POWER command shuts off high power to both robots in a Dual Adept 550 robot system Adept 550 Robot Instruction Handbook Rev A 103 Appendix B Dual Adept 550 Robots The CALIBRATE monitor command will calibrate both robots Robot 1 will be calibrated first then robot 2 If you want to temporarily disable either robot and continue to use the other you can use the DISABLE ROBOT command For example DISABLE ROBOT 2 will cause V to ignore robot 2 If you issue this command before you use the CALIBRATE command then only one robot will be calibrated Robot 1 can be then used normally To re enable robot 2 use the command ENABLE ROBOT 2 Emergency Stop Circuit Shuts Off Both Robots B 5 104 The Adept MV controller has many safety features including the Emergency Stop circuit These are designed to safely stop both robots simultaneously in the event of a problem The Adept multi robot system is designed for multiple robots operating in the same workcell Therefore if one robot has a fault the other robot will also be stopped A brief message will be displayed indicating the problem The message will also state which joint s and which robot is affected The most common system messages are described in the V Operating System User s Guide A full list of system messages with complete explanation and sugges
96. ok Rev A 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 See Figure 2 7 for details the steps are listed below 1 Make sure the controller is turned off before making any connections e r VGB S oco omo PEA Oz A Series Color Monitor Os Os A Series Keyboard Trackball S TI EEETEIEEEEIEEELIELTUICLETIEI II Il I I I l y y 11 Il Ill I I pty I yy yy KEYBOARD II Il rtr rp rrr rjr nant gd II I I II e Figure 2 7 Connecting the A Series Monitor and Keyboard 2 Connect the monitor signal cable to the MONITOR connector on the VGB module 3 Connect the double ended keyboard cable to the KEYBOARD connector and the POINTER connector on the VGB module Adept 550 Robot Instruction Handbook Rev A 27 Chapter 2 Installation 4 Verify the voltage range marked on the monitor is compatible w
97. on 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 Moving the Robot with the MCP This section describes how to use the MCP to move the robot Follow the steps on page 65 to enable High Power and to calibrate the robot Do rot 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 skilled or instructed robot operator see Section 1 9 on page 10 wearing the safety equipment given in Section 1 11 on page 11 is allowed to work with the robot Adept 550 Robot Instruction Handbook Rev A 67 Chapter 4 Commissioning the System MAN HALT Button for Selecting J oint State The MAN HALT button changes the state being used to move the robot Figure 4 4 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 agai
98. onnel could avoid being hit by the robot even in a high acceleration runaway failure condition In consideration of these factors prEN1050 specifies use of a Category 1 Control System per EN954 EN954 defines a Category 1 Control System as one that employs Category B components designed to withstand environmental influences such as voltage current temperature EMI and that employs well tried safety principles The Adept 550 control system Control System described in this Handbook employs hardware components in its safety system that meet or exceed the requirements of the Machinery and Low Voltage Directives Further the control system is fully hardened to all EMI influences per the EMC Directive See Appendix C and meets all functional requirements of I5010218 Manipulating Robots Safely In addition a soft servo mode has been incorporated to limit impact forces on the Operator and production tooling when the robot is operated in Manual Mode In consideration of the above the Adept 550 Control System meets or exceeds the requirements imposed by the EN954 specified Category 1 level of safety as evidenced by the Manufacturer s Declaration at the front of this Handbook Adept 550 Robot Instruction Handbook Rev A Precautions and Required Safeguards 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
99. p a Robotin 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 MCP Press the DIS PWR Disable Power button on the MCP e Press the HIGH POWER ON OFF button on the VFP 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 pressing the Disable Power button 47 Howto Startthe 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
100. pressed air to clean the filter 4 Replace the cleaned air filter and secure the grill Check Lamps on VFP 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 Adept 550 Robot Instruction Handbook Rev A 79 Technical Specification 6 1 Dimensions ida a a a wir A 82 Dimensions for Adept 550 Robor 2c eee leere 82 User Flange DimensionsforAdept550Robot 83 Dimensions for Adept MV 8 Controller 85 Dimensions for Adept MV 19 Controller 86 Dimensions for Adept PA 4 Power Chassis 87 Dimensions of the ExtemalFrontPanel 88 Dimensions of the Mounting Brackets 89 MCP Cradle Dimengdons 1 90 6 2 Joint Motions EE Aaa 91 JOINED oe de yk eee us ea e x wax x ee ea we EG a EG 91 NOIRE 2 c w LESS SPESE neat wea das d m ER dat 91 FONES zc scd sen m E e eR i 92 Joint AA serm mb de esie Boro Sia aie RR eater Re 92 6 3 Adept550 Robot Specifications ccooooccono rrr 93 Adept 550 Robot Working Envelope 95 6 4 Adept PA 4 Power Chassis Specifications lesen 96 Adept 550 Robot Instruction Handbook Rev A 81 Chapter 6 Technical Specification 6 1 Dimensions Dimensions for Adept
101. pt 550 Robot Instruction Handbook Rev A 73 Chapter 5 Maintenance 5 1 Introduction See Table 5 1 for a summary of the preventive maintenance procedures and guidelines on frequency Table 5 1 Inspection and Maintenance Item Period Reference Check robot mounting bolts 6 months See section 5 2 Check leveling of base 6 months See section 5 2 Lubricate Joint 3 Z axis ball 3 months See section 5 3 screw Check tension of Joint 3 3 months See section 5 4 Z axis drive belt Check tension of Joint 4 drive 3 months See section 5 4 belt Check air filter in PA 4 power 1 month See section 5 5 chassis Check lamps on VEP using 1 month See section 5 6 Lamp Test button 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 9 on page 10 The access covers on the robot are not interlocked turn off disconnect power if covers have to be removed 5 2 Checking Robot Mounting Bolts and Leveling Check the tightness of the base mounting bolts every 6 months Tighten to 85 Nm 50 ft Ib Also check the tightness of all cover plate screws and all the captive screws of the cables
102. r in San Jose California USA 1 408 434 5000 1 408 433 9462 FAX service requests 1 408 434 6248 FAX application questions 14 Adept 550 Robot Instruction Handbook Rev A Installation 2 1 Environmental and Facility Requirements forRobot 17 Facility Ambient Air Quality Forbobots 17 Robot Workcell Free Space 17 2 2 Environmental and Facility Requirements for Controller 17 2 3 Environmental and Facility Requirements Power Chassis 18 2 4 Before Unpacking Adept Equipment esee nnn nn nnne 18 2 5 Adept Shipment Specifications leere nnn nnn nnn 18 2 6 Transportand Storage EE nsn hh nhanh aan 18 2 7 Unpacking and Inspecting the Adept Equipment 19 2 8 Repackaging ForRelocation sese nnn nnn nnn 19 2 9 Robot installati0N 0o0ooccooocoo hh hh nmn nhan 20 Mountrig SurfaiCe tr uu SET REED IE uha e Ru EV 20 Tool and Equipment Requirements s s sasan annae a 20 Mounting Procedure nn 20 2 10 Installation of the Adept MV Controller and the AdeptPA 4 PowerChasSSiS ooccococccoocc hh hh EE 22 Joining an Adept PA 4 Power Chassisto an Adept MV Controller 22 Space Around the Chassis osse u em RR RR EE 24 Installation in a RackorPanelMount 24 2 11 Installing the A Series Monitor and Keyboard
103. r the MCP or the supplied pendant jumper plug must be connected Installing the Extemal Front Panel VFP The VFP can be mounted in a standard 19 inch equipment rack See Figure 6 7 on page 88 for dimensions Since the back of the VFP is open make sure that it is securely mounted 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 See Figure 2 9 as you follow the procedure below 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 the 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 MCP install the MCP bypass plug in the MCP connector of the VFP If you are using an MCP refer to page 35 sio SIO Module 2 Meter Front Panel Cable o e 5 el gi Geste External Front Panel VFP LAMP SYSTEM HIGH POWER D Test MANUAL AUTO POWER ON OFF E crier O O Sech eg poga nemon RU Hog O O 800 E A S Figure 2 9 Extemal VME Font Pane
104. rd Before the speed bars will move a joint the correct joint must be selected from the Joint Axis control buttons Joint 2 Jimi 2 Joint 1 Joint 2 e E JJ Joint 3 E Joint 3 Sg S mg m Joint 4 Joint 4 Figure 4 6 J oint 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 One of 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 4 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 Adept 550 Robot Instruction Handbook Rev A 69 Chapter 4 Commissioning the System 70 Selecting and Moving J oint 1 Before you can move Joint 1 you must select it with the MCP On the right side of Figure 4 6 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
105. ries kit See Figure 2 5 and Figure 2 6 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 5 and Figure 2 6 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 Adept 550 Robot Instruction Handbook Rev A Installation of the Adept MV Controller and the Adept PA 4 Power Chassis M4 x 25mm pan head screw 2 places po 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 SL 2 with indicated M4 screws and washers from accessories kit to o Repeat process for other side of controller If the controller is joined to an Adept PA 4 Power Chassis the position of the screws is different on the side of the controller See the drawing for the power chassis o o o M4 x 10mm pan head screw Note See Figure 6 8 on page 89 for dimensions of the controller and mounting brackets 9 Panel Mount M4 x 25mm pan h
106. rx head screws 5 Slide the flange down slowly until itis off of the shaft Be careful not to lose the ball bearing 3 5 mm which is inside the flange behind the setscrew Quill shaft User flange assembly m M5 Torx head screws Setscrew Figure 2 20 User Hange Removal Details Installing the Hange 1 Make sure the ball bearing is in the setscrew hole inside the flange Hold it in place with your finger as you get ready to install the flange 2 Slide the flange up on the quill shaft as far as it will go and rotate until the setscrew is lined up with the original vertical groove 3 Support the flange while using a 2 5 mm Allen driver to tighten the setscrew to finger tight Do not over tighten the setscrew because this will cause the flange to be off center from the quill shaft 4 Usea Torx 25 driver to tighten one of the M5 Torx head screws part of the way then tighten the other one the same amount Alternate between the two screws so there is even pressure on both once they are tight The torque specification for each screw is 8 Nm 70 in Ib Adept 550 Robot Instruction Handbook Rev A 47 Chapter 2 Installation 2 20 User Connections on Robot 48 User Air Lines There are five user air line connectors on the robot back panel see Figure 2 11 on page 32 The five air lines run through the robot up to another set of five matching connectors on the top of the outer link The two larger connectors are 6 mm diameter
107. s 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 the 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 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 Adept 550 Robot Instruction Handbook Rev A 45 Chapter 2 Installation CAUIION 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 chass
108. s for dual 550 robot system 102 voltage changing setting on power chassis 42 maximum operating controller 37 power chassis 39 minimum operating controller 37 power chassis 39 W weight controller 94 powerchassis 94 robot 94 110 Adept 550 Robot Instruction Handbook Rev A 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 Adept 550 Robot Instruction Handbook Rev A de caer adept technology inc 150 Rose Orchard Way San Jose CA 95134 00556 00100 Rev A JOUER SOOO
109. sening two screws and swinging the grill out 3 Inspect the voltage setting it is marked on the front of the voltage selector plug To change the voltage setting remove the selector rotate it 180 so the required setting is shown and replace it See Figure 2 19 4 Close the grill and secure the two screws 5 Clearly mark or alter the ID label on the side of the chassis to show the new voltage configuration 6 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 7 Re connect the power chassis to the AC power source Adept PA 4 Power Chassis with Front Air Intake Grill Removed EA adept O CD technology inc 380 415 V 380 415 V Voltage Selector Plug Voltage elector in 380 415 V position Socket Figure 2 19 Changing Voltage in Power Chassis Adept 550 Robot Instruction Handbook Rev A 43 Chapter 2 Installation 2 17 Additional Power Chassis Information Overview of B Amplifier Module The B Amplifier module is a plug in module that contains the circuitry and amplifying components to drive two of the motors in an Adept 550 robot In a typical Adept 550 robot system there are two identical B Amplifier modules in the Adept PA 4 power chassis The amplifier module on the l
110. sical Connections s hu ees 60 4 3 VFP Operating Modes 0 cece tees 60 Adept 550 Robot Instruction Handbook Rev A ix Table of Contents ManualOperating Mode 60 Automatic Operating Mode tees 61 4 4 Using the Brake Release Button 62 Brak8S 244 uk DR dA sob ede ndm Ed a deu 62 Brake Release Button 62 4 5 Description of the Manual Control Pendant MCP 63 How to Hold the MCP 0 0 00 cece nn 63 Description of Buttons on the MCP ee 64 Mode Control and Joint Axis Control Buttons 64 Speed Bars logs E Rr AERA bk MAR Ee diay Seba mae we 64 4 6 How to Stop a Robot in ManualMode 65 4 7 How to Start the Robot 0 0 cette 65 Enable High Power with the MCR tee 65 In Automatic Mode ooooococoo eene 65 In Manual Mode 66 Calibration of the Robot with the MCP 66 4 8 Moving the Robot with the MCP eh 67 MAN HALT Button for Selecting Joint State 68 Joint Axis Control Buttons 68 Speed Bars nu AA ua kuu aqa Bow AETHERE ORARE 68 Selecting J oint State and Moving the Robot 69 Selecting and Moving Joint1 70 Selecting and Moving Joint 2 70 Selecting and Moving Joint 3 70 Selecting and Moving Joint4
111. st 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 01554 00000 Rev P1 Table of Contents E M TE 1 TLI Introductlom avr A A MEA eI CE EE E 2 Adept Equipment Compatibility oooooooooomoo 3 Definition of a Manipulating Industrial Robot 3 1 2 Notes Cautions and Wamings rns 4 1 3 Risk Assessment Category 1System 4 1 4 Precautions and Required Safeguards 5 Robot Static Fores ru u a MMA Qu mika u sa 5 Safety Bam liada eh eee Rei e u u Ua u 5 Impact and Trapping Points s a saaaa a 6 Hazards from Expelling a Part or Attached Tooling 6 Additional Safety Information a 7 1 5 Intended Use ofthe Robots rn 7 1 6 Robot Modifications 8 Acceptable Modifications mh 8 Unacceptable Mod atons l l 9 1 7 Endangerment Through Additional Equipment 9 L8 Wotklig Areas cier pe bee eee eG eee eS EE Eee 9 1 9 Qualification of Personnel tae 10 1 10 Transp Olin yuya Q cee keh ba Se eRe REX WAR nae ed A owiehe a re a 10 1 11 Safety Equipment forOperators 1
112. standards Table 1 4 Sources for Intemational Standards and Directives BSI British Standards Institute Sales Department Linford Wood Milton Keynes MK14 6LE United Kingdom Phone 0181 996 7000 EN 60204 EN 954 EN292 EN 294 IEC 1131 73 447 Phone 030 26 01 22 60 Fax 0302601 12 60 Phone 0181 996 7001 Beuth Verlag GmbH EN 60204 EN 954 EN292 EN 294 10722 Berlin IEC 1131 73 447 Germany IEC International Electrotechnical Commission 1 Rue de Varembe 1211 Geneva 20 Switzerland Phone 022 34 01 50 EN 60204 EN 954 EN292 EN 294 IEC 1131 73 447 American Electronics Association Europe 40 Rue des Drapiers 1050 Brussels Belgium Phone 322 502 7015 Fax 322 502 6734 15 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 Adept 550 robot is intended for use in small parts assembly and material handling for payloads typically less than 5 5 kg 12 1 Ib WARNING For safety reasons it is prohibited to make certain types of modifications to Adept robots see section 1 6 The Adept MV controller and the Adept PA 4 power chassis are intended for use as component sub assemblies of a complete industrial automation system The controller and power chassis sub asse
113. t 66 connection on External Front Panel 30 dimensions for cradle 90 how to use 63 70 installation 35 Manual mode High Power enable process 50 how to stop robot 65 how to use 50 60 robot speed limited 50 60 Manual keyswitch position 29 maximum payload specification 93 MCP see Manual Control Pendant mode control buttons on MCP 68 monitor installation 27 Motor Power cable installation 32 mounting brackets dimensions 89 install positions controller 25 power chassis 26 installation 24 N Network keyswitch position 29 O operating environment specifications controller and power chassis 17 robots 17 Operating keyswitch on External Front Panel 29 operating modes Automatic 11 61 Manual 11 60 P panelmounting 24 Passive E Stop 52 Pendant connection on External Front Panel 30 power chassis AC power requirements 39 changing voltage setting 42 circuit breaker 45 connecting to controller 34 connecting to robot 32 dimensions 87 fuses 45 grounding 36 interlock circuit 46 joining to controller 22 panel mounting 24 rack mounting 24 power cord from power chassis specifications 40 power entry module on controller 37 Program Running lamp on External Front Panel 29 Program Start switch on External Front Panel 29 Q qualification of personnel 10 R rack mounting 24 reach specification 93 repeatability specification 93 Righty configuration 91 risks that cannot be avoided 12 robot calibrating from MCP 66 de
114. t be connected in the following special pattern See Figure 2 13 a Connect the plug labeled Amplifier Ctrl 1 to the B1 connector on Module 1 b Connect the plug labeled Amplifier Ctrl 3 to the B2 connector on Module 1 c Connect the plug labeled Amplifier Ctrl 2 to the B1 connector on Module 2 d Connect the plug labeled Amplifier Ctrl 4 to the B2 connector on Module 2 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 connector could get pulled out or dislodged unexpectedly Module 1 A cos Module 2 Amplifier Amplifier Ctrl 1 Ctrl 2 Amplifi VJI to AMP Cable Su ei to VJI Module S oO Amplifier in MV Controller Ctrl 3 e slo Figure 2 13 Power Chassis to VJI Cable Installation 34 Adept 550 Robot Instruction Handbook Rev A Signal Interconnection Installation Connecting the MCP to the VFP The MCP is connected to the system at the Pendant connector on the VFP see Figure 2 14 See Chapter 4 for instructions on using the MCP Install the MCP to the connector that is marked PENDANT on the VFP VARNING The VFP has two keyswitches One to select the device that controls program exe
115. ted user actions is in the V Language Reference Guide Examples of faults that can be detected by the Adept control system are Envelope error and Motor stalled Both of these messages may mean that a robot has collided with an unexpected object in the workspace therefore both robots will be stopped The Emergency Stop signal will also stop both robots connected to the same controller It is not possible to use the E Stop signal to stop only one robot The Emergency Stop switches on the external Front Panel VFP and the Manual Control Pendant MCP shut off high power to both robots when the switch is pressed Adept 550 Robot Instruction Handbook Rev A EMC Test Information C 1 Electromagnetic Compatibility Testing Results The Adept 550 robot meets all applicable requirements as mandated by the EMC Directive Table C 1 summarizes the test results of some of the most critical tests Table C 1 EMC Test Results Test Performed Status Fast Transient Burst FTB Passed without qualification IEC61000 4 4 to level 3 2 kV power 1 kV I O Electrostatic Discharge ESD Passed without qualification IEC61000 4 2 to level 4 8 kV contact discharge Radiated Immunity Passed without qualification ENV50140 to level 3 10 V m 80 100 MHz 80 mod 1 kHz Conducted Immunity Passed without qualification ENV50141 to level 3 10 V Damped Oscillatory Passed without qualification IEC255 4 1 kV Gradu
116. ten necessary to make modifications to Adept robots to successfully integrate them into a workcell Unfortunately many seemingly simple modifications can either cause a robot failure or reduce the robot s performance reliability or lifetime 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 Any loads attached to the moving robot parts must be considered part of the payload 8 Adept 550 Robot Instruction Handbook Rev A Endangerment Through Additional Equipment 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 Modific ations 1 7 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 cas
117. the robot and power chassis is called the Motor Power cable It is permanently attached at the robot and has two square connectors on the power chassis end This cable carries high voltage DC power to the motors This independent DC circuit can only be isolated using the circuit breaker on the front of the Adept PA 4 power chassis See Figure 2 10 WARNING Turn off the power to the power chassis before installing or removing any cables Failure to observe this warning could cause injury or damage to your equipment Do not turn on the power chassis without installing the motor power cables Dangerous AC and DC voltages may be present at the Motor Power Output connectors on the amplifier modules 32 Adept 550 Robot Instruction Handbook Rev A Signal Interconnection Installation NOTE The system integrator must add adequate strain relief for the Motor Power cable connectors at the amplifier modules 1 Connect the Motor Power cable to the two matching connectors on the amplifier modules in the following order a Install the plug labeled B Amp 1 in the connector marked Motor Power Output on Module 1 b Install the plug labeled B Amp 2 in the connector marked Motor Power Output on Module 2 2 Pull gently on the connector bodies to ensure they are securely latched WARNING Verify that all connectors are secure and fully inserted Failure to do this could cause unexpected robot motion Installing Signal C
118. ting Modifying any robot electrical component or PC board other than those explicitly stated in the robot instruction handbook Routing additional hoses air lines or wires through the robot Endangerment Through Additional Equipment 1 8 Additional equipment for instance grippers conveyor belts etc are not allowed to reduce the safeguarding of the workcell All Emergency Stop Switches must be always accessible All components in the robot workcell must comply with the safety requirements in the European Machine Directive 89 392 EEC and subsequent amendments and the related harmonized European international and national standards Working Areas Adept robots have both a Manual and an Automatic operating mode While in Automatic mode no personnel are allowed to stay in the workcell In Manual mode operators with additional safety equipment see section 1 11 on page 11 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 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 9 on page 10 for the specifications of the personne
119. to backplane Passive E Stop Output 0 8 A at 12 VDC 0 4 Aat 24 VDC Se Spree Sasa see text Enable LE Stop System Power 5 Controller Switch Q O a O z a DE A O 21 Q 3 Terminal Block MCP Bypass q at the back of the VFP Plug install Enable ao in system Power 41 User External E Stop Devices A N N System SY hp e oaio Faults SC External E Stop Input lt Figure 3 2 E Stop Diagram with VFP and MCP Adept 550 Robot Instruction Handbook Rev A 57 58 Chapter 3 Preparation for Safe and Effective Use of the Robot User supplied 24 V or 12V Ki Terminal block on external Front Panel T ees 1 2 3 4 5 6 7 s ondi A System Power Lo OOOOOOO JOOOOJO Switch VFP E STOP TB 2 TB 6 Pin 44 on digital I O TR connector on SIO Module E n MCP E STOP External E Stop Input e TB K 4 TB 9 MCP Hold to Run TB 10 E User External C E Stop Device TB 3 Safety Gate TE Operating Muted in 7 Mode Manual Mode Switch TB 4 N User External E Stop Device b Pin 42 on digital I O connector o on SIO Module K1 K2 K3 LJ e Ground The implementation of the K3 High Power contactor is not necessary to achieve Category 1 operation per EN 954 Note This drawing is ONLY an example for the implementation of additional safeguards 3 es L1 L2 L3 N
120. um B A Frequency External Circuit Voltage Operating Operating Ran Phasing Voltage Voltage Breaker ange 8 8 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 the On Off power switch 2 0n O Off the AC power cord socket the two incoming AC line fuses Adept 550 Robot Instruction Handbook Rev A 37 Chapter 2 Installation tE adept technology inc NON CO CH NANANA WARNING FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE U wu UU EN Figure 2 15 Adept MV Controller Power Entry Module C C H 2 2 2 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 The installation of the power cord must be done by a skilled person The power supply can injur
121. wer cable is installed here 44 Adept 550 Robot Instruction Handbook Rev A Additional Power Chassis Information Power Chassis Circuit Breaker and Fuse Information 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 Service at the numbers listed in Chapter 1 Chassis Fuses The six chassis fuses F1 to F6 are located on the power control board These fuses are not user replaceable If you suspect that a chassis fuse may have blown contact Customer Service Amplifier Module Fuses 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 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 chassi

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