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1. Safety 2 1 Dangers Warnings Cautions and Notes There are four levels of special alert notation used in this manual In descending order of importance they are DANGER This indicates an imminently hazardous situation which if not avoided will result in death or serious injury injury or major damage to the equipment WARNING This indicates a potentially hazardous N situation which if not avoided could result in serious CAUTION This indicates a situation which if not avoided could result in minor injury or damage to the equipment NOTE This provides supplementary information emphasizes a point or procedure or gives a tip for easier operation AdeptViper s650 s850 Robot User s Guide Rev A 13 Chapter 2 Safety 2 2 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 CAUTION Adept Technology strictly prohibits installation commissioning or operation of an Adept robot without adequate safeguards These must be compliant with applicable local and national standards Installations in EU and EEA countries must comply with EN 775 ISO 10218 especially sections 5 6 EN 292 2 and EN 60204 1 especially section 13 Definition of a Manipulating Industrial Robot The definition of a manipulating robot according to ISO 10218 1992 E is as follows A manipulating robot i
2. Workable space defined by point P Be d 360 190 _ ne Figure 7 2 AdepiViper s650 Top Dimensions and Work Envelope 64 AdeptViper s650 s850 Robot User s Guide Rev A Robot Dimensions 779 88 E MED 779 88 485 0 l 305 d i 218 b Point P 5 ast NG S i S i i LO I4 A Ni 5 S Workable space i defined by point P Y Figure 7 3 AdepiViper s850 Side Dimensions and Work Envelope AdeptViper s650 s850 Robot User s Guide Rev A 65 Chapter 7 Technical Specifications Workable space a defined by point P po lm 4 b _ J6 J4 N 1 Ce 9 O o 5 ks N pa 190 Figure 7 4 AdeptViper s850 Top Dimensions and Work Envelope 66 AdeptViper s650 s850 Robot User s Guide Rev A Robot Flange Dimensions 7 2 Robot Flange Dimensions 0 40 h8 0 039 4X M5 x 0 08 8 Deep 31 5 B C 0 021 Q20 H7 M 6 Deep Figure 7 5 Robot Flange Dimensions AdeptViper s650 s850 Robot User s Guide Rev A 67 Chapter 7 Technical Specifications 7 3 Specifications Table 7 1 Robot Specifications Specification s650 s850 Overall arm length 270 first a
3. 0 00 cee eee 53 5 5 Caution Label on Robot 1 1 eee ee eee 54 6 AdeptViper s650s 850 Robot User s Guide Rev A Table of Contents 5 6 Status Panel Codes on sDAI Module 0 0 cc eee eee 55 6 Maintenance suse RR 57 6 1 Installing and Using Brake Release Box sssssessrsr an 57 6 2 Replacing Encoder Backup Battery 0 0 2 cc eee rer rr rr rss 58 6 3 Installing User Supplied Hardstops 00 ccc eee 61 7 Technical Specifications 2 0 00 cee ees 63 7 1 Robot Dimensions u 3 serie nn 63 7 2 Robot Flange Dimensions lessen 67 7 3 SPCCIIIGGHONS in a 68 OD Se ne NGN KG DAMN TT GN KO re ee BN HS hee eee 71 AdeptViper s650s 850 Robot User s Guide Rev A 7 Table of Contents 8 AdeptViper s650s 850 Robot User s Guide Rev A Introduction 1 1 Product Description AdeptViper s650 s850 Robots The AdeptViper s650 and AdeptViper s850 are high performance six axis robots designed specifically for assembly applications The speed and precision of the AdeptViper robots also make them ideal for material handling packaging machine tending and many other operations requiring fast and precise automation NOTE The descriptions and instructions in this manual apply to both the AdeptViper s650 and the AdeptViper s850 except for instances where there is a difference as in dimension and work envelope drawings In those cases the information is p
4. 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 AdeptViper s650 s850 Robot User s Guide Rev A Precautions and Required Safeguards Hazards From Expelling a Part or Attached Tooling The maximum joint tip speeds that can be achieved by the robot are listed in Table 9 1 on page 83 Any tooling fixtures end effectors etc mounted to the user flange or one of the other axes of the robot must be attached by sufficient means to resist being expelled from the robot Additionally any payload must be held by the end effector in a manner that prevents the payload from being expelled accidentally 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 mv 2 NOTE In the Projectile energy formula above E Energy eM Mass eV Velocity 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 Table 2 1 on page 16 lists some sources for the various standards AdeptViper s650 s850 Robot User s
5. amp B S Q 4X 012 THRU For M10 OT Diamond shaped pin Figure 3 2 Mounting Hole Pattern for Robot 1 See Figure 3 2 for the dimensions of the mounting holes in the robot mounting position where the robot unit is to be secured Drill four bolt holes M10 20 mm deep or more e Drill a dowel pin hole 04 H7 for diamond shaped pin 10 mm deep or more Drill a dowel pin hole 06 H7 for internally threaded positioning pin 10 mm deep or more 2 Locate two alignment pins one round and one diamond shaped supplied in the accessory kit 3 Drive the diamond shaped pin into the 4 H7 hole so that it orients as shown in Figure 3 2 4 Drive the internally threaded alignment pin into the 06 H7 hole NOTE Be sure to drive the alignment pins It can minimize positional deviations that may be caused by the removal installation of the robot unit for maintenance or the vibration during operation 30 AdeptViper s650 s850 Robot User s Guide Rev A Grounding the Robot 5 Set the robot unit into place on the robot mount When transporting the robot unit follow the instructions given in Section 3 3 on page 27 6 Secure the robot unit to the mount with four bolts and plain washers e Bolt M10 x 30 mm strength class 12 9 e Tightening torque 70 14 Nm 3 5 Grounding the Robot Ground the grounding terminal of the robot unit with a wire of 12 AWG or more Ground resistance must be less than 100 millio
6. on sDAI sDIO 1 SmartController NG XDIO Connector 12 Input signals 1001 to 1012 8 Output signals 0001 to 0008 Figure 5 2 Connecting Digital I O to the System AdeptViper s650 s850 Robot User s Guide Rev A 51 Chapter 5 System Operation Table 5 2 Default Digital I O Signal Configuration Single Robot System Location Type Signal Range Controller XDIO connector Inputs 1001 1012 Outputs 0001 0008 sDIO Module 1 Inputs 1033 1064 Outputs 0033 0064 sDIO Module 2 Inputs 1065 1096 Outputs 0065 0096 sDIO Module 3 Inputs 1201 1232 recommended Outputs 0201 0232 sDIO Module 4 Inputs 1233 1264 recommended Outputs 0233 0264 IO Blox 1 Inputs 1113 1120 Outputs 0105 0112 IO Blox 2 Inputs 1121 1128 Outputs 0113 0120 IO Blox 3 Inputs 1129 1136 Outputs 0121 0128 IO Blox 4 Inputs 1137 1144 Outputs 0129 0136 2 For sDIO modules 3 and 4 you must configure the signals using CONFIG_C to have the system support those modules See the Adept SmartController User s Guide for additional information on that process 52 AdeptViper s650 s850 Robot User s Guide Rev A Installing Axis Labels 5 4 Installing Axis Labels The system includes a set of axis directional labels that can be installed on th
7. SMIF ZX S Series UltraOne V V and VisionTeach 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 Table of Contents 1 introduction 00 0 0 cece ccc ccc ccceceececueeecuceeeeturees 9 1 1 Product Description 0 cee nenn 9 AdeptVipers 50 s850 RODO as waa mia 21a 2 npa eed ogee as Q Adept SmanConmoller CX xa ana na 10 Adept PAA ATIS Power CIOSSIS sez 534 aa v kare ae 10 1 2 Installation Ovewiew i 2 0 Rees RR RR 11 1 3 Manufacturer s Declaration 1 2 0 00 cc eee 11 1 4 How Can I Get Help 0 4 paanan tee ee ek eR a a 12 Related MIGMUGIS nassen Aut MG PROD oa Ho oboe dee rs 12 Adeptibecutrnenr UBIA x34 63 8 ace CG Rd ER Ra oiea EEG SERS 12 E A A A A A A E AT 13 2 1 Dangers Warnings Cautions and Notes ers eee eee rr rr eee 13 2 2 Precautions and Required Safeguards 2c cee eee 14 Definition of a Manipulating Industrial Robot 2 rr a 14 SOE Bie lS waxes arenas AA Utada a Pato bP doc ees 14 Impact and Trapping POINIS ss serber ene eme es 14 Hazards From Expelling a Part or Attached Tooling 15 Additional Safety Information 1 4 aaa 15 2 3 Risk Assessment 5 3 00 0482046400046 en owe RIS Ere a dcm Ea 17 EXPOSUNG 5 24 53 ecg ana 17 sevetihy OF InjUty pana Banag RG NG anna 17 Ae ee CA are ee ton EAN ee 18
8. 6 Allowable Range of Center of Gravity Position of End effector AdeptViper s650 s850 Robot User s Guide Rev A 35 Chapter 3 Robot Installation Moment of Inertia Around J4 J5 and J6 Design an end effector so that its moments of inertia around J4 J5 and J6 including workpiece do not exceed the maximum allowable moment of inertia of the robot Moment of inertia around J4 J5 and J6 of end effector including mass of workpiece must be less than or equal to the maximum allowable moment of inertia Maximum allowable moment of inertia around J4 and J5 0 295 kgm Maximum allowable moment of inertia around J6 0 045 kgm When calculating the moment of inertia around J4 J5 and J6 of the end effector use the formulas given in Table 3 3 and see examples in Figure 3 7 on page 37 Table 3 3 Moment of Inertia Formulas 1 Cylinder 1 4 Sphere Axis of rotation Center axis Axis of rotation Center axis ga 2mr Meu 2 Oylinder 2 5 Center of gravity not on the axis of rotation The axis of rotation passes through the center of gravity ls Inertia moment around center of gravity kgm 1 1 m2 3 Rectangular parallelepiped The axis of rotation passes through the center of gravity Moment of inertia b Mass c Ta Radius YA I Fy b c Length 12 NENNEN 36 AdeptViper s650 s850 Robot User s Guide Rev A Designing End Effectors Calculation example When calculating
9. Pilot type cross section Cv an Binata pressure range 0 1 to 0 7 Mpa 5 to 50 C Ambient temperature No dew condensation allowed When dry air is used 1 2 mm Operating voltage 24 V 10 Power consumption current 0 5 W 21 mA Solenoid 2 M4 16 DEEP 2 M3 7 DEEP 104 5 VS 6556E 100 VS 6577E 2 M5 12 DEEP 2 M8 25 DEEP Unit mm Figure 3 5 External Mounting Holes on Robot 34 AdeptViper s650 s850 Robot User s Guide Rev A Designing End Effectors 3 8 Designing End Effectors Design an end effector such that it is in compliance with items described in this section CAUTION If the end effector design precautions are not observed the clamped parts of the robot unit may become loose rattle or be out of position In the worst case the mechanical parts of the robot and robot controller may become damaged Mass of End Effector Design the end effector so that the total mass of the end effector including workpiece will be lighter than the maximum payload capacity of the robot The total mass includes the wiring piping etc Maximum total mass of end effector including workpiece must be less than or equal to maximum payload capacity 5 kg Center of Gravity Position of End Effector Design an end effector so that the center of gravity position of the end effector including workpiece is within the range shown in Figure 3 6 Figure 3
10. XSLV connector on the sDAI module and tighten the latching screws Install the Arm Power Signal cable between the CN22 connector on the robot and the Arm Power Signal connector on the PA 4 Install a ground wire between the PA 4 and the SmartController AdeptViper s650 s850 Robot User s Guide Rev A Installing the PA 4 Power Chassis r J Amp 1 J Amp 2 r J Amp 3 SDAI Module Brake Release Status Panel RS 232 SmartServo 1 amp 2 Latching Screws EXPIO XSLV Interface Box D T Ext Brak Arm Power Signal ea Connector DDU 7 III Figure 4 2 Adept PA 4 Power Chassis with sDAI Module AdeptViper s650 s850 Robot User s Guide Rev A 41 Chapter 4 System Installation 4 4 Connecting 3 Phase AC Power to PA 4 PA 4 3 Phase Power Requirements Table 4 1 Adept PA 4 Power Chassis 3 Phase Power Requirements Recommended Nominal Minimum Maximum External Voltage Frequency Operating Operating Circuit Breaker Range Phasing Voltage Voltage user supplied 200 to 240 50 60Hz 180 VAC 245 VAC 20 amps VAC 3 phase 380 to 415 50 60Hz 342 VAC 424 VAC 20 amps VAC 3 phase with neutral Table 4 2 Typical Robot Power Consumption Average Power Peak Power Robot M
11. in Manual Mode by a skilled programmer see Qualification of Personnel on page 22 who must wear safety equipment see Safety Equipment for Operators on page 22 and carry the pendant T1 or MCP Therefore exposure of personnel to hazards related to the robot is limited seldom and or short exposure time Severity of Injury Provided that skilled personnel who enter the robot work envelope are wearing protective headgear eyeglasses and safety shoes it is likely that any injuries caused by the robot would be slight normally reversible AdeptViper s650 s850 Robot User s Guide Rev A 17 Chapter 2 Safety 18 Avoidance Due to its light payload capacity it is likely that such personnel could avoid being hit by the robot even in a high acceleration runaway failure condition However the programmer must always carry the pendant when inside the work envelope as the pendant provides both E Stop and Enabling switch functions For normal operation AUTO mode user supplied interlocked guarding must be installed to prevent any person entering the workcell while Arm Power is on DANGER The Adept supplied system components provide a Category 1 control system as defined by EN 954 The robot system must be installed with user supplied interlock barriers The interlocked barrier should interrupt the DC and AC supplies to the control system in the event of personnel attempting to enter the workcell when Arm Power is enab
12. indicate the operating status of the robot including detailed fault codes See Table 5 4 for definitions of the status codes These codes provide details for quickly isolating problems during troubleshooting See the Adept PA 4 Power Chassis User s Guide for additional information on the sDAI module Table 5 4 Status Panel Codes LED Status Code LED Status Code OK No Fault H High Temp Encoder Joint ON High Power ON Status hV High Voltage Bus Fault MA Manual Mode l Initialization Stage Step 24 24V Supply Fault IO 24V I O Fault Att Amp Fault Joint LV Low Voltage 24V Bit IO Blox Fault Address M Motor Stalled Joint bF Base Board Fault NV Non Volatile Memory AC AC Power Fault P Power System Fault Code D Duty Cycle Exceeded Joint PR Processor Overloaded E Encoder Fault Joint RC RSC Fault ES E Stop S Safety System Fault Code FM Firmware Mismatch SW Watchdog Timeout FW 1394 Fault V Hard Envelope Error Joint h High Temp Amp Joint AdeptViper s650 s850 Robot User s Guide Rev A 55 Chapter 5 System Operation 56 AdeptViper s650 s850 Robot User s Guide Rev A 6 1 Maintenance Installing and Using Brake Release Box The manual brake release box can be used to release the brakes on a specific axis of the robot This procedure describes how to install and use this device See Figure 6 1 on page
13. of the power cord securely to your AC power source using the color code shown in Table 4 3 The installation must meet all applicable European international and national standards and regulations Table 4 3 3 Phase AC Power Cord Specifications for PA 4 Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 25 amps Number and size of 5 x 2 5 mm2 conductor size Color code 200 240 VAC line 1 black line 2 black or gray line 3 brown no connection blue must be insulated ground green yellow Color code 380 415 VAC line 1 line 2 line 3 neutral ground black black or gray brown blue green yellow 2 Note The two black wires can also be one black and one gray wire but the functionality is the same for either case DANGER Electrical hazard person who installs the cord An incorrect installation can The installation of the power cord must be done by a IN skilled person The power supply can injure or kill the injure or kill anyone that touches the equipment in the robot workcell 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 the ground conductor must be connected to a properly grounded power source WARNING Ensure that a proper protective ground connection exists before turning on the power AdeptViper
14. reduce the workcell safeguards Emergency stop switches must be accessible at all times If the robot is to be used in an EU or EEA member country all components in the robot workcell must comply with the safety requirements in the European Machine Directive 89 392 EEC and subsequent amendments and related harmonized European international and national standards For robot systems these include EN 775 ISO 10218 sections 5 6 EN 292 2 and EN 60204 For safety fences see EN 294 In other countries Adept strongly recommends that a similar level of safety be obtained as well as complying with the applicable local and national regulations including SEMI S2 In the USA applicable standards include ANSI RIA R15 06 and ANSI UL 1740 In Canada applicable standards include CAN CSA Z434 Working Areas Adept robots have a Manual and an Automatic AUTO operating mode While in Automatic Mode personnel are not allowed in the workcell In Manual Mode operators with additional safety equipment see Section 2 10 on page 22 are allowed to work in the robot workcell For safety reasons the operator should whenever possible stay outside of the robot work envelope to prevent injury The maximum speed and power of the robot is reduced but it could still cause injury to the operator Before performing maintenance in the working envelope of the robot High Power must be switched off and the power supply of the robot must be disconnecte
15. the Robot 3 3 Transporting the Robot Precautions in Transporting Robot e The robot weighs approximately 30 kg Use a crane suitable for the robot weight e Have at least two workers handle this job e Workers should wear helmets safety shoes and gloves during transport Do not hold the first arm elbow either side of the 2nd arm 2nd axis cover or 3rd axis cover or apply force to any of them See Figure 1 1 on page 9 CAUTION Pass the hoisting wires through the specified eyebolts as illustrated below Passing them through other sections may drop the robot unit resulting in injuries to personnel or damage to the robot Wire Belt sling Waste Cloth Eyebolts Robot Mounting Bolts Figure 3 1 Robot in Hoisting Sling AdeptViper s650 s850 Robot User s Guide Rev A 27 Chapter 3 Robot Installation Transport Procedure Step Procedure Drawing 1 Before transportation set the robot in a transport position as shown at right by manually moving the second third and fourth axes When unpacked first the robot is in the transport position so this job is not required Transport Position Axis Angle First axis J1 0 Second axis J2 145 Third axis J3 243 Fourth axis J4 90 Fifth axis J5 90 Disconnect the robot control cable air piping and user signal cables from the robot unit When the robo
16. 3338 http www robotics org AdeptViper s650 s850 Robot User s Guide Rev A Risk Assessment 2 3 Risk Assessment Without special safeguards in its control system the AdeptViper robot could inflict serious injury on an operator working within its work envelope Safety standards in several countries require appropriate safety equipment to be installed as part of the system Table 2 2 lists some of the safety standards that affect industrial robots It is not a complete list Safeguards must comply with all applicable local and national standards for the location where the robot is installed Table 2 2 Partial List of Robot and Machinery Safety Standards International USA Canada Europe Title of Standard ISO 10218 EN 775 Manipulating Industrial Robots Safety ANSI RIA CAN CSA Industrial Robots and Robot R15 06 7434 94 Systems Safety Requirements EN 292 2 Safety of Machinery Basic Concepts General Principles for Design EN 954 1 Safety Related Parts of Control Systems General Principles for Design EN 1050 Safety of Machinery Risk Assessment Adept has performed a Risk Assessment for this product based on the intended applications of the robot The conclusions are summarized below Exposure When arm power is on all personnel must be kept out of the robot work envelope by interlocked perimeter barriers The only permitted exception is for teaching the robot
17. 500 mm surface Installation type Floor mount or Overhead mount Ambient temperature During operation 0 to 40 C During storage and transportation 10 to 60 C Humidity During operation 90 or less No dew condensation allowed During storage and transportation 75 or less No dew condensation allowed Vibration During operation 4 9 m s 0 5G or less During storage and transportation 29 4 m s 3G or less Safe Installation The robot should not be installed in an environment where Environment e there are flammable gases or liquids e there are any acidic alkaline or other corrosive gases e there is sulfuric or other types of cutting or grinding oil mist or there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise there are any shavings from metal processing or other conductive material flying about e it may be directly exposed to water oil or cutting chips Working space etc Sufficient service space must be available for inspection and disassembly e Keep wiring space 230 mm or more behind the robot and fasten the wiring to the mounting face or beam so that the weight of the cables will not be directly applied to the connectors Installation conditions Grounding resistance 100 milliohms or less See Figure 3 3 on page 31 26 AdeptViper s650 s850 Robot User s Guide Rev A Transporting
18. 58 WARNING Secure the robot prior to releasing the brakes AN on axes 2 and 3 to prevent injury to personnel or equipment damage 1 Make sure that high power is disabled off 2 Connect the 15 pin male D sub connector into the 15 pin female D sub connector marked Brake on the sDAI board 3 Press one of the E Stops Pendant Front Panel or external NOTE An E Stop must be activated in order for the brake release box to work 4 Using the axis selector switch select the axis that you want to release the brake 5 Depress the brake release pushbutton to release the brake 6 Repeat steps 4 and 5 above for releasing the brakes on another axis NOTE When the Status LED Green is on it indicates that the circuit is enabled when the brake release pushbutton is pressed AdeptViper s650 s850 Robot User s Guide Rev A 57 Chapter 6 Maintenance a Y i 234 O Axis selector switch mA ids 21 status LED PC be N oF BRAKE Brake Release Pushbutton N J 15 pin male D Sub connector Le ud Figure 6 1 Manual Brake Release Box 6 2 Replacing Encoder Backup Battery The encoder backup batteries should be replaced every two years Replace the batteries according to the procedure below 1 Prepare a new set of 3 backup batteries for replacement 2 Turn off AC power to the PA 4 and DC power to the controller 3 Remove the cover from the robot unit
19. A 4 power chassis AIR1 AIR air lines description 33 arm power signal cable installing 40 axisidentification onrobot 9 brake release box installation 57 C CN20 connector description 32 CN20 CN21 connector signal wiring 33 connecting AC power to PA 4 42 45 power chassis cord to AC supply 43 45 connectors on robot description 32 current voltage ratings power chassis 1 phase 45 power chassis 3 phase 42 Customer Service assistance 12 D definition of a Manipulating Industrial Robot 14 dimensions robot flange 67 Index s650 robot side view 63 s650 robot top view 64 s850 robot side view 65 s850 robot top view 66 Document Library CD ROM 12 E emergency situation what todo 24 end effectors flange dimensions 67 inertia 36 mass center of gravity 35 environmental requirements robot 26 external mounting holes onrobot 34 F flange on robot dimensions 67 G grounding therobot 31 H hazards from attached tooling 15 from expelling a part 15 How Can I Get Help 12 I IEEE 1394 cable installing 40 impact and trapping points 14 installation brake release box 57 PA 4 power chassis 40 robot 30 SmartController 40 system overview 11 intended use of the robot 19 interface box locationon PA 4 41 interface panel on robot 32 Manipulating Industrial Robot defined 14 modifications AdeptViper s650 s850 Robot User s Guide Rev A 71 Index acceptable 20 unacceptable 20 mome
20. Adept Equipment Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit Pay special attention to tilt and shock indication labels on the exteriors of the containers if installed If any damage is indicated request that the carrier s agent be present at the time the container is unpacked Upon Unpacking Before signing the carrier s delivery sheet please 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 and free of visible damage If the items received do not match the packing slip or are damaged do not sign the receipt Contact Adept as soon as possible If the items received do not match your order please contact Adept immediately Inspect each item for external damage as it is removed from its container If any damage is evident contact Adept see Section 1 4 on page 12 Retain all containers and packaging materials These items may be necessary to settle claims or at a later date to relocate equipment AdeptViper s650 s850 Robot User s Guide Rev A 25 Chapter 3 Robot Installation 3 2 Environmental and Facility Requirements The Adept robot system installation must meet the operating environment requirements shown in Table 3 1 Table 3 1 Robot System Operating Environment Requirements Item Condition Flatness of the mounting 0 1
21. AdeptViper s650 s850 Robot User s Guide cce AdeptViper s650 s850 Robot Users Guide P N 05173 000 Rev A August 2005 3011 Triad Drive Livermore CA 94551 USA Phone 925 245 3400 Fax 925 960 0452 Otto Hahn Strasse 23 44227 Dortmund Germany Phone 49 231 75 89 40 Fax 49 231 75 89 450 41 rue du Saule Trapu 91300 Massy France Phone 33 1 69 19 16 16 Fax 33 1 69 32 04 62 ceay MG adept Le technology inc 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 sub ject 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 doc umentation Please email your comments to techpubs adept com Copyright O 2005 by Adept Technology Inc All rights reserved The Adept logo AdeptVision AIM HexSight and HexaVision are registered trademarks of Adept Technology Inc ActiveV Adept Adept 1060 Adept 1060 Adept 1850 Adept 1850 XP Adept 540 Adept 560 Adept C40 Adept C60 Adept CC Adept Cobra 550 Adept Cobra 550 CleanRoom Adept Cobra 600 Adept Cobra 800 A
22. Control System Behavior Category ciiin 18 2 4 Intended Use of the Robots eller 19 2 5 RObOF MOANEANONS inasa ieee Reece EE been kee qp een SA 20 Accepioble Modea s Ka 6620604 05 nari i dde dob Ra d GR e LR 20 Unacceptable Modifications sns 20 2 6 IrGnspOlb kaaa DEAN ee eh 21 2 7 Safety Requirements for Additional Equipment 21 2 8 Working ATEUS 555 554 rirnan trn dere TINA NE KINGS Y ED Ie eee 21 2 9 Qualification of Personnel 000 eee 22 2 10 Safety Equipment for Operators ees 22 2 11 Protection Against Unauthorized Operation llsussss 23 2 12 Safety Aspects While Performing Maintenance 23 2 13 Risks That Cannot Be Avoided 0 eee 23 AdeptViper s650s 850 Robot User s Guide Rev A 5 Table of Contents 2 14 Risks Due to Incorrect Installation or Operation 23 2 15 What to Do in an Emergency Situation ssssssserserssssr ere rs rr ee 24 3 Robot Installation aaa 25 3 1 Unpacking and Inspecting the Adept Equipment 25 Before UNMPAGKING rare ae 25 Meere rs ama te Doane rede NYA ee NANG BENG MOO a ATA eee ams 25 3 2 Environmental and Facility Requirements cece eee eee 26 3 3 Transporting the Robot 2 REE RE eee 27 Precautions im Iramsporing ROOST naa ace do ton Feb te Roa baken God KGG 27 Manspo PIOOOQUIE a er 28 3 4 Mounting
23. Cover Cover removed Cross pan head Screw Figure 6 2 58 AdeptViper s650 s850 Robot User s Guide Rev A Replacing Encoder Backup Battery 4 Remove the dummy connector cap from the battery board Dummy connector cap Figure 6 3 5 Connect a new battery 1st one to the pin from which you have disconnected the dummy connector cap in Step 4 NOTE Do not disconnect old backup batteries before connecting anew one to the pin from which the dummy connector cap is removed If you do so the encoder positional data may be lost New backup battery Figure 6 4 6 Disconnect the old backup battery that is right next to the new battery connected in Step 5 and then connect a new battery 2nd one NOTE Be sure to replace all of three batteries with new ones at one time Otherwise the battery service life will be reduced AdeptViper s650 s850 Robot User s Guide Rev A 59 Chapter 6 Maintenance Old backup battery New backup battery Figure 6 5 7 Disconnect the old backup battery that is right next to the new battery connected in Step 6 and then connect a new battery 3rd one Old backup battery New backup battery Figure 6 6 8 Remove the last old battery and connect the dummy connector cap disconnected in Step 4 60 AdeptViper s650 s850 Robot User s Guide Rev A Installing User Supplied Hardstops Dummy connector cap Ol
24. Guide Rev A 15 Chapter 2 Safety Table 2 1 Sources for International Standards and Directives SEMI International Standards 3081 Zanker Road San Jose CA 95134 USA Phone 1 408 943 6900 Fax 1 408 428 9600 http wps2a semi org wps portal pagr 118 p a 118 200 American National Standards Institute ANSI 11 West 42nd Street 13th Floor New York NY 10036 USA Phone 212 642 4900 Fax 212 398 0023 http www ansi org BSI Group British Standards 389 Chiswick High Road London W4 4AL United Kingdom Phone 44 0 20 8996 9000 Fax 44 0 20 8996 7400 http www bsi global com Document Center Inc 1504 Industrial Way Unit 9 Belmont CA 94002 USA Phone 415 591 7600 Fax 415 591 7617 http www document center com DIN Deutsches Institut fur Normung e V German Institute for Standardization Burggrafenstrasse 6 10787 Berlin Germany Phone 49 30 2601 0 Fax 49 30 2601 1231 http www din de http www2 beuth de publishing Global Engineering Documents 15 Inverness Way East Englewood CO 80112 USA Phone 800 854 7179 Fax 303 397 2740 http global ihs com IEC International Electrotechnical Commission Rue de Varembe 3 PO Box 131 CH 1211 Geneva 20 Switzerland Phone 41 22 919 0211 Fax 41 22 919 0300 http www iec ch Robotic Industries Association RIA 900 Victors Way PO Box 3724 Ann Arbor MI 48106 USA Phone 313 994 6088 Fax 313 994
25. One line from AIR input is connected directly to AIR2 on the second arm There are 10 user electric lines The air lines and signal wiring are shown below Connector CN21 Valve Symbols and Air Intake Exhaust States for end effector control 1A and 1B are piping joint symbols signal wires Air piping joint Valve signal Solenoid ir intake Air piping joint M5 CN20 Pin Assignment For controller I O unit NPN type source IN sink OUT p o m Solenoid 1A solenoid valve 1 Solenoid 1B solenoid valve 1 AIR 1 Air piping joint PT 1 4 Solenoid 2A solenoid valve 2 AIR 2 Solenoid 2B solenoid valve 2 Air piping joint PT 1 4 Solenoid 3A solenoid valve 3 CN20 pin layout Solenoid 3B solenoid valve 3 For controller I O unit PNP type sink IN source OUT Grounding terminal M5 Connector CN20 for end effector signal valve control wires Solenoid 3B solenoid valve 3 Note 1 Pins 1 to 10 on CN21 and those on CN20 are connected with each other The allowable current per line is 1 A Note 2 Use the attached connector sets for CN20 and CN21 SRCN6A25 24S For CN20 round type connector Japan Aviation Electronics Industry Ltd JMLP1610M For CN21 L type plug connector DDK Electronics Inc 05019 000 AdeptViper s650 s850 Robot User s Guide Rev A 33 Chapter 3 Robot Installation Table 3 2 Solenoid Valve Specifications aaah on 2 eier double Operating system
26. PA 4 CAT 3 includes dual redundant high power AC contactors that in combination with the sDAI meet the Category 3 E Stop requirements per EN 954 The PA 4 is configured with J Amplifier modules to support the Adept Viper robot systems The J amplifiers in the AdeptViper robot system are controlled by the sDAI distributed control module The sDAI module resides in the PA 4 chassis and contains a RISC microprocessor and interface circuitry that close the servo loops for high performance robot motion The sDAI is connected to a host Adept SmartController via the SmartServo interface based on IEEE 1394 AdeptViper s650 s850 Robot User s Guide Rev A Installation Overview 1 2 Installation Overview The system installation process is summarized in the following table Refer also to the system cable diagram in Figure 4 1 on page 39 Table 1 1 Installation Overview Task to be Performed Reference Location 1 Mount the robot on a flat secure mounting surface See Section 3 4 on page 30 2 Install the SmartController Front Panel and See Section 4 2 on page 40 AdeptWindows software 3 Install the PA 4 power chassis See Section 4 3 on page 40 4 Install the Arm Power Signal cable between the See Section 4 3 on page 40 PA 4 and the robot 5 Install the IEEE 1394 and XSYS cables between See Section 4 3 on page 40 the PA 4 and SmartController 6 Connect AC power to PA 4 power chassis See Section 4 4 on page 42 7 Start AdeptWind
27. a around J4 and J5 of entire end effector lja ljs lu ls l 12 13 2 54x10 kgm Figure 3 7 Moment of Inertia Calculation Examples AdeptViper s650 s850 Robot User s Guide Rev A 37 Chapter 3 Robot Installation 38 AdeptViper s650 s850 Robot User s Guide Rev A System Installation 4 1 System Cable Diagram IEEE 1394 Cable J Amp 1 J Amp 2 Amp 3 User Supplied Ground Wire sDAI Module Between PA 4 and SmartController TAP Adept SmartController CX Terminator Installed User Supplied Ground Wire Controller XFP to 24VDC Power from Adept PA 4 u Front Panel XFP User Supplied Power Chassis a Power Supply to o t nf Controller XDC1 Arm Power gt gt i E R ti Signal Cable i o amp N Q User Supplied Front Panel Power Supply LoL T1 Pendant optional ao DD CD a o gt a oS AdeptViper s650 Desktop or Laptop PC Robot user supplied Grounding Terminal M5 User Supplied Ground Wire Figure 4 1 System Cable Diagram for AdeptViper s650 Robot AdeptViper s650 s850 Robot User s Guide Rev A 39 Chapter 4 System Installation 4 2 Installing the SmartController Refer to the Adept SmartController User s Guide for comp
28. cord is unterminated Connect each conductor of the power cord securely to your AC power source using the color code shown in Table 4 5 See Figure 4 6 on page 47 for a typical power installation diagram The installation must meet all applicable European international and national standards and regulations Table 4 5 1 Phase AC Power Cord Specifications for PA 4 Cord length 3 meters 0 1 m 9 ft 10 in 4 in Cord rating 25 amps Number and size of 3 x 2 5 mm conductor size Color code 200 240 VAC line 1 black line 2 black ground green yellow 2 Note The two black wires can also be one black and one gray wire but the functionality is the same for either case AdeptViper s650 s850 Robot User s Guide Rev A 45 Chapter 4 System Installation DANGER 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 An incorrect installation can injure or kill anyone that touches the equipment in the robot workcell The protective ground conductor colored green yellow of the 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 DANGER Ensure that a proper protective ground connection exists before turning on the power Power cord 19 mm 3 4 inch naapi shrink tubing Black wire B
29. d After these precautions a skilled person is allowed to perform maintenance on the robot See Section 2 9 for the specifications CAUTION Never remove any safeguarding and never AN make changes in the system that will decommission a physical safeguard AdeptViper s650 s850 Robot User s Guide Rev A 21 Chapter 2 Safety 2 9 Qualification of Personnel 2 10 This manual assumes that all 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 e Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers electrical and or mechanical Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers electrical and or mechanical All personnel must observe industry prescribed 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 from the source before attempting any repair or upgrade activity Use appropriate lockout procedures to reduce the risk of power being restored b
30. d backup battery Figure 6 7 9 Replace the cover on the robot Tightening torque Cross pan head screw 0 59 Nm 6 3 Installing User Supplied Hardstops For the purpose of limiting the robot working envelope the hardstops or mechanical ends for Joints 1 2 and 3 on the AdeptViper robots can be changed by installing user supplied hardstop devices In addition the default softstops or software limits must be modified after the hardstops have been installed If you need information on modifying hardstops please contact Adept Customer Service and request the document that describes this process not covered by the warranty even if the robot is under warranty CAUTION Failures caused by user supplied hardstops are AdeptViper s650 s850 Robot User s Guide Rev A 61 Chapter 6 Maintenance 62 AdeptViper s650 s850 Robot User s Guide Rev A Technical Specifications 7 1 Robot Dimensions 578 42 575 68 m 375 T 115 _80__ 295 TOL o rer CUM vo Na ei EN ES Ve B gt ea RUN TE JA Vo og IL n7 o def D e il ff YY y 3 75 t p D Y Workable space defined by point P Figure 7 1 AdeptViper s650 Side Dimensions and Work Envelope AdeptViper s650 s850 Robot User s Guide Rev A 63 Chapter 7 Technical Specifications
31. dept Cobra i600 Adept Cobra i800 Adept Cobra s600 Adept Cobra s800 Adept DeskTop Adept Digital Workcell Adept FFE Adept FlexFeeder 250 Adept IC Adept Impulse Feeder Adept LineVision Adept MC Adept MV Adept MV 10 Adept MV 19 Adept MV4 Adept MV 5 Adept MV 8 Adept NanoBonder EBS Adept NanoBonder LWS Adept NanoCell Adept NanoStage L1P2 Adept NanoStage L3 Adept NanoStage L3P2 Adept OC Adept SmartAmp Adept SmartAxis Adept SmartController CS Adept SmartController CX Adept SmartModule Adept SmartMotion Adept SmartServo Adept sDIO Adept Servo Kit Adept sMI6 Adept SMIF EZ AdeptAlign 650 AdeptAtlas AdeptCartesian AdeptForce AdeptFTP AdeptGEM AdeptModules AdeptMotion AdeptMotion Servo AdeptMotion VME AdeptNet AdeptNFS AdeptOne AdeptOne MV AdeptOne XL AdeptRAPID AdeptSix 300 AdeptSix 300CL AdeptSix 600 AdeptICP IP AdeptThree AdeptThree MV AdeptThree XL AdeptTwo AdeptVicron AdeptVicron 300S AdeptVicron 310D AdeptVision AVI AdeptVision AGS AdeptVision GV AdeptVision I AdeptVision II AdeptVision VME AdeptVision VXL AdeptVision XGS AdeptVision XGS II AdeptWindows AdeptWindows Controller AdeptWindows DDE AdeptWindows Offline Editor AdeptWindows PC AIM Command Server AIM Dispense AIM PCB AIM VisionWare A Series AutoCal AutoTune AutoWidth CCM CCMII CGM FlexFeedWare HyperDrive Microenvironment MicroV MotionWare ObjectFinder ObjectFinder 2000 PackOne PalletWare SMIF C SMIF EZX SMIF Z
32. deptViper s650 s850 Robot User s Guide Rev A Connecting Digital I O to the System 5 3 Connecting Digital I O to the System You can connect digital I O to the system in several different ways See Table 5 1 and Figure 5 2 Table 5 1 Digital I O Connection Options Product I O Capacity For more details XDIO Connector on 12 inputs see Adept SmartController SmartController 8 outputs User s Guide Optional IO Blox Device 8 inputs 8 outputs per device up see Adept IO Blox User s connects to sDAI in PA 4 to four IO Blox devices per robot Guide Optional sDIO Module 32 inputs 32 outputs per module see Adept SmartController connects to controller up to four sDIO per system User s Guide AdeptViper s650 s850 CN20 Connector Robot For input signals to control internal robot solenoids and general user I O Signals can come from 10 Blox 1 IO Blox device or XDIO 8 Input signals 1113 to 1120 on SmartController 8 Output signals 0105 to 0112 a O Adept PA 4 sDIO 1 I 32 Input signals 1033 to 1064 D 32 Output signals 0033 to 0064 Optional nd og IO Blox Device i Optional ass AA eL EL cL rz gt To EXPIO d aisi 0 so C c hp I
33. e robot See Table 5 3 Also refer to Figure 1 1 on page 9 for a drawing of the axis identification The yellow X Y label can be used to indicate the X and Y axes in the World coordinate system in your workcell Table 5 3 Axis Directional Labels Axis 2 dr LP LP sr Or GD a ra ted gn E i Axis 4 Axis 5 Axis 3 AdeptViper s650 s850 Robot User s Guide Rev A 53 54 Chapter 5 System Operation 5 5 Caution Label on Robot The Caution label shown in Figure 5 3 refers to rotation of Joint 4 When power is turned off do not manually rotate Joint 4 more than the Joint Limits of 190 If Joint 4 is rotated beyond these limits the internal wiring can be damaged W4BtANTIMRBAS TBs LUT CESU RAEBYERLET eCALSETG DT MARR Tt RELT lt K KE Never rotate the 4th axis beyond the specified motion space using external force in CALSET as thes wil break the wiring inside the robot unit When performing CALSET be sure to follow the instructions given in the INSTALLATION amp MAINTENANCE GUIDE Figure 5 3 Caution Label on Joint 4 Rotation NOTE There is no CALSET operation on the AdeptViper robot and there is no Installation and Maintenance Guide AdeptViper s650 s850 Robot User s Guide Rev A Status Panel Codes on sDAI Module Status Panel Codes on sDAI Module The status panel display on the sDAI module in the PA 4 displays alpha numeric codes that
34. feguards 14 requirements for additional equipment 21 sources for information 15 safety barriers 14 sDAI module status panel codes 55 SmartController description 10 installation 40 solenoids in robot signal wiring 33 valve specifications 34 sources for international standards and directives 16 specifications robot performance 68 status panel codes on sDAI module 55 system operating environment requirements robot 26 startup procedure 49 T transporting robot 21 precautions 27 setting position 28 U unpacking and inspecting Adept equipment 25 V valve specifications solenoids 34 voltage maximum operating 72 AdeptViper s650 s850 Robot User s Guide Rev A Index power chassis 1 phase AC 45 power chassis 3 phase AC 42 minimum operating power chassis 1 phase AC 45 power chassis 3 phase AC 42 WwW What to do in an emergency situation 24 work envelope s650 robot side view 63 s650 robot top view 64 s850 robot side view 65 s850 robot top view 66 working areas 21 X XSYS cable installing 40 AdeptViper s650 s850 Robot User s Guide Rev A 73 Index 74 AdeptViper s650 s850 Robot User s Guide Rev A P N 05173 000 Rev A cas adept technology inc 3011 Triad Drive Livermore CA 94551 9250245 3400
35. he EU EMC Directive and meets all functional requirements of ISO 10218 EN 775 Manipulating Robots Safety In addition a software based reduced speed mode has been incorporated to limit speed and impact forces on the Operator and production tooling when the robot is operated in Manual Mode AdeptViper s650 s850 Robot User s Guide Rev A Intended Use of the Robots 2 4 The standard control system meets or exceeds the requirements imposed by the EN 954 specified Category 1 level of safety Intended Use of the Robots The installation and use of Adept products must comply with all safety instructions and warnings in this manual Installation and use must also comply with all applicable local and national requirements and safety standards see Section 2 7 on page 21 The AdeptViper robots are intended for use in parts assembly and material handling for payloads less than 5 kg See Chapter 5 for complete information tooling and payloads CAUTION For safety reasons it is prohibited to make certain modifications to Adept robots see Section 2 5 The Adept controller is a component subassembly of a complete industrial automation system The controller subassembly must be installed inside a suitable enclosure The controller subassembly must not come into contact with liquids Additionally the robot must not come into contact with liquids The Adept equipment is not intended for use in any of the following situations e In hazardou
36. hms NOTE Use a dedicated grounding wire and grounding electrode Do not share them with any other electric power or power equipment such as a welder WARNING Wiring must be performed by authorized or certified personnel Failure to observe this caution may result in fire or electric shock Grounding terminal M5 12 AWG or more Figure 3 3 Ground Point on Robot AdeptViper s650 s850 Robot User s Guide Rev A 31 Chapter 3 Robot Installation 3 6 Description of Connectors on Robot Interface Panel CN22 Power Signal Cable to PA 4 AIR 1 AIR 2 CN20 Grounding terminal M5 Figure 3 4 Robot Interface Panel CN22 the Arm Power Signal cable from the PA 4 is installed at this connector CN20 Pins 1 to 10 are wired directly to corresponding pins 1 to 10 on CN21 on the upper arm Pins 12 to 18 are for solenoid control See Section 3 7 on page 33 AIR 1 air piping connector PT1 4 for three solenoids in robot See Section 3 7 on page 33 AIR 2 air piping connector PT1 4 connects directly to AIR 2 on the second upper arm Grounding Terminal ground point on robot see Section 3 5 on page 31 32 AdeptViper s650 s850 Robot User s Guide Rev A Air Lines and Signal Wiring 3 7 Air Lines and Signal Wiring The robot is equipped with 7 air pipes or lines Six lines from AIR1 input are controlled by the 3 internal solenoid valves
37. ional sDIO product Adept PA 4 Power Chassis User s Guide Contains complete information on the installation and operation of the PA 4 Power Chassis Adept Windows Installation Guide Describes installation of AdeptWindows software Instructions for Adept Utility Programs Describes the utility programs used for advanced system configurations system upgrades file copying and other system configuration procedures V Operating System User s Guide Describes the V operating system including disk file operations monitor commands and monitor command programs V Language User s Guide Describes the V language and programming of an Adept control system Adept Document Library The Adept Document Library ADL contains documentation for Adept products You can access a local copy of the ADL from the Adept Software CD shipped with your system or from the separate ADL CD Additionally an Internet version of the ADL can be accessed by going to the Adept Web site and selecting Document Library from the home page To go directly to the Adept Document Library type the following URL into your browser http www adept com Main KE DATA adept_search htm To locate information on a specific topic use the Document Library search engine on the ADL main page To view a list of available product documentation select the Document Titles option 12 AdeptViper s650 s850 Robot User s Guide Rev A
38. lack wire Green Yellow wire L 7 mm 1 4 inch shrink tubing Figure 4 5 1 Phase AC Cable Wiring Blue wire Brown wire 46 AdeptViper s650 s850 Robot User s Guide Rev A Connecting 1 Phase AC Power to PA 4 Typical Single Phase 220 VAC Power Installation Diagrams Facility u Supply T o 10 PE x 200 240V 20A PE L2 L1 Adept PA 4 10 200 240V Figure 4 6 Typical 1 Phase 200 240 VAC Connection AdeptViper s650 s850 Robot User s Guide Rev A 47 Chapter 4 System Installation 48 AdeptViper s650 s850 Robot User s Guide Rev A 5 1 System Operation System Start up Procedure Verify that the robot is securely mounted the system is correctly installed and that all safety equipment is working before going through the system start up process Once the system installation has been verified you are ready to start up the system 1 2 Switch on AC power to the PA 4 Switch on the 24VDC power to the controller Connect to the controller via AdeptWindows and boot the system from the D default drive Refer to the AdeptWindows Installation Guide for complete details on working with AdeptWindows Wait for the system to complete the boot cycle Once completed the system will return with a dot prompt and the following window should be displayed zi Adept V Copyright c 1984 2004 by Adept Technology Inc All rights reserved Adept Exte
39. led except for teaching in Manual Mode Failure to install suitable guarding could result in injury or death The Risk Assessment for teaching this product depends on the application In many applications the programmer will need to enter the robot workcell while Arm Power is enabled to teach the robot Other applications can be designed so that the programmer does not have to enter the work envelope while Arm Power is on Examples of alternative methods of programming include Programming from outside the safety barrier Programming with Arm Power off 1 2 3 Copying program from another master robot 4 Off line or CAD programming Control System Behavior Category The following paragraphs relate to the requirements of European EU EEA directives for Machinery Electric Safety and Electromagnetic Compatibility EMC In situations with low exposure consideration factors European Standard EN 1050 specifies use of a Category 1 Control System per EN 954 EN 954 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 well tried safety principles The standard control system described in this handbook employs hardware components in its safety system that meet or exceed the requirements of the EU Machinery Directive and Low Voltage Directive The standard control system is fully hardened to all EMI influences per t
40. lete information on installing the Adept SmartController This list summarizes the main steps oO oO P C N e Mount the SmartController and Front Panel Connect the Front Panel to the SmartController Connect the optional pendant to the SmartController if included Connect user supplied 24 VDC power to the controller Install a user supplied ground wire between the SmartController and ground Install the AdeptWindows PC software on the user supplied PC Refer to the AdeptWindows Installation Guide This includes connecting the supplied Ethernet crossover cable between the user supplied PC and the Ethernet port on the SmartContoller 4 3 Installing the PA 4 Power Chassis Refer to the Adept PA 4 Power Chassis User s Guide for complete information on the PA 4 chassis This list summarizes the main steps 1 40 Mount the PA 4 chassis NOTE For the PA 4 in an AdeptViper system only the panel mounting option is available Locate these cables typically shipped in the cable accessories box e EFE 1394 cable length 4 5M e XSYS cable length 4 5M Arm Power Signal cable length 4 M Install one end of the IEEE 1394 cable into the SmartServo port 1 1 connector on the SmartController and install the other end into the SmartServo port 1 connector on the sDAI module in the PA 4 See Figure 4 1 on page 39 and Figure 4 2 on page 41 Install the XSYS cable between the XSYS connector on the SmartController and the
41. nt of inertia end effectors 36 mounting hole pattern for robot 30 N Notes Cautions and Warnings description of 13 O overview system installation 11 P PA 4 power chassis AC power requirements I phase 45 AC power requirements 3 phase 42 installing 40 power requirements PA 4 power chassis 1 phase AC 45 PA 4 power chassis 3 phase AC 42 precautions and required safeguards 14 protection against unauthorized operation 23 Q qualification of personnel 22 R related manuals 12 requirements environmental robot 26 PA 4 power chassis 1 phase AC 45 PA 4 power chassis 3 phase AC 42 robot operating environment 26 risk assessment 17 risks that cannot be avoided 23 robot AC power consumption typical 42 and machinery safety standards 17 axis identification 9 brake release box 57 definition of industrial 14 external mounting holes 34 grounding 31 in hoisting sling 27 intended uses 19 interface panel 32 modifications 20 mounting hole pattern 30 mounting procedure 30 operating requirements 26 performance specifications 68 programming 50 s650 dimensions side view 63 s650 dimensions top view 64 s850 dimensions side view 65 s850 dimensions top view 66 solenoids signal wiring 33 transporting 27 unpacking and inspection 25 working area 21 robot flange dimensions 67 S safety 13 during maintenance 23 equipment for operators 22 expelling a part 15 impact and trapping points 14 required sa
42. ove W w b No load Adept cycle 371 947 AdeptViper s650 5 0 kg Adept cycle 477 1526 5 0 kg all joints move 834 2088 a Typical power data is with 220VAC 60Hz 3 phase nominal input b For short durations 100 ms Adept cycle the robot tool performs continuous path straight line motions 25 mm up 305 mm over 25 mm down and back along the same path COARSE is enabled and BREAKs are used at each end location Not achievable over all paths The Adept PA 4 power chassis can be shipped from the factory configured for either 3 phase 200 240 VAC or 380 415 VAC operation depending on your sales order For 1 phase AC see Section 4 5 on page 45 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 the chassis Verify that the setting matches your facility power before installation If you need to change the AC voltage setting from 200 240 VAC to 380 415 VAC or vice versa see the Adept PA 4 Power Chassis User s Guide WARNING 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 42 AdeptViper s650 s850 Robot User s Guide Rev A Connecting 3 Phase AC Power to PA 4 Connecting the PA 4 3 Phase AC Power Cord to AC Supply The user end of the cord is unterminated Connect each conductor
43. ows connect to the controller and See Section 5 1 on page 49 turn on power to the system 1 3 Manufacturer s Declaration The Manufacturer s Declaration of Incorporation and Conformity for AdeptViper robot systems can be found on the Adept Website in the Download Center of the Support section http www adept com support downloads disclaimer asp In the Download Types search box select Regulatory Certificates to find the document which you can then download AdeptViper s650 s850 Robot User s Guide Rev A 11 Chapter 1 Introduction 1 4 How Can I Get Help Refer to the How to Get Help Resource Guide Adept P N 00961 00700 for details on getting assistance with your Adept software and hardware Additionally you can access information sources on Adept s corporate web site http www adept com Related Manuals This manual covers the installation operation and maintenance of an Adept Cobra s600 s800 robot system There are additional manuals that cover programming the system reconfiguring installed components and adding other optional components see Table 1 2 These manuals are available on the Adept Document Library CD ROM shipped with each system Table 1 2 Related Manuals Manual Title Description Adept SmartController User s Guide Contains complete information on the installation and operation of the Adept SmartController and the opt
44. resented for both robots 3rd axis motor cover rear side Second arm 4th axis J4 Bs eae 4th axis cover Xs 3rd axis J3 First arm Second arm cover 6th axis 4 5th axis J5 2nd axis motor cover rear side F 2nd axis J2 1st axis J1 Figure 1 1 Robot Axis Identification AdeptViper s650 s850 Robot User s Guide Rev A Chapter 1 Introduction 10 Adept SmartController CX The SmartController CX is the foundation of Adept s family of high performance distributed motion and vision controllers The SmartController CX is designed for use with Adept Cobra s600 and s800 robots Adept SmartModules the AdeptViper robot and the Adept sMI6 Module for the SmartMotion product The SmartController CX supports an integrated vision option and a conveyor tracking option It offers scalability and support for IEEE 1394 based digital I O and general motion expansion modules The IEEE 1394 interface is the backbone of Adept SmartServo Adept s distributed controls architecture supporting Adept products The controller also includes Fast Ethernet and DeviceNet SmartController CX N L Figure 1 2 Adept SmartController CX Adept PA 4 CAT 3 Power Chassis The PA 4 CAT 3 includes AC DC power conversion electronics that supports a range of Adept power amplifiers and robot control modules In addition the
45. rm 295 second arm 565 mm 365 first arm 405 second arm 770 mm Arm offset J1 swing 75 mm J3 front arm 90 mm J1 swing 75 mm J3 front arm 90 mm Maximum motion area R 733 mm end effector mounting face R 653 mm Point P J4 J5 J6 center R 934 mm end effector mounting face R 854 mm Point P J4 J5 J6 center Motion range J1 170 J2 190 45 J3 29 256 J4 190 J5 120 J6 360 J1 170 J2 190 45 J3 29 259 J4 190 J5 120 J6 360 Maximum joint speed J1 328 sec J2 300 sec J3 375 sec J4 375 sec J5 375 sec J6 600 sec J1 250 sec J2 250 sec J3 250 sec J4 375 sec J5 375 sec J6 600 sec Maximum composite speed 8200 mm s 7600 mm s at the center of an end effector mounting face Maximum payload 5kg 5kg Position repeatability Note 1 In each of X Y and Z directions 0 02 mm In each of X Y and Z directions 0 03 mm Maximum allowable inertia moment Around J4 0 295 kgm Around J5 0 295 kgm Around J6 0 045 kgm Around J4 0 295 kgm Around J5 0 295 kgm Around J6 0 045 kgm Position detection Simplified absolute encoder Simplified absolute encoder Drive motor and brake AC servomotors for all joints Brakes for joints J2 to J6 AC servomotors for all joints Brakes for joints J2 to J6 User air piping Note 2 7 sys
46. rnal Encoder Module AdeptViper 650 Configured as Category 1 Robot System per ISO 10218 and EN954 Software 16 2 7 3100 Edit BS 23 Feb 2005 Preliminary Release Controller 2000 1852 A3 0 Security ID 8437 7520 7D27 Processor 1 0 52 7 5 32MB Robot 1 670 113 0 41 0 38 AdeptViper 650 Servo 16 0 Edit Al 20 May 2005 14 19 25 Figure 5 1 Typical Start up Screen Disengage any E Stops Make sure the Front Panel is set to Auto mode Type enable power ENA POW lt enter gt Press the High Power button on the Front Panel while it is blinking The system will return to the dot prompt once high power is enabled Type calibrate CAL lt enter gt AdeptViper s650 s850 Robot User s Guide Rev A 49 Chapter 5 System Operation 9 Once the calibration is complete the system will return with a dot prompt and the status panel display on the sDAI module will read OK 10 System is ready for operation 5 2 Learning to Program the Robot To learn how to use and program the robot go to the V Operating System User s Guide to find information on basic operation of the Vt Operating System Also refer to the Instructions for Adept Utility Programs for information on using the Adept utility programs For programming information you need to refer to the following list of optional manuals e V Language User s Guide e V Language Reference Guide e V Operating System Reference Guide 50 A
47. rsonnel from turning on power Risks That Cannot Be Avoided 2 14 The Adept control system includes devices that disable High Power if a system failure occurs However certain residual risks or improper situations could cause hazards The following situations may result in risks that cannot be avoided Failure of software or electronics that may cause high speed robot motion in Manual Mode e Failure of hardware associated with enabling device or E Stop system Risks Due to Incorrect Installation or Operation Take precautions to ensure that the following situations do not occur 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 Defeating interlock so that operator can enter workcell with High Power ON Ejection of work piece see Hazards From Expelling a Part or Attached Tooling on page 15 AdeptViper s650 s850 Robot User s Guide Rev A 23 Chapter 2 Safety 2 15 What to Do in an Emergency Situation Press any E Stop button a red push button on a yellow background 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 24 AdeptViper s650 s850 Robot User s Guide Rev A Robot Installation 3 1 Unpacking and Inspecting the
48. s explosive atmospheres e In mobile portable marine or aircraft systems In life support systems e In residential installations e In situations where the Adept equipment will be subject to extremes of heat or humidity CAUTION The instructions for operation installation and maintenance given in this manual must be strictly observed Non intended use of an AdeptViper robot can Cause injury to personnel Damage the robot or other equipment Reduce system reliability and performance AdeptViper s650 s850 Robot User s Guide Rev A 19 Chapter 2 Safety All persons that install commission operate or maintain the robot must Have the necessary qualifications e Read and follow the instructions in this Instruction Handbook exactly If there is any doubt concerning the application ask Adept to determine if it is an intended use or not 2 5 Robot Modifications It is sometimes necessary to modify the robot in order to successfully integrate it into a workcell Unfortunately many seemingly simple modifications can either cause a robot failure or reduce the robot s performance reliability or lifetime The following information is provided as a guideline to modifications Acceptable Modifications In general the following robot modifications do not cause problems but may affect robot performance Attaching tooling utility boxes solenoid packs vacuum pumps cameras lighting etc to the robot
49. s an automatically controlled reprogrammable multipurpose manipulative machine with several degrees of freedom which may be either fixed in place or mobile for use in industrial automation applications Safety Barriers 14 Safety barriers must be provided that prevent personnel from entering the workcell whenever power is applied to the equipment 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 power to the equipment is present The robot system integrator user or operator must ensure that adequate safeguards safety barriers light curtains safety gates safety floor mats etc are installed The robot workcell must comply with applicable local and national standards see Section 2 7 on page 21 The height and the distance of the safety fence from the robot must ensure that personnel cannot reach the danger zone of the robot The Adept control system has features that aid the user in constructing system safeguards including customer emergency stop circuitry and digital input and output lines The emergency power off circuitry is capable of switching external power systems and can be interfaced to the appropriate user supplied safeguards See the Adept SmartController User s Guide for additional information Impact and Trapping Points
50. s650 s850 Robot User s Guide Rev A 43 44 Chapter 4 System Installation Typical 3 Phase AC Power Installation Diagrams Li p 30 L2 200 240V 3 e 20A ER PE L3 L2 ki Adept PA 4 3 200 240V Figure 4 3 Typical 3 Phase 200 240 VAC Connection for PA 4 System 66 30 L2 380 415V 3 20A N o PE PE N L3 L2 L1 Adept PA 4 3 380 415V Figure 4 4 Typical 3 Phase 380 415 VAC Connection for PA 4 System AdeptViper s650 s850 Robot User s Guide Rev A Connecting 1 Phase AC Power to PA 4 45 Connecting 1 Phase AC Power to PA 4 PA 4 1 Phase AC Power Requirements The PA 4 can be shipped from the factory configured for 200 240 VAC single phase operation 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 the chassis Verify that the setting matches your facility power before installation NOTE For 3 Phase AC power wiring information see Section 4 4 on page 42 Table 4 4 Adept PA 4 Power Chassis 1 Phase Power Requirements Nominal Frequency Minimum Maximum Recommended Voltage Phasing Operating Operating External Range Voltage Voltage Circuit Breaker user supplied 200 to 240 50 60Hz 180 VAC 245 VAC 20 amps VAC 1 phase Connecting the PA 4 1 Phase AC Power Cord to AC Supply The user end of the
51. t unit is first unpacked this job is not required As shown at right mount the eyebolts When delivered the robot unit is packed with eyebolts attached so this job is not required Eyebolts 28 AdeptViper s650 s850 Robot User s Guide Rev A Transporting the Robot Step Procedure Drawing As shown at right place a waste cloth on the second arm and pass the wire through the two eyebolts Note Before transporting the robot check that the path to the target position is free of obstacles Wire Belt sling Waste Cloth Eyebolts Robot Mounting Bolts Worker A Remove the four bolts while supporting the robot unit to prevent it from getting overturned Worker B Operate the crane and move the robot unit to the target site Worker B Put the robot unit down in the target position Worker A Temporarily secure the robot unit with four bolts Secure the robot unit according to the instructions in Section 3 4 on page 30 Remove the eyebolts from the robot unit Caution Before running the robot unit be sure to remove the eyebolts Otherwise the robot arm will strike against those eyebolts AdeptViper s650 s850 Robot User s Guide Rev A 29 Chapter 3 Robot Installation 3 4 Mounting the Robot 200 160 0 012 2X 06 5 ig g 66 0 05 __ 142 3 R20 i I LO o 3 munia o eo
52. tems 4x6 6x1 3 solenoid valves 2 position double solenoid contained 7 systems O4x6 6x1 3 solenoid valves 2 position double solenoid contained User signal line 10 for proximity sensor signals etc 10 for proximity sensor signals etc Air source Operating pressure 1 0 x 105 Pa to 3 9 x 105 Pa 1 0 x 105 Pa to 3 9 x 105 Pa 68 AdeptViper s650 s850 Robot User s Guide Rev A Specifications Table 7 1 Robot Specifications Continued Specification s650 s850 Air source Maximum 4 9 x 105 Pa 4 9 x 105 Pa allowable pressure Degree of Protection IP 40 IP 40 Weight Approx 28 kg Approx 29 kg Note 1 Position repeatability is the value at constant ambient temperature Note 2 Only the 04x6 air piping system may be controlled by built in solenoid valves AdeptViper s650 s850 Robot User s Guide Rev A 69 Chapter 7 Technical Specifications 70 AdeptViper s650 s850 Robot User s Guide Rev A A AC power connecting to power chassis 42 45 installation diagram for 200 240VAC 1 phase 47 installation diagram for 200 240VAC 3 phase 44 installation diagram for 380 415VAC 44 requirements for power chassis l phase 45 requirements for power chassis 3 phase 42 robot power consumption typical 42 turning on 49 voltage current ratings power chassis 1 phase 45 power chassis 3 phase 42 Adept Document Library 12 Adept PA 4 see P
53. the Robot cece nnn 30 3 5 Grounding the Robot cee eee 31 3 6 Description of Connectors on Robot Interface Panel 32 3 7 Air Lines and Signal Wiring enken eee 33 3 8 Designing End Effectors sussie meen eee ees 35 Mass of ENG EMSCION sist oss seen nn 35 Center of Gravity Position of End Effector sse 35 Moment of Inertia Around JA J5 and JO 0 0 0 ake ng 36 4 System INSIGUONON 55 road 39 4 1 System Cable Diagram a ams e ee ERR eee 39 4 2 Installing the SmartController 0 060 rr rr rr eee 40 4 3 Installing the PA 4 Power Chassis sossessersersrssrer rr eee eens 40 4 4 Connecting 3 Phase AC Power to PA 4 ers rs rr rss erna 42 PA 4 3 Phase Power Requirements 0 ernennen 42 Connecting the PA 4 3 Phase AC Power Cord to AC Supply 43 Typical 3 Phase AC Power Installation Diagrams 0 000 eee ees 44 4 5 Connecting 1 Phase AC Power to PA 4 ccc eee ee 45 PA 4 1 Phase AC Power Requirements 0 0 a 45 Connecting the PA 4 1 Phase AC Power Cord to AC Supply 45 Typical Single Phase 220 VAC Power Installation Diagrams 47 5 Syslem Operation 4 6545 hocbkcse hove RR KANA beds rer 49 5 1 System Start up Procedure 0 cee eee 49 5 2 Learning to Program the Robot 06 c eee 50 5 3 Connecting Digital I O to the System 00 eee 51 5 4 Installing Axis Labels
54. the moment of inertia of a complicated shape divide it into simple parts as much as possible for easier calculations As shown in the figure below divide the end effector into three parts amp 1 Moment of inertia around J6 Moment of inertia around J6 of I from 3 and 5 in Table 2 3 L 2 0 12 4 0 015 0 14 x 0 017 1 85x10 kgm Moment of inertia around J6 of I from 1 and 5 in Table 2 3 x 2 012 0701 2 ol 0 1x0 04 1 65x10 kgm Moment of inertia around J6 of Q I from 1 and 5 in Table 2 3 1 0x0 02 2 L 5 11 0x0 05 Center of Center of 3 2 gravity of i gravity of 2 7X10 kgm Moment of inertia around J6 of entire end effector lje ls lib l2 15 50 003 kgm Unit mm 2 Moment of inertia around J4 and J5 For the end effector shown below the moment of inertia around J4 and J5 can be calculated according to the same formula Moment of inertia around J4 and J5 of I from 3 and 5 in Table 2 3 24 0 015 0 019 0 14 x 0 08 0 005 40 01 1 03 x 10 kgm Moment of inertia around J4 and J5 of I from 2 and 5 in Table 2 3 2 3 1 o 017 LM 40 1 x 0 08 0 01 0 02 0 047 1 39 x 10 kgm Moment of inertia around J4 and J5 of I from 2 and 5 in Table 2 3 2 18 0 024 S 1 0 x 0 08 0 01 0 05 0 052 2 30 x 10 kgm ls Moment of inerti
55. tool mount flange e Attaching hoses pneumatic lines or cables to the robot These should be designed so they do not restrict joint motion or cause robot motion errors Unacceptable Modifications The modifications listed below may damage the robot reduce system safety and reliability or shorten the life of the robot The warranty of the entire robot or certain parts may be voided CAUTION Making any of the modifications outlined below voids 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 e Modifying any of the robot harnesses or robot to controller cables e Modifying any robot access covers or drive system components e Modifying including drilling or cutting any robot surface e Modifying any robot electrical component or printed circuit board e Routing additional hoses air lines or wires through the inside of the robot e Modifications that compromise EMC performance including shielding 20 AdeptViper s650 s850 Robot User s Guide Rev A Transport 2 6 Transport 2 7 Always use adequate equipment to transport and lift Adept products See Chapter 3 for more information on transporting lifting and installing 7 Safety Requirements for Additional Equipment 2 8 Additional equipment used with the AdeptViper robots grippers conveyor belts etc must not
56. y another person while you are working on the system WARNING The user must get confirmation from every entrusted person before they start working with the robot that the person 1 Has received the manual 2 Has read the manual 3 Understands the manual 4 Will work in the manner specified by the manual Safety Equipment for Operators 22 Operators must wear safety equipment in the workcell For safety reasons operators must wear the following when they are in the robot workcell Safety glasses e Protective headgear hard hats Safety shoes Warning signs should be posted around the workcell to ensure that anyone working around the robot system knows they must wear safety equipment AdeptViper s650 s850 Robot User s Guide Rev A Protection Against Unauthorized Operation 2 11 Protection Against Unauthorized Operation 2 12 The system must be protected against unauthorized use The user or operator must restrict access to the keyboard and the pendant by locking them in a cabinet or use another adequate method to prevent access to them 12 Safety Aspects While Performing Maintenance 2 13 Only skilled persons with the necessary knowledge about the safety and operating the equipment are allowed to maintain the robot controller and power chassis CAUTION During maintenance and repair the power of the Adept controller must be turned off Lockout measures must be used to prevent unauthorized pe

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