Adept Cobra i600/i800 Robot User’s Guide
Adept Cobra i600/i800 Robot User’s Guide P/N: 03589-000, Rev G December, 2011 5960 Inglewood Drive • Pleasanton, CA 94588 • 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 Block 5000 Ang Mo Kio Avenue 5 • #05-12 Techplace II • Singapore 569870 • Phone +65.6755 2258 • Fax +65.
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.
Table of Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adept Cobra i600/i800™ Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adept Amps-in-Base (AIB™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.2 Dangers, Warnings, Cautions, and Notes . . . . .
3.4 Connecting User-Supplied PC to Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PC Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installing Serial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.5 Installing Adept ACE Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.6 Connecting 24 VDC Power to Robot . . . . . . . . . . . .
4.8 Turning On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Verifying Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning on Power and Starting Adept ACE . . . . . . . . . . . . . . . . . . . . . . . . . Enabling High Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verifying E-Stop Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Mounting Locations for External Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.6 Installing the Robot Solenoid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Procedure . . . . . . . . . . . . . . . . . . . . .
List of Figures Figure 1-1. Adept Cobra i800 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 1-2. Robot Joint Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 1-3. Adept AIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 2-1. Cobra Robot on a Transportation Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-2. User Connectors on Joint 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 6-3. User Connectors on Joint 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 6-4. Internal User Connectors - OP3/4, EOAPWR, ESTOP . . . . . . . . . . . . . . . . . . . . 74 Figure 6-5. SOLND Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Figure 6-6.
Introduction 1.1 1 Product Description Adept Cobra i600/i800™ Robots The Adept Cobra i600 and i800 robots are four-axis SCARA robots (Selective Compliance Assembly Robot Arm). See the following figure. Joints 1, 2, and 4 are rotational; Joint 3 is translational. See Figure 1-2 for a description of the robot joint locations. The Adept Cobra i-series robots are programmed and controlled using Adept ACE™ software, running on a user-supplied PC.
Introduction Joint 2 Joint 1 Joint 3 Inner Link Outer Link Joint 4 Figure 1-2. Robot Joint Motions Adept Amps-in-Base (AIB™) The amplifiers for the Adept Cobra i-series robots are embedded in the base of the robot. This amplifier section is known as the AIB (amp-in-base). It provides power amplifiers and full servo control.
Dangers, Warnings, Cautions, and Notes 1.2 Dangers, Warnings, Cautions, and Notes There are six levels of special alert notation used in Adept manuals. In descending order of importance, they are: DANGER: This indicates an imminently hazardous electrical situation which, if not avoided, will result in death or serious injury. DANGER: This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Introduction • The robot system must not be used for purposes other than described in Section 1.6. Contact Adept if you are not sure of the suitability for your application. • The user is responsible for providing safety barriers around the robot to prevent anyone from accidentally coming into contact with the robot when it is in motion. • Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed. 1.
Installation Overview 1.7 Installation Overview The system installation process is summarized in the following table. Refer also to the system cable diagram in Figure 3-1 on page 24. NOTE: The Adept Cobra i600/i800 Robot Quick Setup Guide provides abbreviated instructions on installing your robot system. Table 1-1. Installation Overview 1.8 Task to be Performed Reference Location 1. Mount the robot on a flat, secure mounting surface. See Section 2.5 on page 19. 2.
Introduction 1.9 How Can I Get Help? Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on getting assistance with your Adept software and hardware. Additionally, you can access information sources on Adept’s corporate web site: http://www.adept.com • For Contact information: http://www.adept.com/contact/americas • For Product Support information: http://www.adept.com/support/service-and-support/main • For user discussions, support, and programming examples: http://www.adept.
Robot Installation 2.1 2 Transport and Storage This equipment must be shipped and stored in a temperature-controlled environment, within the range –25° to +55° C (-13° to +131° F). The recommended humidity range is 5 to 90 percent, non-condensing. It should be shipped and stored in the Adept-supplied packaging, which is designed to prevent damage from normal shock and vibration. You should protect the package from excessive shock and vibration.
Robot Installation 2.2 Unpacking and Inspecting the Adept Equipment Before Unpacking Carefully inspect all shipping crates for evidence of damage during transit. Pay special attention to any tilt and shock indication labels on the exteriors of the containers. If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked.
Mounting the Robot 2.4 Environmental and Facility Requirements The Adept robot system installation must meet the operating environment requirements shown in Table 2-1. Table 2-1. Robot System Operating Environment Requirements Ambient temperature 5° to 40° C (41° to 104° F) Humidity 5 to 90%, non-condensing Altitude up to 2000 m (6500 ft) Pollution degree 2 Robot protection class IP-20 (NEMA Type 1) NOTE: See Section 7.1 on page 91 for robot dimensions. 2.
Robot Installation 160 4X Ø 14 THRU +0.015 2x R4 0 6 80 Units in mm 10 45 160 200 50 Ø8 +0.015 6 0 234 90 338 Figure 2-2. Mounting Hole Pattern for Robot Robot Mounting Procedure 1. Using the dimensions shown in Figure 2-2, drill and tap the mounting surface for four M12 - 1.75 x 36 mm (or 7/16 - 14 UNC x 1.50 in.) machine bolts (bolts not provided). See Table 2-2 for bolt and torque specifications. 2.
Mounting the Robot NOTE: The base casting of the robot is aluminum and can easily be dented if bumped against a harder surface. Verify that the robot is mounted squarely (will not rock back and forth) before tightening the mounting bolts. 6. Install the user-supplied mounting bolts and washers. Tighten the bolts to the torque specified in Table 2-2. WARNING: The center of mass of the robot may cause the robot to fall over if the robot is not secured with the mounting bolts.
Robot Installation 2.6 Connectors on the Robot Interface Panel 200-240 VAC XSLV Ground Screw SmartServo Port 1 SmartServo Port 2 24 VDC Input +24 VDC Pin RS-232 XIO XPANEL Figure 2-3. Robot Interface Panel 24 VDC - for connecting user-supplied 24 VDC power to the robot. The mating connector is provided. Ground Screw - for connecting cable shield from user-supplied 24 VDC cable. 200/240 VAC - for connecting 200-240 VAC, single-phase, input power to the robot. The mating connector is provided.
System Installation 3.
System Installation 3.2 System Cable Diagram Installation Procedure Step Step Description Part(s) 1 Connect AIB XPANEL cable to XPANEL on Interface Panel. A 2 Verify XUSR jumper plug is installed on XUSR connector. B 3 Connect Front Panel cable to Front Panel and XFP connector. C, D 4 If no T2, install XMCP jumper or T1/T2 bypass plug. Skip to 5. E, F 4a If you have T2, connect T1/T2 adapter cable to XMCP connector. G, H 5 Connect user-supplied ground. See Section 3.
Cable Connections to the Robot 3.3 Cable Connections to the Robot Installing AIB XPANEL Cable 1. Locate the AIB XPANEL cable. It is shipped in the Accessory Kit. 2. Plug the single end of the AIB XPANEL cable into the XPANEL connector on the robot interface panel. See Figure 3-1 on page 24. The AIB XPANEL cable has these connectors on the opposite ends: XUSR, XFP, and XMCP. NOTE: The plastic molding on each connector is labeled for identification.
System Installation PC Requirements To run and use Adept ACE software, the following hardware and software are required. NOTE: The specifications are also listed in the ACE PackXpert Datasheet, available on the Adept corporate web site. Hardware • Processor: Core2Duo 2.
Installing Adept ACE Software 2. From the Adept Software CD-ROM menu, click Install the Adept ACE Software. Figure 3-2. Adept ACE CD-ROM Startup Menu 3. The Adept ACE Setup wizard opens - see Figure 3-4 and Figure 3-5. Follow the instructions as you step through the installation process. Figure 3-3. Setup Welcome Screen Figure 3-4.
System Installation Figure 3-5. Install Screen 4. When the install is complete, click Finish. Figure 3-6. Installation Completed 5. After closing the Adept ACE Setup wizard, click Exit on the CD-ROM menu and proceed to the Start-up Procedure. NOTE: You will have to restart the PC after installing Adept ACE.
Connecting 24 VDC Power to Robot 3.6 Connecting 24 VDC Power to Robot Specifications for 24 VDC Power Table 3-1. Specifications for 24 VDC User-Supplied Power Supply Customer-Supplied Power Supply 24 VDC (± 10%), 150 W (6 A) (21.6 V< Vin < 26.4 V) Circuit Protectiona Output must be less than 300 W peak or 8 Amp in-line fuse Power Cabling 1.5 – 1.85 mm² (16-14 AWG) Shield Termination Braided shield connects to ground terminal at both ends of cable.
System Installation Connecting 24 VDC This section covers the cable that connects the 24 VDC power supply to the robot. 24 VDC Mating Connector The 24 VDC mating connector and two pins are supplied with each system. They are shipped in the Accessory Kit. Table 3-3.
Connecting 24 VDC Power to Robot Adept Cobra i600/i800 Robot User-Supplied Power Supply 24 VDC 24 V 6A – + Frame Ground Attach shield from usersupplied cable to ground screw on Cobra i600/i800 Interface Panel. GND – + User-Supplied Shielded Power Cable Figure 3-7. User-Supplied 24 VDC Cable NOTE: Adept recommends that DC power be delivered over a shielded cable, with the shield connected to grounds at both ends of the cable.
System Installation Table 3-5. Typical Robot Power Consumption Cobra Robot i600 i800 a b Move Average Power (W) RMS Current (A) Peak Power (W)a No load - Adept cycleb 344 1.56 1559 5.5 kg - Adept cycleb 494 2.25 2061 5.5 kg - all joints move 880 4.00 2667 No load - Adept cycleb 531 2.41 1955 5.5 kg - Adept cycleb 377 1.71 1406 5.5 kg - all joints move 794 3.61 2110 For short durations (100 ms) See Table 7-1 on page 99 for details on Adept cycle.
Connecting 24 VDC Power to Robot AC Power Diagrams L 1Ø 200–240 VAC 20 A Note: F1 is user-supplied, must be slow blow. F1 10 A N E User-Supplied AC Power Cable E L = Line N = Neutral E = Earth Ground N L Adept Cobra s600/s800 and i600/i800 Robots 1 Ø 200–240 VAC Figure 3-8. Typical AC Power Installation with Single-Phase Supply Note: F4 and F5 are user-supplied, must be slow blow.
System Installation Procedure for Creating 200-240 VAC Cable 1. Locate the AC mating connector shown in Table 3-6. 2. Open the connector by unscrewing the screw on the shell and removing the cover. 3. Loosen the two screws on the cable clamp. See Figure 3-10. 4. Use 18 AWG wire to create the AC power cable. Select the wire length to safely reach from the user-supplied AC power source to the robot base. 5. Strip 18 to 24 mm insulation from each of the three wires. 6.
Installing User-Supplied Safety Equipment Ground Point on Robot Base The user can install a protective earth ground wire at the robot base to ground the robot. See Figure 3-11. The robot ships with an M8 x 12 stainless steel, hex-head screw, and M8 split and flat washers installed in the grounding hole. The user is responsible for supplying the ground wire to connect to protective earth ground. Ground Point on Robot Base, with M8 x 12 screw and washers installed Figure 3-11.
System Operation 4.1 4 Robot Status LED The robot Status LED Indicator is located on the top of the robot. See Figure 4-1. Robot Status LED Indicator Figure 4-1 Robot Status LED Indicator Location Table 4-1. Robot Status LED Definition 4.
System Operation Z Brake-Release Button Status Panel for Displaying Fault Codes Figure 4-2 Status Panel Table 4-2.
Using the Brake Release Button 4.3 Using the Brake Release Button Brakes The robot has a braking system which decelerates the robot in an emergency condition, such as when the emergency stop circuit is open or a robot joint passes its softstop. The braking system will not prevent you from moving the robot manually once the robot has stopped (and High Power has been removed). In addition, Joint 3 has an electromechanical brake. The brake is released when High Power is enabled.
System Operation 4.4 Front Panel 2 1 Manual Mode Auto Mode 4 5 3 Figure 4-3 Front Panel 1. XFP connector Connects to the XFP connector on the AIB XPANEL cable on an i600/i800 robot. 2. System 5 V Power-On LED Indicates whether or not power is connected to the robot. 3. Manual/Automatic Mode Switch Switches between Manual and Automatic mode. In Automatic mode, executing programs control the robot, and the robot can run at full speed.
Front Panel NOTE: The Front Panel must be installed to be able to Enable Power to the robot. To operate without a Front Panel, the user must supply the equivalent circuits. See “Remote Front Panel or User-Supplied Replacement” on page 55 for a summary of connections required to replace the Front Panel. 4.5 Connecting Digital I/O to the System You can connect digital I/O to the system in several different ways. See the following table and Figure 4-4. Table 4-3.
System Operation IO Blox Device IO Blox #1 8 Input signals: 1033 to 1040 8 Output signals: 0033 to 0040 Cobra i600/i800 Robot XIO Breakout Cable Adept XIO Termination Block 1 GND XSLV 2 SmartServo +24V DC INPUT (24 VDC) AC INPUT (200-240 VAC 1&) XIO XPANEL RS-232 XIO Connector 12 Input signals: 1001 to 1012 8 Output signals: 0001 to 0008 Figure 4-4 Connecting Digital I/O to the System Table 4-4.
Front Panel 4.6 Using Digital I/O on Robot XIO Connector The XIO connector on the robot interface panel supports 20 digital I/O signals - 12 inputs and 8 outputs. These signals can be used by MicroV+ to perform various functions in the workcell. See Table 4-5 for the XIO signal designations. • 12 Inputs, signals 1001 to 1012 • 8 Outputs, signals 0001 to 0008 XIO Connector Table 4-5. XIO Signal Designations Signal Bank MicroV+ Signal Number Pin No.
System Operation XIO Input Signals The 12 input channels are arranged in two banks of six. Each bank is electrically isolated from the other bank and optically isolated from the robot’s ground. The six inputs within each bank share a common source/sink line. The inputs are accessed through direct connection to the XIO connector (see Table 4-5 on page 43), or through the optional XIO Termination Block. See the documentation supplied with the Termination Block for details.
Front Panel Typical Input Wiring Example Adept-Supplied Equipment User-Supplied Equipment Wiring Terminal Block (equivalent circuit) Signal 1001 Signal 1002 Input Bank 1 Signal 1005 Signal 1006 4 Part Present Sensor 5 Feeder Empty Sensor 6 Part Jammed Sensor 7 Sealant Ready Sensor 8 9 Bank 1 3 Common 2 +24 V GND 1 Signal 1007 Signal 1008 Input Bank 2 Signal 1009 Signal 1010 Signal 1011 Signal 1012 13 14 15 16 17 18 Bank 2 12 Common 10 GND +24 V Bank 2 configured for Sourcing (PNP) Inp
System Operation XIO Output Signals The eight digital outputs share a common, high side (sourcing) Driver IC. The Driver is designed to supply any kind of load with one side connected to ground. It is designed for a range of user-provided voltages from 10 to 24 VDC and each channel is capable of up to 0.7 A of current. This Driver has overtemperature protection, current limiting, and shorted-load protection.
Front Panel Typical Output Wiring Example (equivalent circuit) User-Supplied Equipment Wiring Terminal Block +24 VDC Outputs 1-8 XIO Connector – 26-Pin Female D-Sub Adept-Supplied Equipment Signal 0001 Signal 0002 Signal 0003 Signal 0004 Signal 0005 Signal 0006 Signal 0007 Signal 0008 GND GND Typical User Loads 19 20 21 22 23 Load Load 24 Load 25 26 1 M L 10 N Customer AC Power Supply M Figure 4-6 Typical User Wiring for XIO Output Signals XIO Breakout Cable The XIO Breakout cable is av
System Operation Table 4-8. XIO Breakout Cable Wire Chart Pin No. Signal Designation 1 GND White 2 24 VDC White/Black 3 Common 1 Red 4 Input 1.1 Red/Black 5 Input 2.1 Yellow 6 Input 3.1 Yellow/Black 7 Input 4.1 Green 8 Input 5.1 Green/Black 9 Input 6.1 Blue 10 GND Blue/White 11 24 VDC Brown 12 Common 2 Brown/White 13 Input 1.2 Orange 14 Input 2.2 Orange/Black 15 Input 3.2 Gray 16 Input 4.2 Gray/Black 17 Input 5.2 Violet 18 Input 6.
Front Panel 4.7 Connecting Customer-Supplied Safety and Power Control Equipment Connecting Equipment to the System The connection of the customer-supplied safety and power control equipment to the system is done through the XUSR and XFP connectors on the AIB XPANEL cable. Refer to Table 4-9 for the XUSR pin-out explanations. Refer to Table 4-10 on page 50 for the XFP pin-out explanations. See Figure 4-8 on page 52 for the E-Stop wiring diagram. Table 4-9.
System Operation Table 4-10. Contacts Provided by the XFP Connector Pin Pairs Requirements for User-Supplied Front Panel Description Voltage-Free Contacts Provided by Customer Front Panel E-Stop CH 1 (N/C contacts) User must supply N/C contacts. Front Panel E-Stop CH 2 (N/C contacts) User must supply N/C contacts. 3,11 Remote MANUAL/AUTOMATIC switch CH 1. MANUAL = Open AUTOMATIC = Closed Optional - jumper closed for Auto Mode only operation. 4,12 Remote MANUAL/AUTOMATIC switch CH 2.
Front Panel Table 4-11.
System Operation Cobra i600/i800 Internal Circuits ESTOPGND Front Panel and T2 Circuits (Channel 2) User-Supplied Circuits XFP-2 (XPANEL-10) ESTOPSRC (Channel 1) XFP-1 (XPANEL-1) Front Panel ESTOP Pushbutton XFP-9 (XPANEL-2) NOTE: The “Line E-Stop” and “User Manual/Auto Indication” functions of the XUSR connector are not supported on the Cobra i600/i800 robots.
Front Panel Adept Front Panel Schematic ESTOPSRC XFP 24VS 5VD MANUALSRC1 MANUALSRC2 HPLT5V SYSPWRLT NC 1 2 3 4 5 6 7 8 16 15PDSUBM 9 10 11 12 13 14 15 ESTOPFP1 ESTOPFP2 MANUALRLY1 MANUALRLY2 HIPWRLT HIPWRREQ 17 D "System Power LED" "MANUAL/AUTO" 5VD (XFP-7) SYSPWRLT "HIGH POWER ON/OFF" "EMERGENCY STOP" (XFP-5) HPLT5V (XFP-4) MANUALSRC2 ESTOPSRC (XFP-1) 24VS (XFP-6) MANUALSRC1 (XFP-3) 2PIN_MINI (XFP-15) (XFP-2) D SWL1 SW1 SW2 (XFP-13) HIPWRLT (XFP-12) MANUALRLY2 MANUALRLY1 (XFP-11)
System Operation Personnel" in the Adept Robot Safety Guide), wearing safety equipment and carrying an Adept pendant, is allowable under local regulations. The E-Stop is said to be “muted” in Manual mode (see Figure 4-8 on page 52, Table 4-9 on page 49, Table 4-10 on page 50, and Table 4-11 on page 51 for the customer E-Stop circuitry). The muted capability is useful for a situation where a shutdown must occur if the cell gate is opened in Automatic mode, but you need to open the gate in Manual mode.
Turning On the System Pins 6, 14 and 5, 13 of the XFP connector provide this remote capability. Pins 5, 13 provide power for the lamp, +5 VDC, and ground, respectively. Pins 6, 14 are inputs for voltage-free N/O contacts from a customer-supplied momentary push button switch. WARNING: To fulfill the “Single Point of Control” requirement, do not place the Manual/Automatic and High Power On controls in multiple locations.
System Operation DANGER: After installing the robot, you must test it before you use it for the first time. Failure to do this could cause death or serious injury or equipment damage. Mechanical Checks • Verify that the robot is mounted level and that all fasteners are properly installed and tightened. • Verify that any end-of-arm tooling is properly installed. • Verify that all other peripheral equipment is properly installed and in a state such that it is safe to turn on power to the robot system.
Turning On the System See the following figure. Figure 4-10 Adept ACE Startup Menu 8. Click Open. You will see the message “Working, please wait”. Figure 4-11 Connecting to the iCobra Enabling High Power After you have started Adept ACE and connected to the internal controller, enable high power to the robot motors. Using Adept ACE to Enable High Power 1. From the Adept ACE main menu, click the Enable High Power icon. See the following figure.
System Operation Figure 4-12 High Power and Launch Robot Jog Control Icons 2. Press and release the blinking High Power button on the Front Panel within 10 seconds. The Front Panel is shown in Figure 4-3 on page 40. (If the button stops blinking, you must Enable Power again.) NOTE: The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step. This step turns on high power to the robot motors and calibrates the robot.
Turning On the System The Robot Jog Control opens. See the following figure. Figure 4-13 Robot Jog Control Window b. In the Mode section, click Joint. By default, Comp will be selected. c. Use the Robot Jog Control arrows to move Joint 1 a short distance in both directions. Repeat for Joints 2, 3, and 4. See the following figure.
System Operation Click Joint (default will be Comp) Use Jog Control arrows to move Joints 1 to 4 in each direction. Figure 4-14 Jog Pendant Menu 4. The robot is now ready to use. Go to the next section to verify E-Stops and to Chapter 6 for details on installing optional equipment. Verifying E-Stop Functions Verify that all E-Stop devices are functional (T2, Front Panel, and user-supplied). Test each mushroom button, safety gate, light curtain, etc.
Maintenance 5.1 5 Field-replaceable Parts The following two parts are the only field-replaceable parts: Table 5-1. Field-replaceable Parts Part Adept Part Number Encoder battery 09977-000 (3.6 V, 6.8 Ah) (This has replaced part number 02704-000) AIB (Amp-In-Base) 04900-000 These parts must only be replaced with the Adept Part Numbers identified in the preceding table. 5.
Maintenance WARNING: Lockout and tagout power before servicing. WARNING: The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons, as defined in the Adept Robot Safety Guide. The access covers on the robot are not interlocked – turn off and disconnect power if covers have to be removed. 5.3 Checking Safety Systems It is recommended that tests be done every six months. 1.
Lubricating Joint 3 Ball Screw/Spline Contact Adept if you find any signs of oil in these areas. 5.6 Lubricating Joint 3 Ball Screw/Spline Required Grease for the Robot Ball Screw/Spline Assembly Grease LG-2 Lubricating Grease Lithium Soap, Synthetic Hydrocarbon Adept part number: 85139-00002 CAUTION: Using improper lubrication products on the Adept Cobra i600 or i800 robot may cause damage to the robot. Lubrication Procedure 1. Turn off main power to the robot. 2.
Maintenance 9. Remove 24 VDC power from the robot. 10. Reinstall the outer link cover. Joint 3 Ball Screw Lubrication Points A A A Joint 3 Ball Screw Lubrication Points Lower Quill Grease Locations Upper Quill Grease Locations Quill Shaft Vertical Groove Lube Point A Vertical Groove Lube Point B Top View Looking Down NOTE: Apply grease to the three vertical grooves Vertical Groove Lube Point C and the spiral groove Section A-A Figure 5-1.
Lubricating Joint 3 Ball Screw/Spline 5.7 Replacing the AIB Chassis This procedure provides details on how to replace the AIB chassis on a Cobra i-series robot. CAUTION: Follow appropriate ESD procedures during the removal/replacement phases. CAUTION: All application and robot configuration data are stored on the AIB chassis. Make sure you have backed up this data to the PC before removing the AIB chassis.
Maintenance 8. While holding the chassis heat sink, carefully and slowly lower the chassis down (see Figure 5-3 on page 66), so that enough access is available to remove the internal cables. The chassis can be laid flat or placed to the right side of the robot for better access. Figure 5-3. Opening and Removing AIB Chassis 9. Disconnect the “white” amplifier cable from the amplifier connector located on the chassis bracket. See Figure 5-4. Amplifier Connector PMAI Board J1 J11 J27 J28 Figure 5-4.
Lubricating Joint 3 Ball Screw/Spline 14. Using a 5 mm Allen key, disconnect and remove the ground wire from the chassis. Keep the screw for reassembly later. See the following figure. Figure 5-5. Ground Screw on AIB Chassis 15. Carefully remove the chassis from the robot, and place it aside. Tag it with the appropriate fault diagnosis faults/errors and robot serial number information. Installing a New AIB Chassis 1. Carefully remove the new chassis from its packaging, check it for any signs for damage.
Maintenance Groove in robot base for AIB chassis placement. Figure 5-6. Installing AIB Chassis in Robot Base 9. Carefully insert the chassis into the robot base in the groove at the bottom of the base - see Figure 5-6. Tilt the chassis up and into place against the robot, making sure that none of the cables get trapped or pinched and that the chassis O-ring is not damaged during installation. 10. Once the chassis is in place, use a 5 mm Allen key to tighten the chassis securing screw.
Lubricating Joint 3 Ball Screw/Spline 5.8 Replacing Encoder Battery The data stored by the encoders is protected by a 3.6 V lithium backup battery located in the base of the robot. CAUTION: Replace the battery pack only with a 3.6 V, 6.8 Ah lithium battery pack, Adept P/N 09977-000. Battery information is located in the base of the robot. NOTE: The previous battery, P/N 02704-000, has been superceded by this battery pack. The battery replacement interval and procedure have not changed.
Maintenance Encoder Battery Pack Figure 5-7. Location of Encoder Battery Pack 8. The battery cable assembly has two sets of connectors. Locate the unused battery cable in the wire bundle in the base area. 9. Place the new battery pack next to the original one, but do not disconnect the original one. 10. Connect the new battery pack to the connectors on the unused battery cable. Make sure to verify the positive and negative connections are correct. 11.
Optional Equipment Installation 6.1 6 Installing End-Effectors The user is responsible for providing and installing any end-effector or other end-of-arm tooling. End-effectors can be attached to the tool flange using four M6 screws. See Figure 7-4 on page 94 for a dimension drawing of the tool flange. A 6 mm diameter x 12 mm dowel pin (not supplied) fits in the through-hole in the tool flange and can be used as a keying or anti-rotation device in a user-designed end-effector.
Optional Equipment Installation Quill shaft M4 Socket-head cap screws Tool flange assembly Setscrew Figure 6-1. Tool Flange Removal Details Installing the Flange 1. Make sure the ball bearing is in the setscrew hole between the flange and the shaft. 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.
User Connections on the Robot DeviceNet User Electrical 4 mm Air Lines IO Blox 6 mm Air Lines Figure 6-2. User Connectors on Joint 1 NOTE: See page 41 for information on the IO Blox connector. Also refer to the Adept IO Blox User’s Guide for details. User Electrical Lines There is a 25-pin male connector (24 conductor) on the robot user panel on the back of Joint 1 for user electrical lines (see Figure 6-2).
Optional Equipment Installation 6.4 Internal User Connectors The internal user connectors, OP3/4, EOAPWR, and ESTOP, can be accessed with the outer link cover removed - see Figure 6-4. The SOLND connector is located on the opposite side of the bulkhead area - see Figure 6-5. OP3/4 EOAPWR J3-BRK ESTOP NOTE: On early Cobra i600 robots, the J3-BRK and ESTOP connectors are in opposite locations from those shown in the photo. Verify the function by inspecting the label on the socket. Figure 6-4.
User Connections on the Robot SOLND Connector This 4-pin connector provides the output signals for the optional Robot Solenoid Kit. See the following table and Figure 6-5 on page 74. See Section 6.6 on page 79 for installation details. Table 6-1.
Optional Equipment Installation SOLND Connector Circuit +24VDC Signal 0009 (equivalent circuit) GND Signal 0010 GND OP3/4 Connector Circuit +24VDC Signal 0011 (equivalent circuit) GND Signal 0012 GND For optional Robot Solenoid Kit installation, or other user-supplied devices. Pin 1 Load Pin 2 Pin 3 Load Pin 4 For optional second set of solenoids, or other user-supplied devices. Pin 1 Load Pin 2 Pin 3 Load Pin 4 Figure 6-6.
User Connections on the Robot Internal User Connector Output Specifications The output specifications in the following table apply to the EOAPWR, OP3/4, and SOLND internal user connectors. Table 6-4. Internal User Connector Output Circuit Specifications Parameter Value Power supply voltage range 24 VDC (± 10%), 150 W (6 A) (21.6 V< Vin < 26.4 V) Operational current range, per channel Iout 700 mA Total Current Limitation, all channels on.a Itotal 1.0 A @ 50° C ambient Itotal 1.
Optional Equipment Installation Table 6-5. ESTOP Connector Pin # Description 1 ESTOP_INPUT 2 24 V Pin Location 1 2 ESTOP Connector as viewed on robot Mating Connector: AMP/Tyco #172165-1, 2-pin Mini-Universal Mate-N-Lock AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok Typical ESTOP Connector Circuit Pin 1 Pin 2 User-supplied normally-closed contact. Can be connected to a break-away sensor to cause an E-Stop condition when circuit is open.
Mounting Locations for External Equipment 3. Click the Advanced tab. 4. Check the Break-away E-STOP box. 5. Click Apply. NOTE: When the Break-away E-Stop function has been enabled, you must connect a normally-closed circuit to pins 1 and 2 of the ESTOP connector, as described above. If this is not done, the system will be in an E-Stop condition and you will not be able to enable power. 6.
Optional Equipment Installation The solenoid valve assembly consists of two independent valves (Valve #1 and Valve #2) on a common manifold. The manifold supplies air at the user’s line pressure, 28 psi minimum to 114 psi (0.2 MPa to 0.8 MPa). Each valve has two output ports, A and B. The output ports are arranged so that when Port A is pressurized, Port B is not pressurized. Conversely, when Port B is pressurized, Port A is not.
Installing the Robot Solenoid Kit Spare air line Connector for the solenoid valves Pem nuts to mount the solenoid manifold Figure 6-9. Solenoid Mounting Bracket with Connector and Spare Air Line 4. Cut and discard the cable ties holding the spare air line at the top of the mounting bracket. Move the air line away to facilitate the mounting of the solenoid manifold (see Figure 6-9). 5.
Optional Equipment Installation Air intake coupling with spare air line Tubing connected to output port Mounting screws for solenoid assembly Figure 6-10. Solenoid Placement Using Mounting Hardware 9. Install the appropriate lengths of 4 mm (5/32 in.) plastic tubing (supplied) into the two output ports on the manifold. Route the tubing up along the tower bracket next to the quill and down through the center of the quill. Use cable ties, as needed, to secure the tubing. 10.
Installing the Robot Solenoid Kit Joint 1 cover lifted to access spare air line User Air fitting for connecting spare line. Remove factory installed tubing first. Tubing bundle containing spare air line Figure 6-12. Connecting Spare Air Line to User Connector 13. Disconnect the tubing from the 6 mm User Air fitting shown in Figure 6-12. Fold the tubing out of the way and restrain using cable ties. 14. Locate the spare air line contained in the tubing bundle inside the front end of the cover.
Optional Equipment Installation 6.7 Installing Adjustable Hardstops Adept offers an adjustable hardstop kit for Joint 1 and Joint 2 on the Adept Cobra i600/i800 robots. These are user-installed options that can be used to limit the work envelope of the robot. The Adept part number for the kit is 02592-000. Joint 1 Adjustable Hardstops The Joint 1 Adjustable Hardstops consist of two black rubber stop cylinders, and the screws to install them.
Installing Adjustable Hardstops 3. Click Joint 1. The following screen opens to allow editing the limits: Figure 6-14. Configuration Manager - Modifying Joint 1 Limits 4. In the Lower Limit field, enter the new value for the J1 lower limit softstop. See the following table for recommended softstop values for Position 1 or Position 2. Table 6-7.
Optional Equipment Installation Figure 6-15. Configuration Manager - Apply Changes Joint 2 Adjustable Hardstops The Joint 2 Adjustable Hardstop kit (see Figure 6-16) consists of two curved plates that are the adjustable hardstops, a small, black rectangular block that is the fixed hardstop, and the required screws to install them. The adjustable hardstop plates can be installed in different locations, depending on how much you need to limit the Joint 2 range of motion. Figure 6-16.
Installing Adjustable Hardstops Joint 2 Adjustable Hardstop Plates Installed Figure 6-17. Joint 2 Adjustable Hardstop Locations 2. Use a 4 mm Allen wrench to install four supplied M5 x 10 screws to secure the plate. Tighten the screws to a torque of 4.5 N·m (40 in·lb). Repeat the process for the second plate. Note that the plates can be installed in different positions, depending on how much you need to limit the range of Joint 2. See Table 6-8 on page 89. 3.
Optional Equipment Installation Joint 2 Left Hardstop Plate, installed in +81 degree position Joint 2 Fixed Hardstop Device Joint 2 Positive direction Joint 2 Negative direction + _ 12 thru holes for M5 x 10 screws, for installing Joint 2 hardstops, located 30 degrees apart Joint 2 Right Hardstop Plate, installed in -81 degree position View of under side of Inner Link, looking up Figure 6-19.
Installing Adjustable Hardstops 3. Click Joint 2. The following screen opens to allow editing the limits: Figure 6-20. Configuration Manager - Modifying Joint 2 Limits 4. In the Lower Limit field, enter the new value for the J2 lower limit softstop. See Table 6-8 for recommended softstop values. Table 6-8.
Technical Specifications 7.1 7 Dimension Drawings 417 183 200 Required clearance to open AIB Chassis 934 888 46 37 387 342 177 31 Required cable clearance 600 325 0 234 0 Figure 7-1.
Technical Specifications 417 183 200 Required clearance to open AIB Chassis 918 894 46 37 394 342 31 Required cable clearance 184 Figure 7-2.
Dimension Drawings Cobra s/i600 2X ∅3.0 Cobra s/i800 2X ∅3.0 +.10 6 -.03 +.10 54 7 -.03 45 Cobra s/i600 4X M4x0.7-6H 8 Cobra s/i800 4X M4x0.7-6H 10 10 Figure 7-3.
Technical Specifications 12.0 mm (0.47 in.) See Detail A 20.0 mm (0.79 in.) 3.0 mm (0.12 in.) 43 mm (1.69 in.) ∅ 41.15 mm +.03 mm –.00 mm 45° -A- (∅ 1.620 in.) (+.001 in.) (–.000 in.) Dowel Pin Hole ∅ 6.0 mm +.01 mm – 0 mm ∅ 63.0 mm (2.48 in.) (0.2362 in.) (+.0005 in.) (– 0 in.) -CBC 30° ∅ 50.0 mm (1.9685 in.) 4X M6 x 1- 6H Thru User Ground R 3.56mm (R 0.140in) 5.08mm (0.20in) M3 X 0.5-6H Thru ∅.10 mm (.004 in.) M A M B C M 4.14 mm (0.163 in.) 1.5 mm (0.059 in.) 6.80 mm (0.268 in.
Dimension Drawings 25 4X M4x0.7 - 6H 105 6 Inner Link External Mounting Locations 60 Outer Link External Mounting Locations 4X M4x0.7 - 6H 8 105 Figure 7-5.
Technical Specifications 76 - Cobra s/i600 135 - Cobra s/i800 34 90 4X M4x0.7-6H Outer Link - Bottom View 8 Figure 7-6.
Dimension Drawings Maximum Radial Reach Functional Area 600 mm (23.62 in.) Maximum Intrusion Contact Radius 647 mm (25.50 in.) Minimum Radial Reach 162.6 mm (6.40 in.) 105° 105° 150° 150° Cartesian Limits 300 mm (11.8 in.) Figure 7-7.
Technical Specifications Maximum Intrusion Contact Radius 847.3 mm (33.36 in.) Maximum Radial Reach Functional Area 800 mm (31.50 in.) Minimum Radial Reach 163.6 mm (6.44 in.) 105° 105° 157.5° 157.5° Cartesian Limits 300 mm (11.8 in.) Figure 7-8.
Dimension Drawings 7.2 Robot Specifications Table 7-1. Adept Cobra i600/i800 Robot Specificationsa Description i600 Robot i800 Robot Reach 600 mm (23.6 in) 800 mm (31.5 in) Payload - rated 2.0 kg (4.4 lb) 2.0 kg (4.4 lb) Payload - maximum 5.5 kg (12.1 lb) 5.5 kg (12.
Technical Specifications Table 7-1. Adept Cobra i600/i800 Robot Specificationsa (Continued) Description i600 Robot i800 Robot Joint 1 ±105° ±105° Joint 2 ±150° ±157.5° Joint 3 210 mm (8.3 in.) 210 mm (8.3 in.) Joint 4 ±360° ±360° Joint 1 386°/sec 386°/sec Joint 2 720°/sec 720°/sec Joint 3 1,100 mm/sec (43 in./sec) 1,100 mm/sec (43 in.
Cleanroom Robots 8.1 8 Cobra i600/i800 Cleanroom Option Introduction The Adept Cobra i600/i800 Cleanroom Option is a modification to the standard robot that certifies the robot to meet the Class 3 Airborne Particulate Cleanliness Limits as defined by ISO Standard 14644 (Class 10 for Federal Standard 209E). NOTE: Class 1 Limits can be achieved by maintaining the robot speed at Speed 50 or below. Contact Adept for details. This option is a factory-installed configuration.
Cleanroom Robots Specifications Table 8-1. Adept Cobra Cleanroom Robot Specifications 8.2 Robot Performance Specification See Table 7-1 on page 91. Ambient Temperature Specification 5 - 35° C (41 - 95° F) Connections Compressed Air Inlet Port, 3/8 in. NPT Female Fitting High Flow - Low Vacuum Port, 3/4 in. NPT Female Fitting Figure 8-2. Cleanroom Connections 8.3 Requirements Table 8-2. Cleanroom Robot Requirements Vacuum source 0.80 m3/min (28 ft3/min) minimum volumetric flow rate 6 mm (0.
Exclusions and Incompatibilities 8.4 Exclusions and Incompatibilities Table 8-3. Internally-Mounted Hand Valves 8.5 Installation considerations The internal air line normally used to supply the internally-mounted hand valves (Adept Option Kit P/N 02853-000) is instead used to provide vacuum to the bellows/outer link. One of the passive 6 mm user air lines would need to be used instead.
Cleanroom Robots Upper Bellows Clamp Ring Bellows Lower Bellows Clamp Ring Tool Flange Figure 8-3. Cleanroom Bellows Replacement Lubrication The upper and lower quill requires lubrication in the same manner as the standard Cobra i600/i800 robot. See Section 5.6 on page 63.
Index Numerics C 200/240 VAC connector 22 24 VDC power circuit protection 29 connecting to robot 29 connector 22 making cable 30 mating connector 30 power supplies 29 specifications 29 cable and parts list 23 cable diagram, system 24 camera bracket mounting dimensions 93 circuit protection 24 VDC power 29 cleanroom robot 101 connections 102 exclusions and incompatibilities 103 lubrication 104 replacing bellows 103 requirements 102 specifications 102 vacuum specifications 102 commissioning a system 55 com
Index E I electrical lines, in robot 73 emergency situation, what to do 14 emergency stop circuit 53 diagram 52 Emergency Stop switch, Front Panel 40 enable power using Adept ACE 57 encoder battery, replacing 69 end-effector dowel pin 71 grounding 71 installation 71 environmental requirements 19 EOAPWR connector location 74 mating connector 76 output specifications 77 pinout 76 ESTOP connector enabling Breakaway function 78 location 74 mating connector 78 pinout 77 typical user circuit 78 external equipm
Index system 5 V Power On LED, Front Panel cable diagram 24 O OP3/4 connector location 74 mating connector 75 output specifications 77 pinout 75 typical user circuit 76 operating environment requirements overvoltage protection facility 32 P parts list 23 performance specifications, robot Power On LED, Front Panel 40 programming, robot 60 protection facility overvoltage 32 99 40 T 19 T2 pendant connections 51 tool flange dimensions 94 installation 71 transport and storage 17 transportation pallet 17 t
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