Adept Technology 300Cr Users Manual AdeptSix Robot Instruction Handbook

300CR AdeptSix_300CR_IHB

2015-02-05

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DOCUMENT LIBRARY
AdeptSix 300CR Robot Instruction Handbook

AdeptSix 300CR Robot

Instruction Handbook

AdeptSix 300CR Robot

Instruction Handbook

P/N 01600-000

Rev. A

August 2002

3011 Triad Drive • Livermore, CA 94550 • USA • Phone 925.245.3400 • Fax 925.960.0452

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duced in whole or in part without prior written approval of Adept Technology, Inc. The informa-

tion herein is subject to change without notice and should not be construed as a commitment by

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Printed in the United States of America

AdeptSix 300CR Robot Instruction Handbook, Rev. A 5

Table of Contents

1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Overview of Typical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Read Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Controller and PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . . 14

Installing System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adding End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Turning On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Locating the Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 How Can I Get Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.6 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.7 Knowledge Express . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 Dangers, Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.2 Precautions and Required Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Definition of a Manipulating Industrial Robot . . . . . . . . . . . . . . . . . . . . . . . 20

Safety Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3 Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Severity of Injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Control System Behavior Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4 Intended Use of the Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.5 Robot Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Acceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unacceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.6 AdeptSix 300CR Hazards and Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.8 Safety Requirements for Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.9 Working Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.10 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.11 Safety Equipment for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.12 Protection Against Unauthorized Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Table of Contents

6 AdeptSix 300CR Robot Instruction Handbook, Rev. A

2.13 Safety Aspects While Performing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 30

2.14 Risks That Cannot Be Avoided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.15 Risks Due to Incorrect Installation or Operation . . . . . . . . . . . . . . . . . . . . . . . . 30

2.16 What to Do in an Emergency Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 Safety Guard Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Standard Information (ISO10218) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Using the Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3 Shipping Bracket and Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.5 Types of Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.6 Mounting Procedures for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

When the Robot and Mounting Fixture are

Installed on a Common Installation Base . . . . . . . . . . . . . . . . . . . . . . . . . . 37

When the Robot is Mounted Directly on the Floor . . . . . . . . . . . . . . . . . . . . 38

3.7 Axis Naming Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.8 Grounding the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.9 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4System Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 System Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adept MV Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adept SmartController System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.2 Cable Connections from Robot to PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . 43

Connection to the Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connection to the PA-4 Power Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.3 Cable Connections to MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cable Connections to MV Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connecting User-Supplied Safety and I/O Equipment. . . . . . . . . . . . . . . . . 46

4.4 Cable Connections to SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Installing the SmartController. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cable Connections to SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Connecting User-Supplied Safety and I/O Equipment. . . . . . . . . . . . . . . . . 47

5End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Table of Contents

AdeptSix 300CR Robot Instruction Handbook, Rev. A 7

5.2 Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.3 End of Arm Tooling Load Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.4 Calculating the Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.5 Mounting Equipment - Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.6 User Electrical Lines and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6System Operation - MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

AC Power to Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

User-Supplied Safety Equipment on JUSER and JSIO Connector Checks . 63

6.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.7 Learning to Operate/ Program the AdeptSix 300CR Robot . . . . . . . . . . . . . . . 66

7System Operation - SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Power to the Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

User-Supplied Safety Equipment on XUSR Connector Checks . . . . . . . . . . 69

E-Stop Button and Switch Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.7 Learning to Operate/ Program the AdeptSix 300CR Robot . . . . . . . . . . . . . . . 72

8Using the Manual Control Pendant (MCP) . . . . . . . . . . . . . . . . . . . . . . 73

8.1 MCP Usage for Six-Axis Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Joint Mode (Single-Axis Movement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Table of Contents

8 AdeptSix 300CR Robot Instruction Handbook, Rev. A

WORLD Coordinate System (WORLD Mode on the MCP) . . . . . . . . . . . . . . 75

TOOL Coordinate System (TOOL Mode on the MCP) . . . . . . . . . . . . . . . . . 76

Coordinate System Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

9Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Grease Replenishment for Axis 1 Speed Reducer . . . . . . . . . . . . . . . . . . . . 84

Grease Replenishment for Axis 2 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 85

Grease Replenishment for Axis 3 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 86

Grease Replenishment for Axis 4 and Axis 5 Speed Reducers . . . . . . . . . . 87

Grease Replenishment for Axis 6 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 88

Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Installing and Using Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

9.3 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

10.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

10.2 Robot Cleanroom Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

10.3 Part Names and Working Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

10.4 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

10.5 Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

10.6 Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

10.7 Axis 2 and 3 Effect on Axis 4 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

AdeptSix 300CR Robot Instruction Handbook, Rev. A 9

List of Figures

Figure 1-1. Robot ID Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 2-1. AdeptSix 300CR — Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 3-1. Transporting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 3-2. Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 3-3. Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 3-4. Mounting the Robot Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 3-5. Direct Mounting on the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 3-6. Grounding Method for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 4-1. System Cable Diagram with Adept MV Controller . . . . . . . . . . . . . . . . . . . . 41

Figure 4-2. System Cable Diagram with Adept SmartController . . . . . . . . . . . . . . . . . . 42

Figure 4-3. Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 4-4. Interconnect Cable Connection to the Robot . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 4-5. PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 5-1. Moment Arm Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 5-2. Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 5-3. Center of Gravity: Calculating Tool Load Information . . . . . . . . . . . . . . . . . 51

Figure 5-4. Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 5-5. Center of Gravity: Sealing Gun Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 5-6. Moment of Inertia for Hexahedron and Cylinder . . . . . . . . . . . . . . . . . . . . . 54

Figure 5-7. Center of Gravity: Large Tool and Workpiece Example . . . . . . . . . . . . . . . 55

Figure 5-8. Center of Gravity: Dual End Effector Example . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 5-9. Installing Peripheral Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Figure 5-10. User Electrical and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Figure 5-11. Detailed Drawing of Connector Pin Numbers . . . . . . . . . . . . . . . . . . . . . . . . 60

Figure 8-1. Joint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Figure 8-2. World Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Figure 8-3. Tool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 8-4. Right Hand Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Figure 9-1. Inspection Parts and Inspection Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Figure 9-2. Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Figure 9-3. Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Figure 9-4. Axis 1 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Figure 9-5. Axis 2 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Figure 9-6. Axis 3 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Figure 9-7. Axis 4 and Axis 5 Speed Reducers Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 87

Figure 9-8. Axis 6 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Figure 9-9. Encoder Connector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Figure 9-10. Manual Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Figure 10-1. Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

List of Figures

10 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 10-2. Baseplate Dimensions (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Figure 10-3. Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Figure 10-4. Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Figure 10-5. Axis 2 and Axis 3 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

AdeptSix 300CR Robot Instruction Handbook, Rev. A 11

List of Tables

Table 1-1. Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Table 2-1. Sources for International Standards and Directives . . . . . . . . . . . . . . . . . . . . .22

Table 2-2. Partial List of Robot and Machinery Safety Standards . . . . . . . . . . . . . . . . . . .23

Table 3-1. Maximum Repulsion Forces of the AdeptSix 300CR . . . . . . . . . . . . . . . . . . . . .37

Table 3-2. Axis Naming Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Table 5-1. Moment and Total Inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Table 6-1. LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items . . . . . . . . . . .78

Table 9-2. Inspection Parts and Grease Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Table 10-1. Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

AdeptSix 300CR Robot Instruction Handbook, Rev. A 13

Introduction 1

1.1 Product Description

The AdeptSix 300CR is a compact, high-performance cleanroom robot that provides the

application flexibility of six axis articulation running on the Adept platform. The arm

design provides superior reach capability with a very small footprint to maximize system

flexibility and minimize cell layout size. The AdeptSix 300CR is available with either the

Adept MV controller or the Adept SmartController.

Adept software and controllers simplify integration of the robot by combining all of the

functions found in a typical robot work cell, which is common across the extensive Adept

Product Line. Available options for the AdeptSix 300CR include integral AVI vision,

adaptive Force Sensing, and real-time Conveyor Tracking.

The overall reach of the AdeptSix 300CR is 677 mm with a footprint of 300 mm. Maximum

payload is 3 kg. The AdeptSix 300CR comes standard with the ability to be mounted

either in a tabletop, side or overhead position providing maximum application flexibility.

Applications include assembly, packaging, machine load/unload, quality inspection,

sorting and other high performance tasks.

1.2 Overview of Typical System Installation

This section provides an overview of the installation process for a typical AdeptSix 300CR

system.

Read Safety Information

1. Read Chapter 2 to understand general safety information about the AdeptSix

300CR robot system.

Installing the Robot

1. Prepare for installation, including installing safeguards, by following Section 3.1

to Section 3.3.

2. Mount the robot according to procedures described in Section 3.4. to Section 3.6

3. Install grounding cable on the robot. See Section 3.8.

Chapter 1 - Introduction

14 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Installing the Controller and PA-4 Power Chassis

Adept MV Controller

1. Refer to the AdeptSix Controller Installation Guide to install the Adept MV

controller and the PA-4 power chassis.

2. Install the AdeptWindows PC user interface according to instructions in the

controller manual.

Adept SmartController

1. Refer to the AdeptSix Controller Installation Guide to install the SmartController

and the PA-4 power chassis.

2. Install the AdeptWindows PC user interface according to instructions in the

controller manual.

Installing System Cables

1. Connect the system cables between the robot, controller, and PA-4 power chassis.

See Chapter 4.

2. See Figure 4-1 on page 43 for the system cable diagram for an Adept MV

controller.

3. See Figure 4-2 on page 44 for the system cable diagram for an SmartController.

Adding End of Arm Tooling

Refer to Chapter 5 for complete information on adding end of arm tooling to the robot.

Turning On the System

Refer to Chapter 6 for an Adept MV controller or Chapter 7 for an SmartController. These

chapters contain checklists to verify the installation is correct and to test all safety circuits

before using the robot.

1.3 Checking Package Contents

When the package arrives, check the contents for the following standard items (check any

other options ordered, as well):

• AdeptSix 300CR Robot

• Adept MV controller or SmartController

• Adept PA-4 power chassis

• Manual Control Pendant (MCP) (optional)

• Controller Interface Panel (CIP2) or Adept Front Panel

• Interconnect cables between controller and robot

Locating the Serial Number

AdeptSix 300CR Robot Instruction Handbook, Rev. A 15

1.4 Locating the Serial Number

The ID serial number of the AdeptSix 300CR robot corresponds to the ID number of the

controller. You can check the controller ID using the V+ ID command. The robot’s ID serial

number is located on a label on the robot base. See Figure 1-1.

Figure 1-1. Robot ID Serial Number

WARNING: Confirm that the robot and the controller have

the same serial number. Special care must be taken when

more than one robot is to be installed. If the numbers do

not match, robots may not perform as expected and cause

injury or damage.

Location

of serial

label

Chapter 1 - Introduction

16 AdeptSix 300CR Robot Instruction Handbook, Rev. A

1.5 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 the following information sources on Adept’s corporate web

site:

• For Contact information: http://www.adept.com/main/contact/index.html

• For Product Support information: http://www.adept.com/main/services/index.asp

• For general information about Adept Technology, Inc.: http://www.adept.com

1.6 Related Manuals

This manual covers the installation and maintenance of an AdeptSix 300CR system. There

are additional manuals that cover programming the system, reconfiguring installed

components, and adding other optional components. The following manuals (available on

the Knowledge Express CD-ROM provided with each system) provide information on

advanced configurations and system specifications.

Table 1-1. Related Manuals

Manual Title Description

AdeptSix Controller

Installation Guide

Describes the installation process for the Adept MV controller

and the Adept SmartController.

Adept MV Controller User’s

Guide

Describes the configuration and interface options for all

Adept-supplied processor boards and components that can be

installed in an Adept control system.

Adept SmartController

User’s Guide

Contains complete information on the operation of the Adept

SmartController and the optional sDIO product.

AdeptWindows Installation

Guide

Describes the basic installation process for the AdeptWindows

PC user interface.

AdeptWindows User’s

Guide

Describes complex network installations, installation and use

of NFS server software, the Adept Windows Offline Editor, and

the AdeptWindows DDE 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.

Knowledge Express

AdeptSix 300CR Robot Instruction Handbook, Rev. A 17

1.7 Knowledge Express

In addition to the Knowledge Express CD-ROM containing Adept manuals, you can find

Adept product documentation on the Adept web site in the Knowledge Express area. The

Knowledge Express search engine allows you to locate information on a specific topic.

Additionally, the Library menu provides a list of available product documentation.

To access Adept’s Knowledge Express, type the following URL into your browser:

http://www.adept.com/Main/KE/DATA/adept_search.htm

or, select the Knowledge Base link from the Services area of the Adept web site.

AdeptSix 300CR Robot Instruction Handbook, Rev. A 19

Safety 2

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:

NOTE: This provides supplementary information, emphasizes a point or

procedure, or gives a tip for easier operation.

DANGER: This indicates an imminently hazardous

situation which, if not avoided, will result in death or

serious injury.

WARNING: This indicates a potentially hazardous

situation which, if not avoided, could result in serious

injury or major damage to the equipment.

CAUTION: This indicates a situation which, if not avoided,

could result in minor injury or damage to the equipment.

Chapter 2 - Safety

20 AdeptSix 300CR Robot Instruction Handbook, Rev. A

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.

Definition of a Manipulating Industrial Robot

The definition of a manipulating robot according to (ISO 10218:1992(E)) is as follows:

“A manipulating robot is 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

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 2.8 on

page 28).

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 AdeptSix Controller

Installation Guide for additional information.

Impact and Trapping Points

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.

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.

Precautions and Required Safeguards

AdeptSix 300CR Robot Instruction Handbook, Rev. A 21

Hazards From Expelling a Part or Attached Tooling

The maximum joint tip speeds that can be achieved by the AdeptSix 300CR robot are

listed in Table 10-1 on page 95. 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 = mv2.

NOTE: In the Projectile energy formula above:

•E = Energy

•m = Mass

•v = Velocity

Additional Safety Information

The standards and regulations listed in this handbook contain additional guidelines for

robot system installation, safeguarding, maintenance, testing, startup, and operator

training. Table 2-1 on page 22 lists some sources for the various standards.

---

Chapter 2 - Safety

22 AdeptSix 300CR Robot Instruction Handbook, Rev. A

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://www.semi.org/web/wcontent.nsf/url/stds_home

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 für 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 313-994-3338

http://www.robotics.org

Risk Assessment

AdeptSix 300CR Robot Instruction Handbook, Rev. A 23

2.3 Risk Assessment

Without special safeguards in its control system, the AdeptSix 300 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.

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 in

Manual Mode by a skilled programmer (see “Qualification of Personnel” on page 29),

who must wear safety equipment (see “Safety Equipment for Operators” on page 29)

and carry the Manual Control Pendant (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 AdeptSix 300CR 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).

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

R15.06

CAN/CSA-

Z434-94

Industrial Robots and Robot

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

Chapter 2 - Safety

24 AdeptSix 300CR Robot Instruction Handbook, Rev. A

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 MCP when inside the work envelope, as the MCP

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.

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:

1. Programming from outside the safety barrier.

2. Programming with Arm Power off.

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 AdeptSix 300 robot 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 the 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.

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 enabled, except for teaching in Manual Mode.

Failure to install suitable guarding could result in injury or

death.

Intended Use of the Robots

AdeptSix 300CR Robot Instruction Handbook, Rev. A 25

The standard AdeptSix 300 robot control system meets or exceeds the requirements

imposed by the EN 954 specified Category 1 level of safety.

2.4 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 2.8 on page 28).

The AdeptSix 300CR Robot robots are intended for use in parts assembly and material

handling for payloads less than 3 kg. See Chapter 5 for complete information tooling and

payloads.

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:

• In hazardous (explosive) atmospheres

• In mobile, portable, marine, or aircraft systems

• In life-support systems

• In residential installations

• In situations where the Adept equipment will be subject to extremes of heat or

humidity.

Non-intended use of an AdeptSix 300 robot can:

• Cause injury to personnel

• Damage the robot or other equipment

• Reduce system reliability and performance

All persons that install, commission, operate, or maintain the robot must:

CAUTION: For safety reasons, it is prohibited to make

certain modifications to Adept robots (see Section 2.5).

CAUTION: The instructions for operation, installation, and

maintenance given in this Instruction Handbook must be

strictly observed.

Chapter 2 - Safety

26 AdeptSix 300CR Robot Instruction Handbook, Rev. A

• Have the necessary qualifications

• 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 tool mount flange.

• 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.

• Modifying any of the robot harnesses or robot-to-controller cables.

• Modifying any robot access covers or drive system components.

• Modifying, including drilling or cutting, any robot surface.

• Modifying any robot electrical component or printed-circuit board.

• Routing additional hoses, air lines, or wires through the inside of the robot.

• Modifications that compromise EMC performance, including shielding.

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:

AdeptSix 300CR Hazards and Warning Labels

AdeptSix 300CR Robot Instruction Handbook, Rev. A 27

2.6 AdeptSix 300CR Hazards and Warning Labels

Risks from injury are clearly identified on the AdeptSix 300CR by warning labels. The

location of these labels is illustrated in Figure 2-1.

Figure 2-1. AdeptSix 300CR — Warning Labels

2.7 Transport

Always use adequate equipment to transport and lift Adept products. See Chapter 3 for

more information on transporting, lifting, and installing.

3BC

2BC

1BC

Do not enter

robot work area

WARNING

Moving parts may

cause injury

WARNING

Chapter 2 - Safety

28 AdeptSix 300CR Robot Instruction Handbook, Rev. A

2.8 Safety Requirements for Additional Equipment

Additional equipment used with the AdeptSix 300 robot (grippers, conveyor belts, etc.)

must not 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.

2.9 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 2.11 on page

29) 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 disconnected. After these

precautions, a skilled person is allowed to perform maintenance on the robot. See

Section 2.10 for the specifications.

CAUTION: Never remove any safeguarding and never

make changes in the system that will decommission a

physical safeguard.

Qualification of Personnel

AdeptSix 300CR Robot Instruction Handbook, Rev. A 29

2.10 Qualification of Personnel

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:

•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 by another person while you are working on the system.

1. Has received the instruction handbook

2. Has read the instruction handbook

3. Understands the instruction handbook

4. Will work in the manner specified by the instruction handbook.

2.11 Safety Equipment for Operators

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

• 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.

WARNING: The user must get confirmation from every

entrusted person before they start working with the robot

that the person:

Chapter 2 - Safety

30 AdeptSix 300CR Robot Instruction Handbook, Rev. A

2.12 Protection Against Unauthorized Operation

The system must be protected against unauthorized use. The user or operator must

restrict access to the keyboard and the Manual Control Pendant by locking them in a

cabinet or use another adequate method to prevent access to them.

2.13 Safety Aspects While Performing Maintenance

Only skilled persons with the necessary knowledge about the safety and operating the

equipment are allowed to maintain the robot, controller, and power chassis.

2.14 Risks That Cannot Be Avoided

The AdeptSix 300 robot 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

• Failure of hardware associated with enabling device or E-Stop system

2.15 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 workpiece (see “Hazards From Expelling a Part or Attached Tooling”

on page 21).

CAUTION: During maintenance and repair, the power of

the Adept controller must be turned off. Lockout measures

must be used to prevent unauthorized personnel from

turning on power.

What to Do in an Emergency Situation

AdeptSix 300CR Robot Instruction Handbook, Rev. A 31

2.16 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 CO2 to extinguish the fire.

Chapter 2 - Safety

32 AdeptSix 300CR Robot Instruction Handbook, Rev. A

AdeptSix 300CR Robot Instruction Handbook, Rev. A 33

Robot Installation 3

3.1 Safety Guard Installation

To ensure safety, make sure to install safety guards, which prevent unforeseen accidents

with personnel and damage to equipment. The following standard is noted below for

your information and guidance.

Safety Standard Information (ISO10218)

Responsibility for Safeguarding

The user of a manipulator or robot system shall ensure that safeguards are provided and

used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of

safeguarding, including any redundancies, shall correspond directly to the type and level

of hazard presented by the robot system consistent with the robot application.

Safeguarding may include but not be limited to safeguarding devices, barriers, interlock

barriers, perimeter guarding, awareness barriers, and awareness signals.

WARNING: Install the safety guards. Failure to observe

this warning may result in injury or damage.

WARNING: Install the robot in a location where the fully

extended arm and end-of-arm tooling will not reach the

wall, safety guards, or controller. Failure to observe this

warning may result in injury or damage.

WARNING: Do not start the robot or even turn on the

power before it is firmly anchored. The robot may

overturn and cause injury or damage.

Chapter 3 - Robot Installation

34 AdeptSix 300CR Robot Instruction Handbook, Rev. A

3.2 Transporting Method

Using the Crane

As a rule, a crane should be used to remove the robot from its package and to move the

robot into position. The robot should be lifted using wire slings threaded through the

attached eyebolts. Make sure the robot is fixed with jigs before transporting, and lift it into

the position shown in Figure 3-1 on page 35. Points A and B in Figure 3-1 identify the

locations of the shipping bracket and jig.

WARNING: When mounting the robot on the ceiling or

wall, the base section must have sufficient strength and

rigidity to support the weight of the robot. Also, it is

necessary to consider countermeasures to prevent the

robot from falling. Failure to observe these warnings may

result in injury or damage.

WARNING: Do not install or operate a robot that is

damaged or lacking parts. Failure to observe this caution

may cause injury or damage.

CAUTION: Before turning on the power, make sure that

the shipping bracket and jig have been removed. Failure to

observe this caution may result in damage to the gear

train, motors, and other key system components.

Transporting Method

AdeptSix 300CR Robot Instruction Handbook, Rev. A 35

Figure 3-1. Transporting Position

WARNING: Sling applications via crane or forklift must be

performed by authorized personnel only. Failure to

observe this caution may result in injury or damage.

CAUTION: Avoid excessive vibration or shock during

transporting. The system consists of precision

components, so failure to observe this caution may

adversely affect performance.

2X M8 Eyebolts

(provided at factory)

Details of E

Details of D

2X M5 Washers

(anti-corrosive)

2X M6 Coned disc springs

(anti-corrosive)

2X Urethane washers

1X Urethane washer

2X M5 10 mm Hexagon

socket head cap bolts

(anti-corrosive)

2X M6 40 mm Hexagon

socket head cap bolts

(anti-corrosive)

M6 8 mm Hexagon

socket head cap bolt

(anti-corrosive)

Details of C

Chapter 3 - Robot Installation

36 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Using the Forklift

When using a forklift, the robot should be fixed on a pallet with its shipping bracket and

jig, as shown in Figure 3-2. Insert the forklift blades under the pallet and lift it. The pallet

must be strong enough to support the robot. Transportation of the robot must be

performed slowly in order to avoid overturning, slippage, or damage.

Figure 3-2. Using the Forklift

When using the forklift, note the following:

• Check that the eyebolts are securely fastened.

• Use a wire sling that is strong enough to withstand the weight. (The weight of the

robot is approximately 35 kg, including the shipping bracket and jig.)

• Attached eyebolts are designed to support the robot’s weight. Do not use them for

anything other than transporting the robot.

• Mount the shipping bracket and jig for transporting the robot.

• Avoid exerting force on the arm or motor unit when transporting. Exercise caution

when using transporting equipment other than a crane or forklift, as injury may

occur.

4 x M10 Bolts

Pallet

Forklift Blade Entry

Shipping Bracket and Jig

AdeptSix 300CR Robot Instruction Handbook, Rev. A 37

3.3 Shipping Bracket and Jig

The robot is provided with a shipping bracket and jig at points A and B. See Figure 3-3 on

page 38 for details.

• The shipping bracket and jig are painted yellow.

• The number of hexagon socket head cap screws are: A: M6 X 2, B: M5 X 2.

• To prevent the jigs from damaging the paint of the robot, the resin washers are

inserted between the robot and the jigs.

NOTE: Before turning on the power, make sure that the robot is securely

mounted to its mounting base and that the shipping bracket and jig have

been removed. Then store the shipping bracket and jig for future use (in

the event that the robot must be moved again).

NOTE: Remove the protective covers from the 1BC and 2BC connectors

prior to installing the power and signal interconnect cables.

3.4 Installing Cover Bolts

After mounting the robot, remove the shipping bolts and jigs that were attached when

using the crane, and insert the cover bolts. When transporting the robot again, replace

them with the shipping bolts and jigs. Figure 3-3 illustrates the procedure for installing

the cover bolts

Chapter 3 - Robot Installation

38 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 3-3. Installing Cover Bolts

3.5 Types of Mounting

The robot can be mounted in three different ways: floor-mounted (standard),

wall-mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted

types, contact Adept.

2X Urethane washers

Detail A

Detail B

Shipping jig

2X M8 Eyebolts

Detail A

Detail B

Remove shipping jig and

insert the cover bolts

2X M6 Hexagon socket head bolts (anti-corrosive)

( Attached with shipping products)

Remove shipping jig and

insert the cover bolts

2X M5 Washers (anti-corrosive)

Use shipping bolts

2X M5 Hexagon socket head bolts (anti-corrosive)

2X Urethane washers

Mounting Procedures for Robot

AdeptSix 300CR Robot Instruction Handbook, Rev. A 39

3.6 Mounting Procedures for Robot

The robot should be firmly mounted on a baseplate or foundation strong enough to

support the robot and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand maximum

repulsion forces of the robot as shown in Table 3-1.

During installation, if the level of the mounting plane is not right, the robot’s functional

ability may be compromised. The level of the plane of installation must be kept at 0.5 mm

or less. Mount the baseplate in either of the two ways described on page 40.

When the Robot and Mounting Fixture are

Installed on a Common Installation Base

The common base should be rugged and durable to prevent shifting of the robot or the

mounting fixture. The thickness of the common base should be 30 mm or more, and an

M10 size or larger anchor bolt is recommended. Affix the robot by fastening the plate with

the M10 (mm) anchor bolts. The plate is tapped for M10 (35 mm length) bolts. Tighten the

plate fixture, mounting bolts, and anchor bolts securely so that they will not work loose

during operation. See Figure 3-4 for details.

Figure 3-4. Mounting the Robot Baseplate

Table 3-1. Maximum Repulsion Forces of the AdeptSix 300CR

Maximum horizontal rotating torque

(direction of motion Axis 1)

500 N·m (51.0 kgf·m)

Maximum vertical rotating torque

(direction of motion Axes 2 and 3)

700 N·m (71.4 kgf·m)

4X M10 Spring washers

(anti-corrosive, provided at factory)

4X M10 Washers

(anti-corrosive, provided at factory)

4X M10 35 mm Hexagon socket head cap bolts

(anti-corrosive, provided at factory)

Common installation base

Anchor bolts M10 or more

Details of A

Chapter 3 - Robot Installation

40 AdeptSix 300CR Robot Instruction Handbook, Rev. A

When the Robot is Mounted Directly on the Floor

The floor should be strong enough to support the robot. Construct a solid foundation with

the appropriate thickness to withstand maximum repulsion forces of the robot as shown

in Table 3-1 on page 39. As a rough standard, when there is a concrete thickness (floor) of

150 mm or more, the base of the robot can be fixed directly to the floor with M10 anchor

bolts. Before mounting the robot, however, check that the floor is level and that all cracks,

etc. are repaired. Any thickness less than 150 mm is insufficient for mounting, even if the

floor is concrete.

Figure 3-5. Direct Mounting on the Floor

3.7 Axis Naming Conventions

The robot’s six axes are referred to throughout this documentation as either Axis 1-6 or

Joint (J) 1-6. These terms are used interchangeably. For legacy reasons, these axes are

labelled on the robot as S-axis, L-axis, U-axis, R-axis, B-axis, and T-axis. The table below

shows how these current axis labels correspond to the legacy labels.

150 mm

or more

4X M10 Spring washers

(anti-corrosive)

4X M10 35 mm Hexagon

socket head cap bolts (anti-corrosive)

4X M10 Washers

(anti-corrosive)

Anchor bolts M10 or mor

Details of A

Installation base

Grating

Grounding the Robot

AdeptSix 300CR Robot Instruction Handbook, Rev. A 41

See Figure 10-1 on page 96 for a drawing that identifies the various axes.

3.8 Grounding the Robot

Follow local regulations for grounding line size.

NOTE: Do not use this line in common with other ground lines or

grounding electrodes for other electric power, motor power, welding

devices, etc.

NOTE: Where metal ducts, metallic conduits, or distributing racks are

used for cable laying, ground in accordance with Electric Equipment

Technical Standards.

Table 3-2. Axis Naming Conventions

Current Axis

Labels

Legacy Axis

Labels

Axis 1 (J1) S-axis

Axis 2 (J2) L-axis

Axis 3 (J3) U-axis

Axis 4 (J4) R-axis

Axis 5 (J5) B-axis

Axis 6 (J6) T-axis

WARNING: Ground resistance must be 100 Ω or less.

Failure to observe this warning may result in fire or

electric shock.

WARNING: Before wiring, make sure to switch off the

primary power supply, and place a warning sign (for

example, Do not switch on the power). Failure to observe this

warning may result in fire or electric shock.

Chapter 3 - Robot Installation

42 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 3-6. Grounding Method for Robot

3.9 Environmental Requirements

The environmental conditions of the area in which the robot is installed must satisfy the

conditions listed below:

• Ambient temperature must be from 0° to +45° C

• No moisture should be present (20 to 80% RH)

• Level of the mounting plane for installation must be 0.5 mm or less

• System must be isolated from excessive electrical interference or noise (plasma)

• The area must be free from:

• Dust, soot, and water

• Corrosive gases and liquids, as well as explosive gases

• Excessive vibration (less than 0.5 G)

WARNING: Wiring must be performed by authorized or

certified personnel. Failure to observe this caution may

result in fire or electric shock.

M8 Bolt - for grounding

(provided at factory)

5.5 mm2 or more

View A

AdeptSix 300CR Robot Instruction Handbook, Rev. A 43

System Cable Installation 4

4.1 System Cable Diagrams

Adept MV Controller System

Figure 4-1. System Cable Diagram with Adept MV Controller

AWC II

STP

SCR

VME

adept

technology, i nc.

ENC

PORTS

IEEE

1394

ENC

MAI STATUS

MAI

DSP STATUS

LOW VOL TS ON

HV SAG/OV ER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOLTS ON

CH2

CH2CH1

DUAL E AMP

LOW VOLTS ON

HV SAG/OV ER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOL TS ON

CH2

CH2CH1

DUAL E AMP

W V

G/O

V ER TEMP FA

T REM

R IN

TALL THI

RT FA

PEN

KT FA

NLE

H V

MPLETELY DI

TIN

PWM ON

CH1

H V

CH2

CH1

AL E AM

Ethernet to PC

WARNING:

FOR CONTINUED PROTECTION

AGAINST RISK OF FIRE,

REPLACE ONLY WITH SAME

TYPE AND RATING OF FUSE.

USE ONLY WITH

250V FUSES

~100-240V

50/60HZ

5AF

Adept MV

Controller

CIP-

Arm Power Cable

< 250 mm/s 100%

STOP

MCP

NET

Arm

Signal

Cable 1B

CIP (JSLV) to MAI-2 (XSLV1)

CIP (JAWC) to AWC (CIP)

AWC IEEE 1394 (Port 1) to

MAI-2 IEEE 1394 (Port 1)

CN29

Cable

MCP

AdeptSix 300CR

Robot

Adept PA-4

Power Chassis

Desktop or Laptop PC User-Supplied

Ground Wire

Dual E Amp #1

Dual E Amp #2

Dual E Amp #3

MAI-2 Module

Chapter 4 - System Cable Installation

44 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Adept SmartController System

Figure 4-2. System Cable Diagram with Adept SmartController

adept

technology, inc.

ENC

PORTS

IEEE

1394

ENC

MAI STATUS

MAI

DSP STATUS

LOW VOLTS ON

HV SAG/OVER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOLTS ON

CH2

CH2CH1

DUAL E AMP

LOW VOLTS ON

HV SAG/OVER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOLTS ON

CH2

CH2CH1

DUAL E AMP

W V

G/O

VER TEMP FA

T REM

R IN

TALL THI

RT FA

PEN

KT FA

NLE

H V

MPLETELY DI

TIN

PWM ON

CH1

H V

CH2

CH1

AL E AM

Ethernet to PC

Arm

Power

Cable

Arm

Signal

Cable 1B

Controller SmartServo (Port 1.1) to

MAI-2 IEEE 1394 (Port 1)

CN29

Cable

Adept PA-4

Power Chassis

Adept

ontrolle

AdeptSix 300CR

Robot

User-Supplied

Power Supply

Controller

(

XFP

)

Front Panel

(

XFP

)

nt P

Controller (XSYS) to MAI-2 (XSLV1)

24VDC Power from

User-Supplied

Power Supply to

Controller (XDC1)

MCP

Controller (XMCP) to MCP

Desktop or Laptop PC

P Ada

ter

abl

User-Supplied Ground Wire

User-Supplied

Ground Wire

User-Supplied Ground Wire

Between PA-4 and SmartController

Dual E Amp #1

Dual E Amp #2

Dual E Amp #3

MAI-2 Module

STOP

ntroller

356

1-XXXXX

Cable Connections from Robot to PA-4 Power Chassis

AdeptSix 300CR Robot Instruction Handbook, Rev. A 45

4.2 Cable Connections from Robot to PA-4 Power Chassis

There are two interconnect cables: the arm signal cable (1BC) and the arm power cable

(2BC). Connect these cables to the robot base connectors and the PA-4 power chassis. Refer

to Figure 4-3 and Figure 4-4 on page 46.

Connection to the Robot

1. Remove the protective covers from the 1BC and 2BC connectors on the back plate

of the robot prior to installing the power and signal cables.

2. Before connecting the two cables described above to the robot, verify the

numbers, 1BC and 2BC, on both interconnect cables and the robot base

connectors.

3. When connecting, adjust the cable connector positions to the main key positions

of the robot, and insert the cables in the following order: Arm Power (2BC), Arm

Signal (1BC).

4. Secure the cables via the locking latch.

Figure 4-3. Interconnect Cables

2BC

1 BC

Connection to PA-4 Chassis Connection to the Robot

Connector

CNPG123

CNPG456

Ground

CN29

CN1

CN2

CN3

CN4

CN5

CN6

Motor Output

Connector Clamp

Terminal

1BC

Arm Signal

Cable

2BC

Arm Power

Cable

M3 Bolt

Connector

Robot Base Side

Chapter 4 - System Cable Installation

46 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 4-4. Interconnect Cable Connection to the Robot

Connection to the PA-4 Power Chassis

Refer to the following information for details on connecting the cabling between the robot

and the Adept PA-4 power chassis, and peripheral equipment. See Figure 4-1 on page 43

or Figure 4-2 on page 44, depending on which controller you are using.

1. Connect the end of the Arm Power cable with the motor output connector clamp

to the six connectors on the three Dual E amp modules.

NOTE: The CH connectors on all the Dual E Amps are labelled CH1 and

CH2. For reference, Figure 4-5 on page 47 matches CN plugs 1 to 6 with

the CH connectors (labelled CH 1 to 6 in the drawing).

2. Install the plug labeled CN29 on the Arm Power cable in the CN29 connector on

the Multi-Axis Interface (MAI-2) module.

3. Connect the end of the Arm Signal cable with two plugs to the two connectors on

the MAI-2 module in the following order.

a. Install the plug labeled CNPG456 in the CNPG456 connector.

b. Install the plug labeled CNPG123 in the CNPG123 connector.

4. Install one ground wire each from the Arm Signal Cable and the Arm Power

Cable to the front right screw on the top of the Adept PA-4 power chassis.

NOTE: Provide strain relief for the motor power and signal cable

connectors at the amplifier modules.

onnection details

of the power suppl

cable

(

robot

)

Cable Connections from Robot to PA-4 Power Chassis

AdeptSix 300CR Robot Instruction Handbook, Rev. A 47

Figure 4-5. PA-4 Power Chassis

adept

technology, inc.

ENC

MAI STATUS

MAI

DSP STATUS

LOW VOLTS ON

HV SAG/OVER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOLTS ON

CH2

CH2CH1

DUAL E AMP

LOW VOLTS ON

HV SAG/OVER TEMP FAULT

DO NOT REMOVE OR INSTALL THIS

SHORT FAULT

OPEN CKT FAULT

MODULE UNLESS HIGH VOLTS LED

IS COMPLETELY DISTINGUISHED

PWM ON

CH1

HIGH VOLTS ON

CH2

CH2CH1

DUAL E AMP

W V

G/O

VER TEMP FA

T REM

R IN

TALL THI

RT FA

PEN

KT FA

NLE

H V

MPLETELY DI

TIN

PWM ON

CH1

H V

CH2

CH1

AL E AM

CH3

CH6

CH2

CH5

CH1

CH4

Status LEDs

Break Release Box

XSLV1

XSLV2

RS-232

CNPG456

CNPG123

IEEE 1394 Port 1

IEEE 1394 Port 2

CN29 Arm Brake

CN25 (Future options)

Dual E Amp #3

Dual E Amp #2

Dual E Amp #1

MAI-2 Mo

Chapter 4 - System Cable Installation

48 AdeptSix 300CR Robot Instruction Handbook, Rev. A

4.3 Cable Connections to MV Controller

Installing the MV Controller

Refer to the AdeptSix Controller Installation Guide for complete information on

installing the Adept MV controller. This list summarizes the main steps.

1. Connect the CIP-2 to the AWC-II in the MV controller.

2. Connect the MCP to the CIP-2.

3. Connect AC power to the controller.

4. Install the AdeptWindows PC user interface.

Cable Connections to MV Controller

See Figure 4-1 on page 43.

1. Install one end of the IEEE 1394 cable into the top (upper-most) 1394 connector on

the AWC-II board, and install the other end into the IEEE 1394 port 1 connector on

the MAI-2.

2. Install the cable between the MAI-2 module XSLV-1 safety interlock connector

and CIP-2 (JSLV) connector, and tighten the latching screws.

3. Install the cable between the AWC-II (CIP-2) and CIP-2 (JAWC). Verify that the

plug is latched on both ends of the cable.

Connecting User-Supplied Safety and I/O Equipment

Refer to the Adept MV Controller User’s Guide for information on connecting the

following equipment:

• safety equipment incorporated into the E-Stop system

• digital I/O equipment

• serial I/O equipment

Cable Connections to SmartController

AdeptSix 300CR Robot Instruction Handbook, Rev. A 49

4.4 Cable Connections to SmartController

Installing the SmartController

Refer to the AdeptSix Controller Installation Guide for complete information on

installing the Adept SmartController. This list summarizes the main steps.

1. Mount the SmartController and Front Panel.

2. Connect the Front Panel to the SmartController.

3. Connect the MCP to the SmartController.

4. Connect user-supplied 24 VDC power to the controller.

5. Install a user-supplied ground wire between the SmartController and ground.

6. Install a user-supplied ground wire between the SmartController and the PA-4

chassis.

7. Install the AdeptWindows PC user interface.

Cable Connections to SmartController

See Figure 4-2 on page 44.

1. 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 IEEE 1394 port 1 connector

on the MAI-2 module.

2. Install the cable between the MAI-2 module XSLV1 safety interlock connector and

XSYS connector on the SmartController, and tighten the latching screws.

Connecting User-Supplied Safety and I/O Equipment

Refer to the Adept SmartController User’s Guide for information on connecting the

following equipment:

• safety equipment incorporated into the E-Stop system

• digital I/O equipment

• serial I/O equipment

Chapter 4 - System Cable Installation

50 AdeptSix 300CR Robot Instruction Handbook, Rev. A

AdeptSix 300CR Robot Instruction Handbook, Rev. A 51

End of Arm Tooling 5

5.1 Allowable Wrist Load

The allowable wrist load is 3 kg. If force is applied to the wrist instead of the load, force on

Axes 4, 5, and 6 should be within the values shown in Table 5-1. Contact your Adept

representative for further information or assistance.

When the volume load is small, refer to the moment arm rating shown in Figure 5-1.

The allowed total inertia is calculated when the moment is at the maximum. Contact your

Adept representative when:

• Only load moment is small and inertia moment is large

• The load mass is combined with an outside force

Figure 5-1. Moment Arm Rating

Table 5-1. Moment and Total Inertia

Axis Moment N·m (kgf·m) a

aValues that appear inside parentheses are given in gravitational units.

GD2/4 Total Inertia kg·m2

Axis 4 5.39 (0.55) 0.1

Axis 5 5.39 (0.55) 0.1

Axis 6 2.94 (0.3) 0.03

Load Gravity Position

Axis 6 Rotation

Centerline

Axis 5 Rotation

Centerline

LAxis 5

LAxis 6

(mm)

Axis6

(mm)

Axis5

200

100

0100 200

W=1.5 kg

W=3 kg

300

Chapter 5 - End of Arm Tooling

52 AdeptSix 300CR Robot Instruction Handbook, Rev. A

5.2 Wrist Tool Flange

The wrist tool flange dimensions are shown in Figure 5-2. In order to see the tram marks,

it is recommended that the attachment be mounted inside the fitting. The fitting depth of

the inside and outside fittings must be 6 mm or less.

Figure 5-2. Wrist Tool Flange

NOTE: Clean off the anticorrosive material on the tool flange area prior to

mounting the end of arm tooling. This anticorrosive material is only used

to protect the robot during shipping.

Tram mark

45˚

P.C.D31.5

4-M5 x P0.8 Depth 9 mm

Ø20H6 Ø40H6

Ø5H7 Depth 7 mm

45°

End of Arm Tooling Load Definitions

AdeptSix 300CR Robot Instruction Handbook, Rev. A 53

5.3 End of Arm Tooling Load Definitions

The end of arm tooling payload includes weight, location of the center of gravity, and the

moment of inertia at the center of gravity of the installed tool. See Figure 5-3.

Figure 5-3. Center of Gravity: Calculating Tool Load Information

Weight: W (kg)

The total weight of the installed tooling is set based on the above calculations.

For rough calculations, set a slightly larger value and keep increasing the value for each

unit by 0.5 to 1 kg for small to medium size robots; for larger robots, increase the value by

0.5 to 5 kg units.

Center of Gravity: xg, yg, zg (mm)

The location of the center of gravity of the installed tool is set based on the position of the

tool flange coordinates.

Moment of inertia at the center of gravity: lx, ly, lz (kg.m²)

This is the moment of inertia of the tool based on the location of the center of gravity. The

value is calculated around each axis of the coordinate system, which is in parallel to the

flange coordinates, with its origin at the center of gravity of the tool.

This is used to calculate the moment of inertia and provide verification based on the

arm-specification requirements. The moment of inertia is typically not critical; in many

cases, calculated moment of inertia values are small, based on the payload and the center

of gravity. However, this is extremely critical when either the payload, or specifically the

moment of inertia, is exceeded. This condition has a drastic impact on arm performance

and reliability. See Figure 5-4.

* Flange Coordinates

XF: Direction right above when Axis 6 (T axis)

is at 0 pulse position and the flange surface

of the robot is turned to the front.

YF: Y axis led by XF, ZF

ZF: Perpendicular direction from flange surface

Center of Gravity Position

(Xg, Yg, Zg)

Inertia moment around center of gravity

Ix, Iy, Iz

Weight: W

XF*

ZF*

YF*

Chapter 5 - End of Arm Tooling

54 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 5-4. Moment of Inertia

5.4 Calculating the Moment of Inertia

The following methods can be used to calculate the rough values for the moment of

inertia, based on the center of gravity.

• Approximate the entire tool as a hexahedron or cylinder.

• Calculate the center of gravity position (plural mass) for each part weight.

The following examples provide details on the calculation methods.

Example 1

In this example, a sealing gun is utilized. It is assumed that the location of the center of

gravity is slightly offset from the centerline of the head, based on the tool flange

coordinates. See Figure 5-5.

In this case, there seems to be no problem, based on the size and weight of the gun, and

the moment of inertia with respect to the center of gravity.

The size of the tool is not too big.

Setting the inertia moment at the

center or gravity is not necessary.

The size of the tool is sufficiently large

that setting the inertia moment at the

center of gravity is necessary.

Calculating the Moment of Inertia

AdeptSix 300CR Robot Instruction Handbook, Rev. A 55

Figure 5-5. Center of Gravity: Sealing Gun Example

Tooling Details

• W:7.000 kg

• Xg:100.000 mm

• Yg:0.000 mm

• Zg:70.000 mm

• lx:0.000 kg.m²

• ly:0.000 kg.m²

• lz: 0.000 kg.m²

100

Center of Gravity Position

= (100, 0, 70)

Total Weight

Approx. 6.3 [kg]

7.00 [kg]

Chapter 5 - End of Arm Tooling

56 AdeptSix 300CR Robot Instruction Handbook, Rev. A

The following figures show examples of the moment of inertia for a hexahedron and

cylinder.

Figure 5-6. Moment of Inertia for Hexahedron and Cylinder

3 r 2 + H2

Ix = Iy = * W

r 2

Iz = * W

Ly2 + Lz2

Ix = * W

Lx2 + Lz2

Iy = * W

Lx2 + Ly2

Iz = * W

12 * Unit of Length: [m]

* Unit of Ix, Iy, Iz: [kg.m2]

* Unit of Weight: [kg]

Weight: W

Calculating the Moment of Inertia

AdeptSix 300CR Robot Instruction Handbook, Rev. A 57

Example 2

It is necessary to set the moment of inertia at the center of gravity when the entire size of

the tool and workpiece are large compared with the distance from the tool flange relative

to the position of the center of gravity. See Figure 5-7.

Roughly calculate the moment of inertia at the center of gravity based on “Example 1” on

page 54, using the hexahedron and cylinder concept for the entire tool.

Figure 5-7. Center of Gravity: Large Tool and Workpiece Example

Tooling Details

• W:100.000 kg

• Xg:0.000 mm

• Yg:0.000 mm

• Zg:250.000 mm

• lx:10.000 kg.m²

• ly:3.500 kg.m²

• lz: 10.500 kg.m²

Weight: W=55 + 40 = 95, approximated to 100 kg.

Center of gravity: Z offset position (Xg, Yg, Zg) = (0, 0, 250)

Moment of inertia at the center of gravity:

• The hexahedron of 0.500 x 0.400 x 1.000(m), which encloses the entire tool

including the assumed workpiece.

• Use the following formula to calculate the moment of inertia of a hexahedron.

lx = (Ly²*Lz²/12) * W = ((0.400²+1.000²)/12) * 100=9.667 Approx. 10.000

ly = (Lx²*Lz²/12) * W = ((0.500²+0.400²)/12) * 100=3.417 Approx. 3.500

lz = (Lx²*Ly²/12) * W = ((0.500²+1.000²)/12) * 100=10/417

Weight of Hand:

Approx. 55 kg

Weight of Workpiece:

Approx. 40 kg

250

1000

400

500

XF ZF

Chapter 5 - End of Arm Tooling

58 AdeptSix 300CR Robot Instruction Handbook, Rev. A

The steps below describe how to calculate the center of gravity, including the moment of

inertia, based on the center of gravity of the plural mass. This can be calculated based on

the weight and the center of gravity of each mass, when the tool is considered to consist of

two or more large mass objects, like a dual gun system.

1. Divide the tool into individual parts, so as to calculate the weight and center of

gravity of each part.

2. Calculate the weight and center of gravity of each part, based on the tool flange

coordinates. Refer to “Example 1” on page 54 for details on how to use the

hexahedron and cylinder examples to calculate these values.

Wi: Weight of the i-th parts (kg)

(xi, yi, zi): Center of gravity of the i-th parts (mm)

lcxi, lcyi, lczi: Moment of inertia of each i-th parts (kg.m²)

3. The position of the center of gravity for the entire tool is calculated using the

following formula.

xg={w1*x1+w2*x2+…+wi*xi}/(w1+w2+…+wi)

yg={w1*y1+w2*y2+…+wi*yi}/(w1+w2+…+wi)

zg={w1*z1+w2*z2+…+wi*zi}/(w1+w2+…+wi)

4. The moment of inertia at the center of gravity for the entire tool is calculated

using the following formula.

lx = {w1*((y1-yg)²+(z1-zg)²)*10-6 +lcx1}

+{w2*((y2-yg)²+(z2-zg)²)*10-6 +lcx2}

………………………………….

+ {wi*((yi-yg)²+(zi-zg)²)*10-6 +lcxi}

ly = {w1*((x1-xg)²+(z1-zg)²)*10-6 +lcy1}

+{w2*((x2-xg)²+(z2-zg)²)*10-6 +lcy2}

………………………………….

+ {wi*((xi-xg)²+(zi-zg)²)*10-6 +lcyi}

lz = {w1*((x1-xg)²+(y1-yg)²)*10-6 +lcz1}

+{w2*((x2-xg)²+(y2-yg)²)*10-6 +lcz2}

………………………………….

+ {wi*((xi-xg)²+(yi-yg)²)*10-6 +lczi}

Calculating the Moment of Inertia

AdeptSix 300CR Robot Instruction Handbook, Rev. A 59

Example 3

The following example shows how to calculate the center of gravity in cases where more

then two workpieces, such as the dual end effector system shown in Figure 5-8, are

utilized.

1. Define the center of gravity, based on the position of the center of gravity of the

tool being used, and define the moment of inertia based on the center of gravity of

the entire tool. Use the hexahedron and cylinder principle as described in

“Example 1” on page 54.

2. When the weight of each part and the center of gravity have been defined, the

position of the center of gravity, including the moment of inertia at the center of

gravity, can be calculated for the entire tool. Refer to “Example 1” on page 54 and

“Example 2” on page 57 for details.

Figure 5-8 shows how to calculate the required values.

Figure 5-8. Center of Gravity: Dual End Effector Example

Weight: W=w1+w2 = 3+6 = 9. Approx. 10 kg

Center of gravity: g=(w1*x1+w2*x2)/(w1+w2)

= (3*100+6*100)/(3+6) = 100 mm

Yg= (3*50+6*(-150))/(3+6) = -83.333 mm

Zg= (3*40+6*70)/(3+6) = 60 mm

The moment of inertia at the center of gravity:

lx = {w1*((y1-Yg)²+(z1-Zg)²)*10-6 +lcx1}

+{w2*((y2-Yg)²+(z2-Zg)²)*10-6 +lcx2}

= 3*((50(-83))² + (40-60)²* 10-6

+ 6*(((-150) – (-83))²+(70-60)²)* 10-6

= 0.082 = Approx. 0.100

ly = 3*((100-100)²+(40-60)²)* 10-6

+ 6*((100-100)²+(70-60)²)* 10-6

Gun 1

Gun 2

(Gun 1)

Weight: w1 = 3 kg

Center of Gravity:

x1 = 100 mm

y1 = 50 mm

z1 = 40 mm

(Gun 2)

Weight: w2 = 6 kg

Center of Gravity:

x2 = 100 mm

y2 = -150 mm

z2 = 70 mm

Center of Flange

100

50 150

Gun 1

Gun 2

(Top View)

Chapter 5 - End of Arm Tooling

60 AdeptSix 300CR Robot Instruction Handbook, Rev. A

= 0.002 = Approx. 0.010

lz = 3*((100-100)²+(50-(-83))²)* 10-6

+ 6*((100-100)²+((-150)-(-83))²)* 10-6

= 0.080 = Approx. 0.100

Tooling Details:

• W:10.000 kg

• Xg:100.000 mm

• Yg:-83.333 mm

• Zg:60.000 mm

• lx:0.100 kg.m²

• ly:0.010 kg.m²

• lz: 0.100 kg.m²

5.5 Mounting Equipment - Allowable Load

When peripheral equipment is attached to Axis 3, the following conditions must be

observed:

The allowable load on Axis 3 is a maximum of 4 kg, including the wrist load.

For instance, when the mass installed at the wrist point is 3 kg, the mass which can be

installed on the upper arm becomes 1 kg.

Figure 5-9. Installing Peripheral Equipment

119

Axis 3 Rotation Center

49 2-M6XP1.0 Tapped

Depth 12 mm

View A

User Electrical Lines and Air Lines

AdeptSix 300CR Robot Instruction Handbook, Rev. A 61

5.6 User Electrical Lines and Air Lines

There are 9 electrical cables (0.2mm) and an 1 air line that are used in the robot for the

peripheral devices mounted on the arm, as shown in Figure 5-10

The connector pins (1 to 9) are assigned as shown in Figure 5-11. Wiring must be

performed by user.

• The allowable current for cables is 2.5A or less for each cable

• The maximum pressure for the air hose is 490kPa (5 kgf/cm2). The inside diameter

is φ2.5 mm.

Figure 5-10. User Electrical and Air Lines

Air suppl

inlet 1

Air supply inlet

Air suppl

inlet

Air suppl

inlet 5

Port 2

(

)

Port 1

(

)

Air Inl

Axi

Air D

(

OUT

)

Valve t

pe: 10-VQD1151W-5M-M5(SMC

)

Air Supply Inlets: 1 to 4

Barb couplin

s for flexible tube (4 couplin

)

se a tube with an inner diameter of 2.

Air exhaust port: 5

Barb couplin

s for flexible tub

se a tube with an inner diameter of 2.

Internal Air Intake Port

Outer diameter: 34 mm

ser cable connector: HR1

A-1

TR-12

Mating plug: HR10A-10TP-12P

ser cable connector:

HR1

A-1

TR-12

Matin

plu

HR1

A-1

TP-12

Air Exh

aus

t Por

ed hole PT1/8

with cover plu

Air Intake Inlets

(

)

Tapped holes PT1/8 - with cover plu

er inlet: Port 1

Low

r inl

t: Port

Chapter 5 - End of Arm Tooling

62 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Figure 5-11. Detailed Drawing of Connector Pin Numbers

Pins number (1 to 9) of both connectors are used for end-of-arm tooling signals (0.2 mm2).

Pin numbers

712

11 (For incorporated valve)  For driving the valve 1 (24VDC, 4W)

12 (For incorporated valve)  For driving the valve 2 (24VDC, 4W)

10 (For incorporated valve)  24VDC, common

AdeptSix 300CR Robot Instruction Handbook, Rev. A 63

System Operation -

MV Controller 6

6.1 Introduction

This chapter covers system operation for AdeptSix robot systems using the Adept MV

Controller. If you have an Adept SmartController, refer to Chapter 7.

Verifying that the system is correctly installed and that all safety equipment is working

correctly is a three-step process. This chapter discusses the first two steps.

• Step one reviews starting the control system for the first time and verifying that all

components have been correctly installed.

• Step two (referred to as “commissioning the system”) verifies that all safety

equipment is working properly, after the safe initialization of the control system

has been verified.

• Step three verifies that the robot moves correctly. The Manual Control Pendant is

used for this step and is reviewed in Chapter 8.

6.2 Installation Check List

Before using the robot, make the following checks to ensure that the robot and controller

have been properly installed.

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 where

it is safe to turn on power to the robot system.

WARNING: After installing the robot, it must be tested

before it is used for the first time. Failure to do this could

cause serious injury or equipment damage.

Chapter 6 - System Operation - MV Controller

64 AdeptSix 300CR Robot Instruction Handbook, Rev. A

AC Power to Adept Components Checks

Verify that the Adept controller is correctly connected to the AC power source.

1. Make sure that AC power is shut off to the Adept controllers (MV and PA-4

power chassis).

2. Verify that the single phase AC power (180-245 VAC) is connected to the Adept

power controller.

3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected

to the Adept PA-4 power chassis. For information on single-phase AC power to

the PA-4, see the AdeptSix Controller Installation Guide.

4. If the System Power On/Off switch on the CIP-2 is used, check the connections to

this switch.

Board and Cable Installation Checks

Make sure that all the boards in the Adept controller and PA-4 power chassis are secured

and the connection cables are correctly installed.

1. Secure all boards and blank front panels to the Adept controller chassis. Tighten

both the top and bottom mounting screws on each front panel. This ensures

proper grounding of the controller from an EMC standpoint and ensures good

connection to the controller backplane.

2. Secure all amplifier modules and the MAI-2 (multi-axis interface) module in the

amp chassis. Tighten both the top and bottom mounting screws on each front

panel. This ensures proper grounding of the amplifier controller subsystems from

an EMC standpoint and ensures good connection to the drawer connectors at the

rear of the chassis. The drawer connectors carry power and interlock signals

from/into the power chassis from the amplifiers.

NOTE: There is a safety interlock built into the amp chassis that prevents

high power from being applied if the amplifier modules, or the MAI-2

module are not correctly screwed into place.

3. Verify the following cable connections. Check to see that the plugs are latched on

both ends of the cables. See Figure 4-1 on page 43.

• Robot to amps in PA-4 power chassis (Arm Power Cable)

• Robot CN29 connector to MAI-2 CN29 connector (Arm Power Cable)

• Robot to PA-4 power chassis MAI-2 (Arm Signal Cable)

• Install one ground wire each from Arm Signal Cable and Arm Power Cable

to front right screw on the top of the Adept PA-4 power chassis.

• 1394 AWC-II connector to MAI-2 IEEE 1394 connector

• CIP-2 to optional MCP (install bypass plug if not used)

• CIP-2 (JAWC connector) to AWC-II (CIP) connector

• CIP-2 (JSLV connector) to MAI-2 (XSLV1) connector

• JUSER to user-supplied equipment (install jumper plug if not used)

Installation Check List

AdeptSix 300CR Robot Instruction Handbook, Rev. A 65

4. Check the manual brake release box cable into the MAI-2 connector marked

Manual Brake Release. (if used)

5. If you are using the AdeptWindows PC user interface, connect a shielded

Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the

AWC-II board. Unshielded cables will degrade the integrity of the

AdeptWindows PC link, particularly when power is applied to the robot or

mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone

PC.

User-Supplied Safety Equipment on JUSER and JSIO Connector Checks

Check the following safety equipment connected to the JUSER and JSIO connectors on the

CIP-2:

1. There are eight pairs of contacts that must be connected on the JUSER connector

(see Adept MV Controller User’s Guide) to ensure proper continuity of the

emergency stop circuitry. Verify that these connections are secure and reliable and

that a redundant pair of contacts is installed, one for each E-Stop channel. Double

check that the state of the contacts on each pair matches and the contacts are

closed. Each contact is separately connected to its respective E-Stop channel.

Inadvertent connection between the E-Stop channels will short the E-Stop power

supply, making it impossible to apply High Power.

2. There are two pairs of contacts in the JSIO connector that must be connected to

ensure proper continuity of the emergency stop circuitry. Verify that these

connections are secure, reliable, and closed prior to enabling power.

3. Make sure that guarding around the workcell is properly connected to either the

Muted Safety gate inputs on the JUSER connector or, if appropriate, to the User

E-Stop connections on the JUSER connector. Make sure that all gate, E-Stop push

button switches, and other interlocks have two independent electrical poles.

Make sure that a pair of redundant contacts is installed and that these contacts are

separately connected to their respective E-Stop channels. Make sure that all

interlock or emergency stop devices are wired in series (not in parallel) before

connecting to the User E-Stop connections. Identify all wiring with Channel 1 or

Channel 2. Inadvertent connection between the channels will short the E-Stop

power supply, making it impossible to apply High Power.

4. Make sure that workcell components have been properly interlocked to avoid

hazards when the robot/motion system is operated in Manual Mode. (Per “ISO

10218 Manipulating Robots Safety”, the robot control system must employ a

“single point of control” when operated in Manual Mode.)

Chapter 6 - System Operation - MV Controller

66 AdeptSix 300CR Robot Instruction Handbook, Rev. A

E-Stop Button and Switch Checks

1. Verify that the red E-Stop push buttons on the CIP-2, MCP, and User Panel (if

installed) are in the normal, unlatched (electrically closed) position.

2. Verify that the MCP jumper plug on the CIP-2 is installed or that the optional

MCP is mounted on a rack that holds the MCP Enable switch in the ON position.

3. Verify that the user panel (if installed) enable contacts are closed, that a pair of

redundant contacts is installed and that these contacts are separately connected to

their respective E-Stop channels. Inadvertent connection between the channels

will short the E-Stop power supply, making it impossible to apply High Power to

the robot.

6.3 Applying Power to the Adept Control System

After you have made the checks listed above, system power is ready to be turned on.

1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (l)

position.

2. Turn the AC power switch on the Adept MV controller to the ON (l) position

3. Turn the System Power switch on the CIP-2, if used, to the ON (l) position.

4. The AWC-II will execute its boot sequence. When the boot sequence has

completed, the SF/OK LED should be green. If this LED is red, the AWC-II has

not booted properly. Turn off power to the controller and reboot. If the problem

persists, call Adept Customer Service. Note the state of the LEDs marked 1 to 3,

which indicate the problems shown in Table 6-1 on page 67.

5. The other LEDs should be off. If the ES (E-Stop) LED on the AWC-II board is

flickering red, this could result from:

a. An oscillation may be the result of a mismatch between the contacts forming

a “pair of contacts” in the two E-Stop channels. Perhaps on one channel, the

user E-Stop contacts are closed, and on the other they are open. Check each

pair of contacts to make sure that they match and that they are all closed per

Adept MV Controller User's Guide.

b. Also, a short between the two E-Stop channels may sometimes result in this

oscillating red ES LED. If the problem persists, call Adept Customer Service.

6. If the E-Stop LED is continuously red, then at least one pair of E-Stop contacts is

open or the E-Stop contacts on the JSIO connector are open. Review the checklist

items above to resolve the problem. If the problem persists, call Adept Customer

Service.

CAUTION: All safety systems must be in place and

operating before applying power to the system. Extra care

should be taken during the initial tests of the robot system.

Checks After Applying Power

AdeptSix 300CR Robot Instruction Handbook, Rev. A 67

LED Status Indicators on the AWC-II

The LEDs on the front of the AWC-II indicate the following conditions:

O = off G = green R = red

If the AWC-II displays any of the above errors, contact Adept Customer Service (see

“How Can I Get Help?” on page 16).

6.4 Checks After Applying Power

1. Verify that High Power can be enabled:

a. Enter the following command at the dot prompt in the monitor window:

enable power

Or press the COMP/PWR button on the MCP

b. When the High Power push button/light on the CIP-2 begins flashing, press

and hold the push button for 1 - 2 seconds. When you release the push

button, the light should remain lit continuously indicating that High Power

has successfully been enabled.

c. If the light does not stay on, the High Power enable process has failed and a

message will be displayed on the monitor and MCP indicating why.

2. Verify that all E-Stop devices are functional (MCP, CIP-2, and user supplied). Test

each mushroom button, safety gate, light curtain, etc., by enabling High Power

and opening the safety device. The High Power push button/light on the CIP-2

should go out and the red ES LED on the AWC-II should be lit.

Table 6-1. LED Status Indicators

LED Display Error # Description

O-O-O 0 No error.

O-O-R 1 System clock is dead or too fast. Clock interrupts are not being

received.

O-R-O 2 Hardware configuration error. Address switches/SYSCTL wrong.

O-R-R 3 Graphics board failure. VGB not responding.

R-O-O 4 Memory test failure. Free storage error.

R-R-O 6 Software serial I/O configuration error.

G-O-O C Uninitialized trap.

G-O-G D Bus error detected.

Chapter 6 - System Operation - MV Controller

68 AdeptSix 300CR Robot Instruction Handbook, Rev. A

6.5 Calibrate Robot

The AdeptSix robot uses optical absolute encoders to determine position of each axis, and

establish commutation reference for the phases of the motors. Since the motors are

brushless AC, the rotor must be commutated by electronics rather that using physical

brushes to switch current from phase to phase. The absolute encoders have the ability to

determine position for a full turn of the motor rotor. Built into the absolute encoder is a

multiple turn counter that keeps track of the number of times the absolute encoder has

completed a full revolution. The encoder system is powered by the Adept PA-4 power

chassis, and also has a battery backup to maintain position tracking during shipment of

the robot, or periods when the system is turned off.

1. Verify that you have enabled power as described above.

2. Enter the following command at the dot prompt in the monitor window:

calibrate

When calibration is complete, the monitor displays the dot prompt. This means

the system is ready for operation.

6.6 Turning Off the System

Follow these steps to turn off power to the robot system.

1. Make sure that robot motion has stopped.

2. Abort any programs that are running using the abort command.

3. Turn off High Power to the robot using the disable power command, or by

pressing the DIS PWR button on the MCP.

4. Turn off the AC power switch on the Adept MV controller.

5. Turn off the AC power switch on the PA-4 power chassis.

6.7 Learning to Operate/ Program the AdeptSix 300CR Robot

When the robot has been calibrated, refer to Chapter 8 to learn how to move the robot

with the optional MCP or go to the V+ Operating System User’s Guide to find information

on basic operation of the V+ Operating System. Also refer to the Instructions for Adept

Utility Programs for information on using the Adept utility programs.

For additional programming information you need to refer to the following list of

optional manuals:

• V+ Language User’s Guide

• V+ Language Reference Guide

• V+ Operating System Reference Guide

AdeptSix 300CR Robot Instruction Handbook, Rev. A 69

System Operation -

SmartController 7

7.1 Introduction

This chapter covers system operation for AdeptSix 300CR robot systems using the Adept

SmartController. If you have an Adept MV Controller, refer to Chapter 6.

Verifying that the system is correctly installed and that all safety equipment is working

correctly is a three-step process. This chapter discusses the first two steps.

• Step one reviews starting the control system for the first time and verifying that all

components have been correctly installed.

• Step two (referred to as “commissioning the system”) verifies that all safety

equipment is working properly, after the safe initialization of the control system

has been verified.

• Step three verifies that the robot moves correctly. The Manual Control Pendant is

used for this step. For more information about the MCP, see the Chapter 8 in this

manual and the Adept SmartController User’s Guide.

7.2 Installation Check List

Before using the robot, make the following checks to ensure that the robot and controller

have been properly installed.

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 where

it is safe to turn on power to the robot system.

WARNING: After installing the robot, it must be tested

before it is used for the first time. Failure to do this could

cause serious injury or equipment damage.

Chapter 7 - System Operation - SmartController

70 AdeptSix 300CR Robot Instruction Handbook, Rev. A

Power to the Adept Components Checks

Verify that the Adept control system is correctly connected to the DC and AC power

sources.

1. Make sure that power is shut off to the Adept SmartController and the PA-4

power chassis).

2. Verify that 24 DC power is connected to the Adept SmartController.

3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected

to the Adept PA-4 power chassis. For information on single-phase AC power to

the PA-4, see the AdeptSix Controller Installation Guide.

Board and Cable Installation Checks

Make sure that all the boards in the Adept SmartController and PA-4 power chassis are

secured and the connection cables are correctly installed.

1. Secure all amplifier modules and the MAI-2 (multi-axis interface) module in the

amp chassis. Tighten both the top and bottom mounting screws on each front

panel. This ensures proper grounding of the amplifier controller subsystems from

an EMC standpoint and ensures good connection to the drawer connectors at the

rear of the chassis. The drawer connectors carry power and interlock signals

from/into the power chassis from the amplifiers.

NOTE: There is a safety interlock built into the amp chassis that prevents

high power from being applied if the amplifier modules, or the MAI-2

module are not correctly screwed into place.

2. Secure the motor output connector clamp of the arm power cable onto the six

motor power output (Motor Power Outlet) connections on the three Dual E amps.

Verify that the clamp is securely latched.

3. Verify the following cable connections. Check to see that the plugs are latched on

both ends of the cables. See Figure 4-2.

• Robot to amps in PA-4 power chassis (Arm Power Cable)

• Robot CN29 connector to MAI-2 CN29 connector (Arm Power Cable)

• Robot to PA-4 power chassis MAI-2 CNPG123 and CNPG456 (Arm Signal

Cable)

• Install one ground wire each from Arm Signal Cable and Arm Power Cable

to front right screw on the top of the Adept PA-4 power chassis.

• SmartController SmartServo port 1.1 connector to MAI-2 1394 connector

• SmartController XSYS connector to MAI-2 XSLV1 connector

• SmartController XFP to Front Panel XFP

• SmartController XMCP to optional MCP, requires MCP adapter cable and

MCP3 dongle (install bypass plug if not used)

• SmartController XUSR to user-supplied equipment (install jumper plug if

not used)

Installation Check List

AdeptSix 300CR Robot Instruction Handbook, Rev. A 71

4. Secure the optional manual brake release box cable into the MAI-2 connector

marked Manual Brake Release. (if used)

5. If you are using the AdeptWindows PC user interface, connect a shielded

Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the

AWC-II board. Unshielded cables will degrade the integrity of the

AdeptWindows PC link, particularly when power is applied to the robot or

mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone

PC.

User-Supplied Safety Equipment on XUSR Connector Checks

Check the following safety equipment connected to the XUSR connector on the

SmartController.

1. There are eight pairs of contacts that must be connected on the XUSR connector

(see Adept SmartController User’s Guide) to ensure proper continuity of the

emergency stop circuitry. Verify that these connections are secure and reliable and

that a redundant pair of contacts is installed, one for each E-Stop channel. Double

check that the state of the contacts on each pair matches and the contacts are

closed. Each contact is separately connected to its respective E-Stop channel.

Inadvertent connection between the E-Stop channels will short the E-Stop power

supply, making it impossible to apply High Power.

2. Make sure that guarding around the workcell is properly connected to either the

Muted Safety gate inputs on the XUSR connector or, if appropriate, to the User

E-Stop connections on the XUSR connector. Make sure that all gate, E-Stop push

button switches, and other interlocks have two independent electrical poles.

Make sure that a pair of redundant contacts is installed and that these contacts are

separately connected to their respective E-Stop channels. Make sure that all

interlock or emergency stop devices are wired in series (not in parallel) before

connecting to the User E-Stop connections. Identify all wiring with Channel 1 or

Channel 2. Inadvertent connection between the channels will short the E-Stop

power supply, making it impossible to apply High Power.

3. Make sure that workcell components have been properly interlocked to avoid

hazards when the robot/motion system is operated in Manual Mode. (Per “ISO

10218 Manipulating Robots Safety”, the robot control system must employ a

“single point of control” when operated in Manual Mode.)

Chapter 7 - System Operation - SmartController

72 AdeptSix 300CR Robot Instruction Handbook, Rev. A

E-Stop Button and Switch Checks

1. Verify that the red E-Stop push buttons on the Front Panel, MCP, and User Panel

(if installed) are in the normal, unlatched (electrically closed) position.

2. Verify that the MCP jumper plug is installed on the controller or that the optional

MCP is mounted on a rack that holds the MCP Enable switch in the ON position.

3. Verify that the user panel enable contacts are closed, that a pair of redundant

contacts is installed and that these contacts are separately connected to their

respective E-Stop channels. Inadvertent connection between the channels will

short the E-Stop power supply, making it impossible to apply High Power to the

robot.

7.3 Applying Power to the Adept Control System

After you have made the checks listed above, system power is ready to be turned on.

1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (l)

position.

2. Turn on DC power to the Adept SmartController.

3. The SmartController will execute its boot sequence. When the boot sequence has

completed, the OK/SF LED should be green. If this LED is red, the

SmartController has not booted properly. Turn off power to the controller and

reboot. If the problem persists, call Adept Customer Service. Note the state of the

LEDs marked 1 to 3.

4. If the HPE/ES LED is continuously red, then at least one pair of E-Stop contacts is

open. Check all E-stops.

NOTE: For information on the Status LEDs, refer to the Adept

SmartController User’s Guide.

7.4 Checks After Applying Power

1. Verify that High Power can be enabled:

a. Enter the following command at the dot prompt in the monitor window:

enable power

Or press the COMP/PWR button on the MCP

CAUTION: All safety systems must be in place and

operating before applying power to the system. Extra care

should be taken during the initial tests of the robot system.

Calibrate Robot

AdeptSix 300CR Robot Instruction Handbook, Rev. A 73

b. When the High Power push button/light on the Front Panel begins flashing,

press and hold the push button for 1 - 2 seconds. When you release the push

button, the light should remain lit continuously indicating that High Power

has successfully been enabled.

c. If the light does not stay on, the High Power enable process has failed and a

message will be displayed on the monitor and MCP indicating why.

2. Verify that all E-Stop devices are functional (MCP, Front Panel, and user

supplied). Test each mushroom button, safety gate, light curtain, etc., by enabling

High Power and opening the safety device. The High Power push button/light on

the Front Panel should go out and the red HPE/ES LED on the SmartController

should be lit.

7.5 Calibrate Robot