Adept Cobra

s600/s800 Robot
User's Guide
 Adept Cobra
s600/s800 Robot
User's Guide

P/N: 03017-000, Rev L

August, 2012

5960 Inglewood Drive • Pleasanton, CA 94588 • USA • Phone 925.245.3400 • Fax 925.960.0452
Otto-Hahn-Strasse 23 • 44227 Dortmund • Germany • Phone +49.231.75.89.40 • Fax +49.231.75.89.450
Block 5000 Ang Mo Kio Avenue 5 • #05-12 Techplace II • Singapore 569870 • Phone +65.6755 2258 • Fax +65.6755 0598
 Copyright Notice

The information contained herein is the property of Adept Technology, Inc., and shall not be reproduced
in whole or in part without prior written approval of Adept Technology, Inc. The information herein is
subject to change without notice and should not be construed as a commitment by Adept Technology,
Inc. The documentation is periodically reviewed and revised.
Adept Technology, Inc., assumes no responsibility for any errors or omissions in the documentation. Crit-
ical evaluation of the documentation by the user is welcomed. Your comments assist us in preparation
of future documentation. Please submit your comments to: [email protected].
Copyright  2003-2012 by Adept Technology, Inc. All rights reserved.
Adept, the Adept logo, the Adept Technology logo, AdeptVision, AIM, Blox, Bloxview, FireBlox, Fireview,
Meta Controls, MetaControls, Metawire, Soft Machines, and Visual Machines are registered trademarks
of Adept Technology, Inc.
Brain on Board is a registered trademark of Adept Technology, Inc. in Germany.

Adept ACE, Adept AIB, Adept Cobra s600, Adept Cobra s800, Adept eAIB, Adept SmartController CX,
Adept SmartController EX, Adept T2, Adept T20, eV+, and V+ are trademarks of Adept Technology, Inc.

Any trademarks from other companies used in this publication

are the property of those respective companies.
Created in the United States of America
 Table of Contents

Chapter 1: Introduction 11
1.1 Product Description 11
Adept Cobra s600/s800™ Robots 11
AIB™, eAIB™ (Amplifiers in Base) 12
Adept SmartController™ 13
1.2 Dangers, Warnings, Cautions, and Notes 14
1.3 Safety Precautions 14
1.4 What to Do in an Emergency Situation 15
1.5 Additional Safety Information 15
Manufacturer’s Declaration of Conformity (MDOC) 15
Adept Robot Safety Guide 15
1.6 Intended Use of the Robots 15
1.7 Installation Overview 15
1.8 Manufacturer’s Declaration 16
1.9 How Can I Get Help? 17
Related Manuals 17
Adept Document Library 17

Chapter 2: Robot Installation 19

2.1 Transport and Storage 19
2.2 Unpacking and Inspecting the Adept Equipment 20
Before Unpacking 20
Upon Unpacking 20
2.3 Repacking for Relocation 20
2.4 Environmental and Facility Requirements 20
2.5 Mounting the Robot 21
Mounting Surface 21
Robot Mounting Procedure 22

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 Table of Contents

2.6 Description of Connectors on Robot Interface Panel 23

Chapter 3: System Installation 25

3.1 System Cable Diagram 25
3.2 Cable and Parts List 26
3.3 Installing the SmartController 26
3.4 Connecting User-Supplied PC to SmartController 27
PC Requirements 27
3.5 Installing Adept ACE Software 27
3.6 Cable Connections from Robot to SmartController 27
3.7 Connecting 24 VDC Power to Robot 28
Specifications for 24 VDC Power 28
Details for 24 VDC Mating Connector 29
Procedure for Creating 24 VDC Cable 30
Installing 24 VDC Robot Cable 30
3.8 Connecting 200-240 VAC Power to Robot 31
Specifications for AC Power 32
Details for AC Mating Connector 34
Creating the 200-240 VAC Cable 34
Installing AC Power Cable to Robot 35
3.9 Grounding the Adept Robot System 35
Grounding the Robot Base 35
Grounding Robot-Mounted Equipment 36
3.10 Installing User-Supplied Safety Equipment 36

Chapter 4: System Operation 37

4.1 Robot Status LED Description 37
4.2 Status Panel Fault Codes 37
4.3 Brakes 39
Programmable E-Stop Delay 39
Brake Release Button 39
4.4 Front Panel 40
4.5 Connecting Digital I/O to the System 41
Using Digital I/O on Robot XIO Connector 43
Optional I/O Products 44
XIO Input Signals 44
XIO Output Signals 46
XIO Breakout Cable 48
4.6 Starting the System for the First Time 50
Verifying Installation 50
Turning on Power 51

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Starting Adept ACE 51

Enabling High Power 52
Verifying E-Stop Functions 53
Verify Robot Motions 53
4.7 Learning to Program the Adept Cobra s-Series Robot 53

Chapter 5: Maintenance 55
5.1 Field-replaceable Parts 55
5.2 Periodic Maintenance Schedule 55
5.3 Checking Safety Systems 56
5.4 Checking Robot Mounting Bolts 56
5.5 Checking Robot for Oil Around Harmonic Drive 56
5.6 Lubricating Joint 3 Ball Screw 57
Required Grease for the Robot 57
Lubrication Procedure 57
5.7 Replacing the AIB or eAIB Chassis 60
Removing the AIB or eAIB Chassis 60
Installing a New AIB or eAIB Chassis 62
5.8 Commissioning a System with an eAIB 63
Safety Commissioning Utilities 64
E-Stop Configuration Utility 66
E-Stop Verification Utility 66
Teach Restrict Configuration Utility 67
Teach Restrict Verification Utility 67
5.9 Replacing the Encoder Battery 68
Battery Replacement Time Periods 69
Battery Replacement Procedure 69

Chapter 6: Optional Equipment Installation 71

6.1 Installing End-Effectors 71
6.2 Removing and Installing the Tool Flange 71
Removing the Flange 71
Installing the Flange 72
6.3 User Connections on Robot 72
User Air Lines 72
User Electrical Lines 73
6.4 Internal User Connectors 73
SOLND Connector 75
OP3/4 Connector 75
EOAPWR Connector 76
Internal User Connector Output Specifications 76
ESTOP Connector 77

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6.5 Mounting Locations for External Equipment 79

6.6 Installing the Robot Solenoid Kit 79
Tools Required 81
Procedure 81
6.7 Installing the Camera Bracket Kit 85
Tools Required 85
Procedure 85
6.8 DeviceNet Communication Link 86
Recommended Vendors for Mating Cables and Connectors 88
6.9 Installing Adjustable Hardstops 88
Joint 1 Adjustable Hardstops 89
Joint 2 Adjustable Hardstops 93

Chapter 7: Technical Specifications 101

7.1 Dimension Drawings 101
7.2 Cobra s600/s800 Internal Connections 107
7.3 XSLV Connector 107
7.4 Robot Specifications 108

Chapter 8: IP-65 Option 111

8.1 Cobra s800 IP-65 Classification 111
8.2 Installing Cable Seal Assembly 111
Cable Seal Identification 111
Installation Procedure 112
8.3 Robot Outer Link Cover Removal and Reinstallation 114
Cover Removal Procedure 114
Cover Reinstallation Procedure 115
8.4 Customer Requirements 116
Sealing the Tool Flange 116
Pressurizing the Robot 116
8.5 User Connectors 117
User Electrical and DeviceNet 117
User Air Lines 119
Robot Solenoid Option 119
8.6 Maintenance 119
IP-65 Bellows Replacement 119
8.7 Dimension Drawing for Cable Seal Assembly 121

Chapter 9: Cleanroom Robots 123

Specifications 123

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9.1 Connections 124

9.2 Requirements 124
9.3 Exclusions and Incompatibilities 124
9.4 Maintenance 125
Bellows Replacement 125
Lubrication 126

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 Chapter 1: Introduction

1.1 Product Description

Adept Cobra s600/s800™ Robots

The Adept Cobra s600 and s800 robots are four-axis SCARA robots (Selective Compliance
Assembly Robot Arm). See the following figure. Joints 1, 2, and 4 are rotational; Joint 3 is trans-
lational. For a description of the robot joint locations, see Robot Joint Motions on page 12.
The Adept Cobra s600 and s800 robots require an Adept SmartController™ motion controller.
The robots are programmed and controlled using the SmartController, running on the Adept
SmartServo distributed motion control platform. Mechanical specifications for the Adept Cobra
s600 and s800 robots are provided in Technical Specifications on page 101.

NOTE: The descriptions and instructions in this manual apply to both the Cobra
s600 and the Cobra s800, except for instances where there is a difference, as in
dimension and work envelope drawings. In those cases the information is pre-
sented for both robots.

Figure 1-1. Adept Cobra s800 Robot

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 Chapter 1: Introduction

Joint 2

Joint 1

Joint 3

Outer
Inner Link
Link Joint 4

Figure 1-2. Robot Joint Motions

AIB™, eAIB™ (Amplifiers in Base)

The amplifiers for the Adept Cobra s600 and s800 robots are embedded in the base of the
robot. There are two versions offered: the AIB and the eAIB. Both provide power amplifiers and
full servo control.
Adept AIB and eAIB feature:
l On-board digital I/O

l Low EMI for use with noise sensitive equipment

l No external fan for quiet robot operation

l 4 kHz (AIB)/8 kHz (eAIB) servo rate to deliver low positional errors and superior path
following
l Sine wave commutation to lower cogging torque and improve path following

l Digital feed forward design to maximize efficiency, torque, and velocity

l Temperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
Adept eAIB only:
l Hardware-based E-Stop and Teach Restrict controls
These are required to meet European standards implemented in 2012.
The two amplifiers look very similar, and both fit either Cobra model.

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 Chapter 1: Introduction

Figure 1-3. Adept AIB

Adept SmartController™
The SmartController is the foundation of Adept’s family of high-performance distributed
motion controllers. The SmartController is designed for use with:
l Adept Cobra s-series robots

l Adept Quattro robots

l Adept Viper s-series robots

l Adept Python linear modules

l Adept MotionBlox-10

l Adept sMI6 (SmartMotion)

The SmartController supports a conveyor tracking option, as well as other options. There are
two models available: the SmartController CX, which uses the V+ Operating System, and the
SmartController EX, which uses the eV+ Operating System. Both models offer scalability and
support for IEEE 1394-based digital I/O and general motion expansion modules. The IEEE
1394 interface is the backbone of Adept SmartServo, Adept's distributed controls architecture
supporting Adept products. The SmartController also includes Fast Ethernet and DeviceNet.

Figure 1-4. Adept SmartController EX, CX

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 Chapter 1: Introduction

sDIO Module

The sDIO module provides 32 optical isolated digital inputs and 32 optical isolated outputs
and also includes an IEEE 1394 interface.

1.2 Dangers, Warnings, Cautions, and Notes

There are six levels of special alert notation used in Adept manuals. In descending order of
importance, they are:

DANGER: This indicates an imminently hazardous electrical sit-

uation which, if not avoided, will result in death or serious
injury.

DANGER: This indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING: This indicates a potentially hazardous electrical sit-

uation which, if not avoided, could result in injury or major dam-
age to the equipment.

WARNING: This indicates a potentially hazardous situation

which, if not avoided, could result in injury or major damage to
the equipment.

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

could result in damage to the equipment.

NOTE: Notes provide supplementary information, emphasize a point or procedure,

or give a tip for easier operation.

1.3 Safety Precautions

DANGER: An Adept Cobra s600/s800 robot can cause serious

injury or death, or damage to itself and other equipment, if the
following safety precautions are not observed.

l All personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Adept Robot Safety Guide, and complete a training course for their
responsibilities in regard to the robot.
l All personnel who design the robot system must read this guide, read the Adept Robot

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 Chapter 1: Introduction

Safety Guide, and must comply with all local and national safety regulations for the loca-
tion in which the robot is installed.
l The robot system must not be used for purposes other than described in Intended Use of
the Robots on page 15. Contact Adept if you are not sure of the suitability for your appli-
cation.
l The user is responsible for providing safety barriers around the robot to prevent anyone
from accidentally coming into contact with the robot when it is in motion.
l Power to the robot and its power supply must be locked out and tagged out before any
maintenance is performed.

1.4 What to Do in an Emergency Situation

Press any E-Stop button (a red push-button on a yellow background/field) and then follow the
internal procedures of your company or organization for an emergency situation. If a fire
occurs, use CO to extinguish the fire.
2

1.5 Additional Safety Information

Adept provides other sources for more safety information:

Manufacturer’s Declaration of Conformity (MDOC)

This lists all standards with which each robot complies. For details, see Manufacturer’s Dec-
laration on page 16.

Adept Robot Safety Guide

The Adept Robot Safety Guide provides detailed information on safety for Adept robots. It also
gives resources for more information on relevant standards.
It ships with each robot manual, and is also available from the Adept Document Library. For
details, see Adept Document Library on page 17.

1.6 Intended Use of the Robots

The Adept Cobra s600 and s800 robots are intended for use in parts assembly and material
handling for payloads less than 5.5 kg (12.1 lb).

1.7 Installation Overview

The system installation process is summarized in the following table. Also, refer to System
Cable Diagram for Adept Cobra s600/s800 Robots - AIB Shown on page 25.

NOTE: For dual-robot installations, see the Adept Dual-Robot Configuration Procedure,

which is available in the Adept Document Library.

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 Chapter 1: Introduction

Table 1-1. Installation Overview

Task to be Performed Reference Location

Mount the robot on a flat, secure mounting surface. See Mounting the Robot on page 21.
Install the SmartController, Front Panel, pendant, See Installing the SmartController on
and Adept ACE™ software. page 26.
Install the IEEE 1394 and XSYS cables between the See Cable Connections from Robot to
robot and SmartController. SmartController on page 27.
Create a 24 VDC cable and connect it between the See Connecting 24 VDC Power to
robot and the user-supplied 24 VDC power supply. Robot on page 28.
Create a 200-240 VAC cable and connect it between See Connecting 200-240 VAC Power to
the robot and the facility AC power source. Robot on page 31.
Install user-supplied safety barriers in the workcell. See Installing User-Supplied Safety
Equipment on page 36.
Learn about connecting digital I/O through the XIO See Using Digital I/O on Robot XIO
connector on the robot. Connector on page 43.
Learn about starting the system for the first time. See Starting the System for the First
Time on page 50.
Learn about installing optional equipment, includ- See Installing End-Effectors on page 71.
ing end-effectors, user air and electrical lines, exter-
nal equipment, solenoids, etc.

1.8 Manufacturer’s Declaration

The Manufacturer’s Declaration of Incorporation and Conformity for Adept robot systems can
be found on the Adept website, in the Download Center of the Support section.

http://www.adept.com/support/downloads/file-search

NOTE: The Download Center requires that you are logged in for access. If you are
not logged in, you will be redirected to the Adept website Login page, and then auto-
matically returned to the Download Center when you have completed the login
process.

1. From the Download Types drop-down list, select Manufacturer Declarations

2. From the Product drop-down list, select your Adept robot product category (such as
Adept Cobra Robots, Adept Viper robots, etc.).
3. Click Begin Search. The list of available documents is shown in the Search Results area,
which opens at the bottom of the page. You may need to scroll down to see it.
4. Use the Description column to locate the document for your Adept robot, and then click
the corresponding Download ID number to access the Download Details page.
5. On the Download Details page, click Download to open or save the file.

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 Chapter 1: Introduction

1.9 How Can I Get Help?

Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on getting assis-
tance with your Adept software and hardware. Additionally, you can access information
sources on Adept’s corporate website:
http://www.adept.com
l For Contact information:
http://www.adept.com/contact/americas
l For Product Support information:
http://www.adept.com/support/service-and-support/main
l For user discussions, support, and programming examples:
http://www.adept.com/forum/

Related Manuals
This manual covers the installation, operation, and maintenance of an Adept Cobra s600/s800
robot system. For additional manuals covering programming the system, reconfiguring
installed components, and adding optional components, see the following table.

Table 1-2. Related Manuals

Manual Title Description

Adept Robot Safety Guide Contains safety information for Adept robots.
Adept SmartController User's Contains information on the installation and operation of the
Guide Adept SmartController and the optional sDIO product.
Adept ACE User’s Guide Instruction for the use of the Adept ACE software.
Adept Dual-Robot Con- Contains cable diagrams and configuration procedures for a
figuration Procedure dual-robot system.
Adept IO Blox User’s Guide Describes the IO Blox product.

Adept Document Library

The Adept Document Library (ADL) contains documentation for Adept products. You can
access the ADL from the Adept website. Select:

Support > Document Library

from the Adept home page. To go directly to the Adept Document Library, type the following
URL into your browser:

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

To locate information on a specific topic, use the Document Library search engine on the ADL
main page. To view a list of available product documentation, select the Active Documents
option.

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 Chapter 2: Robot Installation

2.1 Transport and Storage

This equipment must be shipped and stored in a temperature-controlled environment, within
the range –25 C to +55 C. The recommended humidity range is 5 to 90 percent, non-con-
densing. It should be shipped and stored in the Adept-supplied packaging, which is designed
to prevent damage from normal shock and vibration. You should protect the package from
excessive shock and vibration.
Use a forklift, pallet jack, or similar device to transport the packaged equipment (see the fol-
lowing figure).
The robots must always be stored and shipped in an upright position in a clean, dry area that
is free from condensation. Do not lay the crate on its side or any other position: this could dam-
age the robot.
The s600 robot weighs 41 kg (90 lb) and the s800 weighs 43 kg (95 lb) with no options
installed.
Eyebolt for lifting robot
after robot has been
unbolted from the
transportation pallet.

Place forklift or pallet-jack here.

Figure 2-1. Cobra s600 Robot on a Transportation Pallet

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 Chapter 2: Robot Installation

2.2 Unpacking and Inspecting the Adept Equipment

Before Unpacking
Carefully inspect all shipping crates for evidence of damage during transit. Pay special atten-
tion to any tilt and shock indication labels on the exteriors of the containers. If any damage is
indicated, request that the carrier’s agent be present at the time the container is unpacked.

Upon Unpacking
Before signing the carrier’s delivery sheet, please compare the actual items received (not just
the packing slip) with your equipment purchase order and verify that all items are present and
that the shipment is correct and free of visible damage.
l If the items received do not match the packing slip, or are damaged, do not sign the
receipt. Contact Adept as soon as possible.
l If the items received do not match your order, please contact Adept immediately.

Inspect each item for external damage as it is removed from its container. If any damage is
evident, contact Adept. See How Can I Get Help? on page 17.
Retain all containers and packaging materials. These items may be necessary to settle claims
or, at a later date, to relocate equipment.

2.3 Repacking for Relocation

If the robot or other equipment needs to be relocated, reverse the steps in the installation pro-
cedures that follow this chapter. Reuse all original packing containers and materials and fol-
low all safety notes used for installation. Improper packaging for shipment will void your
warranty. Specify this to the carrier if the robot is to be shipped.

CAUTION: Before unbolting the robot from the mounting sur-

face, fold the outer arm against the Joint 2 hardstops to help cen-
tralize the center of gravity. The robot must always be shipped
in an upright orientation.

2.4 Environmental and Facility Requirements

The Adept robot system installation must meet the operating environment requirements
shown in the following table.

Table 2-1. Robot System Operating Environment Requirements

Ambient temperature 5 to 40° C (41 to 104° F)

Humidity 5 to 90%, non-condensing

Altitude up to 2000 m (6500 ft)

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 Chapter 2: Robot Installation

Pollution degree 2

Robot protection class IP 20 (NEMA Type 1)

NOTE: For robot dimensions, see Dimension Drawings on page 101.

2.5 Mounting the Robot

WARNING: Only qualified service personnel may install or

service the robot system.

Mounting Surface
The Adept Cobra s600 and s800 robots are designed to be mounted on a smooth, flat, level
tabletop. The mounting structure must be rigid enough to prevent vibration and flexing during
robot operation. Adept recommends a 25 mm (1 in.) thick steel plate mounted to a rigid tube
frame. Excessive vibration or mounting flexure will degrade robot performance. The following
figure shows the mounting hole pattern for the Adept Cobra s600 and s800 robots.

NOTE: On the under side of the base there is a hole and a slot that can be used as
locating points for user-installed dowel pins in the mounting surface; see the fol-
lowing figure. Using locating pins could improve the ability to remove and reinstall
the robot in the same position.

4X Ø 14 THRU
160
+0.015
2x R4 0 6 80

10

45

200
160
50

+0.015
Ø8 6
0 90 234 Units in mm

338

Figure 2-2. Mounting Hole Pattern for Robot

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 Chapter 2: Robot Installation

Robot Mounting Procedure

1. Using the dimensions shown in the previous figure, drill and tap the mounting surface
for four M12 - 1.75 x 36 mm (or 7/16 - 14 UNC x 1.50 in.) machine bolts (bolts are user-
supplied).
2. While the robot is still bolted to the transportation pallet, connect the hydraulic lift to
the eyebolt at the top of the inner link (see Figure 2-1). Take up any slack, but do not lift
the robot at this time.

WARNING: Do not attempt to lift the robot at any points other

than the eyebolt provided. Do not attempt to extend the inner
or outer links of the robot until the robot has been secured in
position. Failure to comply could result in the robot falling and
causing either personnel injury or equipment damage.

3. Remove the four bolts securing the robot base to the pallet. Retain these bolts for pos-
sible later relocation of the equipment.
4. Lift the robot and position it directly over the mounting surface.

5. Slowly lower the robot while aligning the base and the tapped mounting holes in the
mounting surface.

NOTE: The base casting of the robot is aluminum and can easily be dented if
bumped against a harder surface.

6. Verify that the robot is mounted squarely (will not rock back and forth) before tightening
the mounting bolts.
7. Install the user-supplied mounting bolts and washers. Tighten bolts to the torque spec-
ified in Table 2-2.

WARNING: The center of mass of the robot may cause the

robot to fall over if the robot is not secured with the mounting
bolts.

NOTE: Check the tightness of the mounting bolts one week after initial installation,
and then recheck every 6 months. See Chapter 5 for periodic maintenance.

Table 2-2. Mounting Bolt Torque Specifications

Standard Size Specification Torque

Metric M12 x P1.75 ISO Property Class 8.8 85 N·m

SAE 7/16-14 UNC 65 ft-lb

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 Chapter 2: Robot Installation

2.6 Description of Connectors on Robot Interface Panel

Figure 2-3. Robot Interface Panel - AIB and eAIB

The following connections are the same for both the AIB and the eAIB:
24 VDC—for connecting user-supplied 24 VDC power to the robot. The mating connector is
provided.
Ground Point—for connecting cable shield from user-supplied 24 VDC cable.

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 Chapter 2: Robot Installation

200/240 VAC—for connecting 200-240 VAC, single-phase, input power to the robot. The mat-
ing connector is provided.
SmartServo x2 (IEEE 1394) — for connecting the IEEE 1394 cable from the controller (Smart-
Servo 1.1) to the robot. The other robot connector can be used to connect to a second robot or
another 1394-based motion axis.
XIO (DB26, high density, female) — for user I/O signals for peripheral devices. This connector
provides 8 outputs and 12 inputs. For connector pin allocations for inputs and outputs, see
Using Digital I/O on Robot XIO Connector on page 43. That section also contains details on
how to access these I/O signals via V+/eV+.
The following connections are different on the AIB and the eAIB:
XSYSTEM (eAIB only) — includes the functions of the XPANEL and XSLV on the AIB. This
requires either the eAIB XSLV Adapter cable, to connect to the XSYS cable, or an eAIB XSYS
cable, which replaces the XSYS cable. See Cable Connections from Robot to SmartController on
page 27.
XPANEL (DB26, high density, male; AIB only) — used only with Cobra i-series robots, for con-
necting the front panel and MCP circuit.
XSLV (DB-9, female; AIB only) — for connecting the supplied XSYS cable from the controller
XSYS connector.
XBELTIO (eAIB only) — adds two belt encoders, EXPIO at the back of the robot (which is not
available on an AIB), and an RS-232 interface.
RS-232 (DB-9, male; AIB only) — used only with Cobra i-series robots, for connecting a system
terminal.
Ethernet x2 (eAIB only) — these are not used with the SmartController CX, and are not cur-
rently used with the SmartController EX.

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 Chapter 3: System Installation

3.1 System Cable Diagram

IEEE 1394 Cable
Controller SmartServo (Port 1.1) to
Adept Cobra
AIB/eAIB SmartServo
s600/s800 Robot

Adept
SmartController
*S/N 3562-XXXXX*

CAMERA RS-232/TERM
R
RS-422/485

SmartController CX
OK
SF
HPE
ES
LAN
HD
SW1
1 2 3 4
SmartServo
1.1 1.2
IEEE-1394
2.1 2.2
Device Net Eth 10/100
BELT ENCODER RS-232-1 RS-232-2
XSYS/eAIB XSYS Cable
1 2 3
XDIO
ON

OFF

XUSR XSYS XFP XMCP XDC1 XDC2

Controller (XSYS) to
24V 5A

-+ -+
AIB/eAIB (XSLV/XSYSTEM)
Terminator
Installed

User-Supplied Ground Wire

Controller (XFP) to
Front Panel (XFP)
Ethernet to PC

24 VDC Power to
STOP
Controller (XDC1)

Front Panel

Controller (XMCP) GND XSLV 2

SmartServo

to Pendant +24V
DC INPUT
(24 VDC)
AC INPUT
(200-240 VAC 1F) XIO XPANEL RS-232

User-Supplied
Pendant Ground Wire on
(optional) Robot Base

24 VDC Power
User-Supplied PC running to Robot
Adept ACE software (+24 VDC Input) User-Supplied
200-240 VAC,
User-Supplied
single phase
24 VDC Power
Supply

Figure 3-1. System Cable Diagram for Adept Cobra s600/s800 Robots - AIB Shown

NOTE: For additional system grounding information, see Installing 24 VDC Robot

Cable on page 30.

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3.2 Cable and Parts List

Table 3-1. Cable and Parts List

Part Description Notes

IEEE 1394 Cable, 4.5 M Standard cable—supplied
with system
XSYS Cable, AIB only, 4.5 M Standard cable—supplied
with AIB system
eAIB XSYS Cable, 4.5 M Standard cable--supplied
with eAIB system
eAIB XSLV Adapter Cable, 250 mm Standard for AIB-eAIB
upgrade
Front Panel Cable Supplied with Front Panel
T1/T2 Pendant Adapter Cable, 2 M Supplied with Adept T2™
pendant option
T20 Pendant Adapter Cable, 3 M Supplied with Adept T20™
pendant option
Power Cable Kit, contains 24 VDC Available as option
and AC power cables
XIO Breakout Cable, 12 inputs/ Available as option—see
8 outputs, 5 M XIO Breakout Cable on
page 48.
Y Cable, for XSYS cable connections Available as option -- see
to dual robots - attaches at the con- the Dual Robot Configuration
troller only for an eAIB system Guide.

3.3 Installing the SmartController

Refer to the Adept SmartController User's Guide for complete information on installing the Adept
SmartController. This list summarizes the main steps.
1. Mount the SmartController and Front Panel.

WARNING: Ensure that the front panel is located outside of the

workcell and outside of the work envelope.

2. Connect the Front Panel to the SmartController.

3. Connect the optional pendant to the SmartController.

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

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

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3.4 Connecting User-Supplied PC to SmartController

The SmartController for Adept Cobra s600/s800 robots must be connected to a user-supplied
PC for setup, control, and programming. The user loads the Adept ACE software onto the PC
and connects it to the SmartController via an Ethernet cable.

PC Requirements
The Adept ACE CD-ROM will display a ReadMe file when inserted in your PC. This contains
hardware and software requirements for running Adept ACE software.

NOTE: The specifications are also listed in the ACE PackXpert Datasheet, available
on the Adept corporate website.

3.5 Installing Adept ACE Software

You install Adept ACE from the Adept Software CD-ROM. Adept ACE needs Microsoft .NET
Framework. The Adept ACE Setup Wizard scans your PC for .NET, and installs it auto-
matically if it is not already installed.
1. Insert the CD-ROM into the CD-ROM drive of your PC.
If Autoplay is enabled, the Adept software CD-ROM menu is displayed. If Autoplay is
disabled, you will need to manually start the CD-ROM.

NOTE: The online document that describes the installation process opens in

the background when you select one of software installation steps below.

2. Especially if you are upgrading your Adept ACE software installation: from the Adept
ACE software CD-ROM menu, click Read Important Information.
3. From the Adept ACE software CD-ROM menu, select:

Install the Adept ACE Software

The Adept ACE Setup wizard opens.
4. Follow the online instructions as you step through the installation process.

5. When the installation is complete, click Finish.

6. After closing the Adept ACE Setup wizard, click Exit on the CD-ROM menu to close the
menu.

NOTE: You will have to restart the PC after installing Adept ACE software.

3.6 Cable Connections from Robot to SmartController

The following cables are shipped in the cable/accessories box.
l Locate the IEEE 1394 cable (length 4.5 M).

l For an AIB system, locate the XSYS cable.

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 Chapter 3: System Installation

l For an eAIB system, locate the eAIB XSYS cable or eAIB XSLV Adapter cable, which can
be used with an existing XSYS cable.
Install one end of the IEEE 1394 cable into the SmartServo port 1.1 connector on the Smart-
Controller, and the other end into a SmartServo connector on the AIB or eAIB interface panel.
See Figure 3-1.
AIB only: 
l Install the XSYS cable between the robot interface panel XSLV safety interlock connector
and XSYS connector on the SmartController, and tighten the latching screws.
eAIB only:
l For a new SmartController system with an eAIB, the system will be supplied with a 15
ft (4.5 m) cable with connectors for XSYS (DB9) on one end and XSYSTEM (DB44) on
the other. Connect the XSYSTEM end to the eAIB, and the XSYS end to the Smart-
Controller.
l For a field upgrade from an old AIB, if you already have the old XSYS (DB9-DB9) cable
routed and all you want to do is adapt your new eAIB to plug into the old cable, use the
eAIB XSLV Adapter cable. This is a 1 ft (250 mm) long adapter that essentially turns the
XSYSTEM into the old XSLV connector. Connect the XSYSTEM end to the eAIB, and the
XSLV end to the old XSYS cable.

3.7 Connecting 24 VDC Power to Robot

Specifications for 24 VDC Power

Table 3-2. Specifications for 24 VDC User-Supplied Power Supply

Customer-Supplied Power Supply 24 VDC (± 10%), 150 W (6 A)

(21.6 V < V < 26.4 V)
in
Circuit Protectiona Output must be less than 300 W peak
or
8 Amp in-line fuse
Power Cabling 1.5 – 1.85 mm² (16-14 AWG)
Shield Termination Braided shield connected to frame ground
terminal at both ends of cable. See Figure
3-2.
aUser-supplied 24 V power supply must incorporate overload protection to limit peak power
to less than 300 W, or 8 A in-line fuse protection must be added to the 24 V power source.
(In case of multiple robots on a common 24 V supply, each robot must be fused individ-
ually.)

NOTE: Fuse information is located on the AIB/eAIB electronics.

The power requirements for the user-supplied power supply will vary depending on the con-
figuration of the robot and connected devices. Adept recommends a 24 V, 6 A power supply to
allow for startup current draw and load from connected user devices, such as solenoids and

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 Chapter 3: System Installation

digital I/O loads. If multiple robots are sharing a 24 V power supply, increase the supply
capacity by 3 A for each additional robot.

CAUTION: Make sure you select a 24 VDC power supply that

meets the specifications in the previous table. Using an under-
rated supply can cause system problems and prevent your
equipment from operating correctly. See the following table for
recommended power supplies.

Table 3-3. Recommended 24 VDC Power Supplies

Vendor Name Model Ratings

XP Power JPM160PS24 24 VDC, 6.7 A, 160 W
Astrodyne SP-150-24 24 VDC, 6.3 A, 150 W
Mean Well SP-150-24 24 VDC, 6.3 A, 150 W

Details for 24 VDC Mating Connector

The 24 VDC mating connector and two pins are supplied with each system. They are shipped
in the cable/accessories box.

Table 3-4. 24 VDC Mating Connector Specs

Connector Details Connector receptacle, 2 position, type:

Molex Saber, 18 A, 2-Pin
Molex P/N 44441-2002

Digi-Key P/N WM18463-ND

Pin Details Molex connector crimp terminal,

female, 14-18 AWG
Molex P/N 43375-0001

Digi-Key P/N WM18493-ND

Recommended crimping tool, Molex Hand Molex P/N 63811-0400

Crimpers
Digi-Key P/N WM9907-ND

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 Chapter 3: System Installation

NOTE: The 24 VDC cable is not supplied with the system, but is available in the
optional Power Cable kit. See Table 3-1.

Procedure for Creating 24 VDC Cable

1. Locate the connector and pins shown in Table 3-4.

2. Use 14-16 AWG wire to create the 24 VDC cable. Select the wire length to safely reach
from the user-supplied 24 VDC power supply to the robot base.

NOTE: You also must create a separate 24 VDC cable for the SmartController. That
cable uses a different style of connector. See the Adept SmartController User's Guide.

3. Crimp the pins onto the wires using the crimping tool.

4. Insert the pins into the connector. Confirm that the 24 V and 24 V return wires are in
the correct terminals in the plug.
5. Prepare the opposite end of the cable for connection to the user-supplied 24 VDC power
supply.

Installing 24 VDC Robot Cable

1. Connect one end of the shielded 24 VDC cable to your user-supplied 24 VDC power
supply. See Figure 3-2. . The cable shield should be connected to frame ground on the
power supply. Do not turn on the 24 VDC power until instructed to do so in Chapter 4.
2. Plug the mating connector end of the 24 VDC cable into the 24 VDC connector on the
interface panel on the back of the robot. The cable shield should be connected to the
ground point on the interface panel.

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 Chapter 3: System Installation

Adept Cobra
s600/s800 Robot

GND
– User-Supplied
+ Power Supply
24 VDC

+ 24V, 8A
–
User-Supplied Shielded
Frame Ground
Attach shield from user- Power Cable
supplied cable to ground
screw on Cobra s600/s800
+ 24V, 5A
Interface Panel. –

Attach shield from user-

supplied cables to frame
Adept SmartController Attach shield from user-supplied ground on power supply.
cable to side of controller using
star washer and M3 x 6 screw.
-+

User-Supplied Shielded
Power Cable

Figure 3-2. User-Supplied 24 VDC Cable

NOTE: In order to maintain compliance with standards, Adept recommends that

DC power be delivered over a shielded cable, with the shield connected to frame
ground at both ends of the cable.

3.8 Connecting 200-240 VAC Power to Robot

WARNING: Appropriately sized Branch Circuit Protection and

Lockout / Tagout Capability must be provided in accordance
with the National Electrical Code and any local codes.Ensure
compliance with all local and national safety and electrical codes
for the installation and operation of the robot system.

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 Chapter 3: System Installation

Specifications for AC Power

Table 3-5. Specifications for 200/240 VAC User-Supplied Power Supply

Recommended
Auto-Ranging
Minimum Oper- Maximum Oper- Frequency/ External Circuit
Nominal Volt-
ating Voltagea ating Voltage Phasing Breaker, User-
age Ranges
Supplied
200 V to 240 V 180 V 264 V 50/60 Hz 10 Amps
1-phase
a Specifications are established at nominal line voltage. Low line voltage can affect robot
performance.

Table 3-6. Typical Robot Power Consumption

Average RMS Current Peak Power
Cobra Robot
Move Power (W) (A) (W) a

s600 No load—Adept cycleb 344 1.56 1559

5.5 kg—Adept cycleb 494 2.25 2061
5.5 kg—all joints move 880 4.00 2667
s800 No load—Adept cycleb 531 2.41 1955
5.5 kg—Adept cycleb 377 1.71 1406
5.5 kg—all joints move 794 3.61 2110
aFor short durations (100 ms).
bFor details on Adept cycle, see Robot Specifications on page 108.

NOTE: The Adept robot system is intended to be installed as a piece of equipment

in a permanently-installed system.

WARNING: Adept systems require an isolating transformer

for connection to mains systems that are asymmetrical or use
an isolated (impedant) neutral. Many parts of Europe use an
impedant neutral.

DANGER: AC power installation must be performed by a

skilled and instructed person—refer to the Adept Robot Safety
Guide. During installation, unauthorized third parties must be
prevented from turning on power through the use of fail-safe
lockout measures.

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 Chapter 3: System Installation

Facility overvoltages Protection

The user must protect the robot from excessive overvoltages and voltage spikes. If the country
of installation requires a CE-certified installation, or compliance with IEC  1131-2, the following
information may be helpful: IEC 1131-2 requires that the installation must ensure that
Category II overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded.
Transient overvoltages at the point of connection to the power source shall be controlled not to
exceed overvoltages Category II, i.e., not higher than the impulse voltage corresponding to the
rated voltage for the basic insulation. The user-supplied equipment or transient suppressor
shall be capable of absorbing the energy in the transient.
In the industrial environment, nonperiodic overvoltage peaks may appear on mains power
supply lines as a result of power interruptions to high-energy equipment (such as a blown fuse
on one branch in a 3-phase system). This will cause high current pulses at relatively low volt-
age levels. The user shall take the necessary steps to prevent damage to the robot system (such
as by interposing a transformer). See IEC 1131-4 for additional information.

AC Power Diagrams

Note: F1 is user-supplied, must be slow blow.

L
1Ø
F1 10A
200–240VAC N
20A E

User-Supplied
AC Power Cable
L = Line
N = Neutral E N L
E = Earth Ground
Adept Cobra
s600/s800 and
i600/i800 Robots
1Ø 200–240VAC

Figure 3-3. Typical AC Power Installation with Single-Phase Supply

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 Chapter 3: System Installation

Note: F4 and F5 are user-supplied, must be slow blow.

L1

F5 10A 200–240VAC
3Ø L2
200–240VAC F4 10A
L3

User-Supplied
AC Power Cable

E N L

L = Line 1 Adept Cobra

N = Line 2 s600/s800 and
E = Earth Ground i600/i800Robots
1Ø 200–240VAC

Figure 3-4. Single-Phase Load across L1 and L2 of a Three-Phase Supply

NOTE: If a three-phase power source is used, it must be symmetrically-earthed

(with grounded neutral). Connections called out as single-phase can be wired Line-
to-Neutral or Line-to-Line.

Details for AC Mating Connector

The AC mating connector is supplied with each system. It is typically shipped in the cable/ac-
cessories box. The supplied plug is internally labeled for the AC power connections (L, E, N).

Table 3-7. AC Mating Connector Details

AC Connector details AC in-line power plug,

straight, female, screw ter-
minal, 10 A, 250 VAC
Qualtek P/N 709-00/00

Digi-Key P/N Q217-ND

The AC power cable is not supplied with the system, but is available in the
optional Power Cable kit; see Table 3-1.

Creating the 200-240 VAC Cable

1. Locate the AC mating connector shown in the previous table.

2. Open the connector by unscrewing the screw on the shell and removing the cover.

3. Loosen the two screws on the cable clamp. See Figure 3-5.

4. Use 18 AWG wire to create the AC power cable. Select the wire length to safely reach

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 Chapter 3: System Installation

from the user-supplied AC power source to the robot base.

5. Strip approximately 18 to 24 mm insulation from each of the three wires.

6. Insert the wires into the connector through the removable bushing.

7. Connect each wire to the correct terminal screw, and tighten the screw firmly.

8. Tighten the screws on the cable clamp.

9. Reinstall the cover and tighten the screw to seal the connector.

10. Prepare the opposite end of the cable for connection to the facility AC power source.

Figure 3-5. AC Power Mating Connector

Installing AC Power Cable to Robot

1. Connect the unterminated end of the AC power cable to your facility AC power source.
See AC Power Diagrams on page 33. Do not turn on AC power at this time.
2. Plug the AC connector into the AC power connector on the interface panel on the robot.

3. Secure the AC connector with the locking latch.

3.9 Grounding the Adept Robot System

Proper grounding is essential for safe and reliable robot operation. Follow these rec-
ommendations to properly ground your robot system.

Grounding the Robot Base

The user can install a ground wire at the robot base to ground the robot. See Figure 3-6. The
robot ships with an M8 x 12 stainless steel, hex-head screw, and M8 split and flat washers
installed in the grounding hole. The user is responsible for supplying the ground wire to con-
nect to earth ground.

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 Chapter 3: System Installation

Figure 3-6. Ground Point on Robot Base

Grounding Robot-Mounted Equipment

The following parts of an Adept Cobra s600/s800 robot are not grounded to protective earth:
the Joint 3 quill and the tool flange. If hazardous voltages are present at any user-supplied
robot-mounted equipment or tooling, you must install a ground connection from that equip-
ment/tooling to the ground point on the robot base. Hazardous voltages can be considered any-
thing in excess of 30 VAC (42.4 VAC peak) or 60  VDC .
Also, for the grounding point on the tool flange, see Figure 7-4.

DANGER: Failing to ground robot-mounted equipment or

tooling that uses hazardous voltages could lead to injury or
death of a person touching the end-effector when an elec-
trical fault condition exists.

3.10 Installing User-Supplied Safety Equipment

The user is responsible for installing safety barriers to protect personnel from coming in con-
tact with the robot unintentionally. Depending on the design of the workcell, safety gates, light
curtains, and emergency stop devices can be used to create a safe environment. Read the Adept
Robot Safety Guide for a discussion of safety issues.
Refer to the Adept SmartController User's Guide for information on connecting safety equipment
into the system through the XUSR connector on the SmartController. There is a detailed section
on Emergency Stop Circuits and diagrams on recommended E-Stop configurations.

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 Chapter 4: System Operation

4.1 Robot Status LED Description

The robot Status LED indicator is located on the top of the robot. The blinking pattern indicates
the status of the robot.
The current robot models support the UL standard. The LED on these robots is amber. See the
following figure and table.

Figure 4-1. Robot Status LED Indicator Location

Table 4-1. Status LED Definitions on UL-Certified Robots

LED Status 2-Digit Status Panel Display Description

Off Off 24 VDC not present
Off OK High Power Disabled
Amber, Solid ON High Power Enabled
Amber, Slow Blink N/A Selected Configuration Node
Amber, Fast Blink Fault Code(s) Fault, see Status Panel Fault
Codes on page 37
Amber, Solid Fault Code(s) Fault, see Status Panel Fault
Codes on page 37

4.2 Status Panel Fault Codes

The status panel, shown in the following figure, displays alpha-numeric codes that indicate
the operating status of the robot, including detailed fault codes. The following table gives

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 Chapter 4: System Operation

meanings of the fault codes. These codes provide information for quickly isolating problems
during troubleshooting.
The displayed fault code will continue to be displayed even after the fault is corrected or addi-
tional faults are recorded. All displayed faults will be cleared from the display, and reset to a
no-fault condition, upon successfully enabling high power to the robot, or power cycling the 24
V supply to the robot.

Figure 4-2. Status Panel

Table 4-2. Status Panel Codes

LED Status Code LED Status Code

OK No Fault H# High Temp Encoder (Joint #)
ON High Power ON Status hV High Voltage Bus Fault
MA Manual Mode I# Initialization Stage (Step #)
24 24 V Supply Fault M# Motor Stalled (Joint #)
A# Amp Fault (Joint #) NV Non-Volatile Memory
B# IO Blox Fault (Address #) P# Power System Fault (Code #)
AC AC Power Fault PR Processor Overloaded
D# Duty Cycle Exceeded (Joint #) RC RSC Fault
E# Encoder Fault (Joint #) S# Safety System Fault (Code #)
ES E-Stop SE E-Stop Delay Fault
F# External Sensor Stop SW Watchdog Timeout
FM Firmware Mismatch T# Safety System Fault
(Code 10 + #)
FW IEEE 1394 Fault TR Teach Restrict Fault
h# h# High Temp Amp (Joint #) V# Hard Envelope Error (Joint #)

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For more information on status codes, go to the Adept Document Library on the Adept website,
and in the Procedures, FAQs, and Troubleshooting section, look for the Adept Status Code Sum-
mary document.

4.3 Brakes
The robot has a braking system that decelerates the robot in an emergency condition, such as
when the emergency stop circuit is open or a robot joint passes its softstop.
The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements.
It supports a customer-programmable E-Stop delay that maintains motor power for a pro-
grammed time after the E-Stop is activated. This customizable feature allows the motors to
decelerate under servo control to a stop. This can aid in eliminating coasting or overshooting
on low friction mechanisms. It can also aid in the reduction of wear on highly-geared, high-
inertia mechanisms, while maintaining safety compliance per all standards.
The Programmable E-Stop delay can be set up in Adept ACE, in the robot editor. The default
setting is appropriate for most applications. See Programmable E-Stop Delay on page 39.
The braking system will not prevent you from moving the robot manually once the robot has
stopped (and high power has been removed).
In addition, Joint 3 has an electromechanical brake. The brake is released when high power is
enabled. When high power is turned off, the brake engages and holds the position of Joint 3.

Programmable E-Stop Delay

To set the programmable E-Stop delay from the ACE software, go to the object editor for the
robot, and enable Expert Access:

Object > Expert Access

NOTE: This requires a password to enable.

Once enabled, you will be able to see and modify the following three parameters (among
others):
l Auto Mode E-Stop Shutdown Timeout

l Hold-to-Run E-Stop Shutdown Timeout

l Manual Mode E-Stop Shutdown Timeout

Each of these is the time, in seconds, after that mode E-Stop is asserted, in which V+/eV+ is
allowed to decelerate the robot, engage the brakes, and shut down power before the servo
nodes automatically shut down power. The value can be set from 0 (immediate power-off) to
0.512 seconds. If the deceleration is too slow, or the brake-on delay too long, the servo will auto-
matically cut power.

Brake Release Button

Under some circumstances you may want to manually position Joint 3 on the Z-Axis without
turning on high power. For such instances, a “Z” Brake Release button is located above the
robot status panel, as shown in Figure 4-2. When system power is on, pressing this button
releases the brake, which allows movement of Joint 3.

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NOTE: 24 Volt robot power must be ON to release the brakes.

If this button is pressed while high power is on, high power will automatically shut down.

WARNING: Due to the effect of gravity, pressing the Brake

Release button may cause the quill and tool flange to fall.

When the Brake Release button is pressed, Joint 3 may drop to

the bottom of its travel. To prevent possible damage to the
equipment, make sure that Joint 3 is supported while releasing
the brake and verify that the end-effector or other installed tool-
ing is clear of all obstructions.

4.4 Front Panel

Manual Auto
2 Mode Mode 4
1

3
Figure 4-3. Front Panel

XFP connector
Connects to the XFP connector on the SmartController.
System 5 V Power-On LED
Indicates whether or not power is connected to the robot.
Manual/Automatic Mode Switch
Switches between Manual and Automatic mode. In Automatic mode, executing programs con-
trol the robot, and the robot can run at full speed. In Manual mode, the system limits robot
speed and torque so that an operator can safely work in the cell. Manual mode initiates soft-
ware restrictions on robot speed, commanding no more than 250 mm/sec.
High Power On/Off Switch and Lamp
Controls high power, which is the flow of current to the robot motors. Enabling high power is

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 Chapter 4: System Operation

a two-step process. An “Enable Power” request must be sent from the user-supplied PC, an
executing program, or the Adept pendant. Once this request has been made and the High
Power On/Off lamp/button is blinking, the operator must press and release this button, and
high power will be enabled.

NOTE: The use of the blinking High Power button can be configured (or eliminated)
in software. Your system may not require this step.

NOTE: If enabled, the Front Panel button must be pressed while blinking (default
time-out is 10 seconds). If the button stops blinking, you must enable power again.

Emergency Stop Switch

The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements.
Pressing this button turns off high power to the robot motors.

NOTE: The Front Panel must be installed to be able to Enable Power to the robot. To
operate without a Front Panel, the user must supply the equivalent circuits.

4.5 Connecting Digital I/O to the System

You can connect digital I/O to the system in several different ways. See the following table and
figure.

Table 4-3. Digital I/O Connection Options

Product I/O Capacity For more details

XIO Connector on Robot 12 inputs see Using Digital I/O on
8 outputs Robot XIO Connector on page
43
XDIO Connector on 12 inputs see Adept SmartController
SmartController 8 outputs User's Guide
Optional IO Blox Device, 8 inputs, 8 outputs per device; up see Adept IO Blox User’s Guide
connects to robot to four IO Blox devices per robot
Optional sDIO Module, 32 inputs, 32 outputs per mod- see Adept SmartController
connects to controller ule; up to eight sDIO per system User's Guide

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Cobra s600/s800 Robot

IO Blox #1
8 Input signals: 1113 to 1120
8 Output signals: 0105 to 0112

Optional
IO Blox Device

sDIO #1
32 Input signals: 1033 to 1064
32 Output signals: 0033 to 0064

Optional IEEE-1394 *S/N 3563-XXXXX*

R 1.1 1.2 X1 X2 X3 X4

SC-DIO
XDC1 XDC2
LINK 24V 0.5A

sDIO #1
OK SF -+ -+

GND XSLV *S/N 3561-XXXXX*

2
R
SmartServo

SmartController CS
IEEE-1394
+24V Device Net

SmartController
Eth 10/100
OK HPE LAN SW1 1.1 1.2 RS-232/TERM RS-422/485
DC INPUT SF ES HD 1 2 3 4
(24 VDC)
AC INPUT ON
(200-240 VAC 1Φ) XIO XPANEL RS-232
OFF
1 2 3
XDIO XUSR XSYS XFP XMCP XDC1 XDC2
24V 5A

-+ -+

XIO Connector XDIO Connector

12 Input signals: 1097 to 1108 12 Input signals: 1001 to 1012
8 Output signals: 0097 to 0104 8 Output signals: 0001 to 0008

Figure 4-4. Connecting Digital I/O to the System

Table 4-4. Default Digital I/O Signal Configuration, Single Robot System

Location Type Signal Range

Controller XDIO connector Inputs 1001–1012
Outputs 0001–0008
sDIO Module 1 Inputs 1033–1064
Outputs 0033–0064
sDIO Module 2 Inputs 1065–1096
Outputs 0065–0096
sDIO Module 3 Inputs 1201–1232
(recommendeda )
Outputs 0201–0232
sDIO Module 4 Inputs 1233–1264
(recommendeda )
Outputs 0233–0264
Robot 1 XIO connectorb  Inputs 1097–1108
Outputs 0097–0104

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Location Type Signal Range

IO Blox 1 Inputs 1113–1120
Outputs 0105–0112
03017-000 03017-000 1121–1128
03017-000 0113–0120
03017-000 03017-000 1129–1136
03017-000 0121–0128
IO Blox 4 Inputs 1137–1144
Outputs 0129–0136
aFor sDIO modules 3 and 4 (and beyond), you must configure the signals to
have the system support those modules, using the Controller Editor in the Adept
ACE software. For details, see the topic on V+/eV+ System Configuration in the
Adept ACE User’s Guide.
bFor Dual Robot systems, see Adept Dual-Robot Configuration Procedure.

Using Digital I/O on Robot XIO Connector

The XIO connector on the robot interface panel offers access to digital I/O, 12 inputs and 8 out-
puts. These signals can be used by V+/eV+ to perform various functions in the workcell. See
the following table for the XIO signal designations.
l 12 Inputs, signals 1097 to 1108

l 8 Outputs, signals 0097 to 0104

Table 4-5. XIO Signal Designations

Signal V+/eV+ Signal

Pin No. Designation
Bank Number
1 GND
2 24 VDC
3 Common 1 1
4 Input 1.1 1 1097
5 Input 2.1 1 1098
6 Input 3.1 1 1099
7 Input 4.1 1 1100
8 Input 5.1 1 1101
9 Input 6.1 1 1102
10 GND
11 24 VDC

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Signal V+/eV+ Signal

Pin No. Designation
Bank Number
12 Common 2 2
13 Input 1.2 2 1103
14 Input 2.2 2 1104
15 Input 3.2 2 1105
16 Input 4.2 2 1106
17 Input 5.2 2 1107
18 Input 6.2 2 1108
19 Output 1 0097
20 Output 2 0098
21 Output 3 0099
22 Output 4 0100
23 Output 5 0101
24 Output 6 0102
25 Output 7 0103
26 Output 8 0104
Pin 9 Pin 1

Pin 18 Pin 10
Pin 26 Pin 19

Optional I/O Products

These optional products are also available for use with digital I/O:
l XIO Breakout Cable, 5 meters long, with flying leads on user’s end. For information,
see XIO Breakout Cable on page 48. This cable is not compatible with the XIO Ter-
mination Block mentioned below.
l XIO Termination Block, with terminals for user wiring, plus input and output status
LEDs. Connects to the XIO connector with 6 foot cable. See the Adept XIO Termination
Block Installation Guide for details.

XIO Input Signals

The 12 input channels are arranged in two banks of six. Each bank is electrically isolated from
the other bank and is optically isolated from the robot’s ground. The six inputs within each
bank share a common source/sink line.
The inputs are accessed through direct connection to the XIO connector (see the previous
table), or through the optional XIO Termination Block. See the documentation supplied with
the termination block for details.

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The XIO inputs cannot be used for REACTI programming, high-speed interrupts, or vision
triggers.

XIO Input Specifications

Table 4-6. XIO Input Specifications

Operational voltage range 0 to 30 VDC

“Off” state voltage range 0 to 3 VDC
“On” state voltage range 10 to 30 VDC
Typical threshold voltage V = 8 VDC
in
Operational current range 0 to 7.5 mA
“Off” state current range 0 to 0.5 mA
“On” state current range 2.5 to 7.5 mA
Typical threshold current 2.0 mA
Impedance (V /I ) 3.9 K Ω minimum
in in
Current at V = +24 VDC I ≤ 6 mA
in in
Turn on response time (hardware) 5 µsec maximum
Software scan rate/response time 16 ms scan cycle/
32 ms max response time
Turn off response time (hardware) 5 µsec maximum
Software scan rate/response time 16 ms scan cycle/
32 ms max response time

NOTE: The input current specifications are provided for reference. Voltage sources
are typically used to drive the inputs.

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Typical Input Wiring Example

Adept-Supplied Equipment User-Supplied Equipment

Note: all Input signals
Wiring can be used for either
Terminal Typical User
sinking or sourcing
Block Input Signals
configurations.

(equivalent circuit)
4 Part Present Sensor
Signal 1097
5 Feeder Empty Sensor
Signal 1098
6 Part Jammed Sensor
Signal 1099

Sinking (NPN) Inputs

Bank 1 configured for
XIO Connector – 26-Pin Female D-Sub

7 Sealant Ready Sensor

Input Bank 1

Signal 1100
8
Signal 1101
9
Signal 1102
Bank 1 3
Common
2
+24V

GND 1

13
Signal 1103
14
Signal 1104
15
Signal 1105

Sourcing (PNP) Inputs

Bank 2 configured for
16
Input Bank 2

Signal 1106
17
Signal 1107
18
Signal 1108
Bank 2 12
Common
10
GND
11
+24V

Figure 4-5. Typical User Wiring for XIO Input Signals

NOTE: The OFF state current range exceeds the leakage current of XIO outputs. This
guarantees that the inputs will not be turned on by the leakage current from the out-
puts. This is useful in situations where the outputs are looped-back to the inputs for
monitoring purposes.

XIO Output Signals

The eight digital outputs share a common, high side (sourcing) driver IC. The driver is
designed to supply any kind of load with one side connected to ground. It is designed for a
range of user-provided voltages from 10 to 24 VDC and each channel is capable of up to 0.7 A
of current. This driver has overtemperature protection, shorted load protection, and is current
limiting. In the event of an output short or other overcurrent situation, the affected output of
the driver IC turns off and back on automatically to reduce the temperature of the IC. The

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driver draws power from the primary 24 VDC input to the robot through a self-resetting poly-
fuse.
The outputs are accessed through direct connection to the XIO connector (see Table 4-5).
Optionally, use the XIO Termination Block. See the documentation supplied with the ter-
mination block for details.

XIO Output Specifications

Table 4-7. XIO Output Circuit Specifications

Parameter Value
Power supply voltage range See Specifications for 24 VDC
Power on page 28.
Operational current range, per chan- I ≤ 700 mA
out
nel
Total Current Limitation, all chan- I ≤ 1.0 A @ 50° C ambient
total
nels on.
I ≤ 1.5 A @ 25° C ambient
total

On state resistance (I
out
= 0.5 A) R ≤ 0.32 Ω @ 85° C
on

Output leakage current I ≤ 25 µA

out

Turn on response time 125 µsec max., 80 µsec typical

(hardware only)
Turn off response time 60 µsec. max., 28 µsec typical
(hardware only)
Output voltage at inductive load (+V - 65) ≤  V ≤ (+V - 45)
demag
turnoff (I = 0.5A, Load = 1 mH)
out
DC short circuit current limit 0.7A ≤ I ≤ 2.5 A
LIM
Peak short circuit current I ≤ 4A
ovpk

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Typical Output Wiring Example

Adept-Supplied Equipment User-Supplied Equipment

XIO Connector – 26-Pin Female D-Sub Wiring
Terminal
+24VDC
Block

19 Typical User Loads

Signal 0097
(equivalent Signal 0098
20
circuit) 21
Outputs 1-8

Signal 0099
22
Signal 0100 Load
23
Signal 0101 Load
24
Signal 0102 Load
25
Signal 0103
26
Signal 0104 Customer
GND
1 M AC Power
10 L N Supply
GND

Figure 4-6. Typical User Wiring for XIO Output Signals

XIO Breakout Cable

The XIO Breakout cable is available as an option—see the following figure. This cable connects
to the XIO connector on the robot, and provides flying leads on the user’s end, for connecting
input and output signals in the workcell. The cable length is 5 M (16.4 ft).
For the wire chart on the cable, see the following table.

NOTE: This cable is not compatible with the XIO Termination Block.

Figure 4-7. Optional XIO Breakout Cable

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Table 4-8. XIO Breakout Cable Wire Chart

Signal
Pin No. Designation Wire Color
1 GND White
2 24 VDC White/Black
3 Common 1 Red
4 Input 1.1 Red/Black
5 Input 2.1 Yellow
6 Input 3.1 Yellow/Black
7 Input 4.1 Green
8 Input 5.1 Green/Black
9 Input 6.1 Blue
10 GND Blue/White
11 24 VDC Brown
12 Common 2 Brown/White
13 Input 1.2 Orange
14 Input 2.2 Orange/Black
15 Input 3.2 Gray
16 Input 4.2 Gray/Black
17 Input 5.2 Violet
18 Input 6.2 Violet/White
19 Output 1 Pink
20 Output 2 Pink/Black
21 Output 3 Light Blue
22 Output 4 Light Blue/Black
23 Output 5 Light Green
24 Output 6 Light Green/Black
25 Output 7 White/Red
26 Output 8 White/Blue
Shell Shield
Pin 1 Pin 9

Pin 10 Pin 18

Pin 19 Pin 26

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4.6 Starting the System for the First Time

Follow the steps in this section to safely bring up your robot system. The steps include:
l Verifying installation, to confirm all tasks have been performed correctly

l Starting up the system by turning on power for the first time

l Verifying all E-Stops in the system function correctly

l Move each axis of the robot (generally with the pendant) to confirm it moves in the
proper directions

Verifying Installation
Verifying that the system is correctly installed and that all safety equipment is working cor-
rectly is an important process. Before using the robot, make the following checks to ensure that
the robot and controller have been properly installed.

DANGER: After installing the robot, you must test it before

you use it for the first time. Failure to do this could cause death,
or serious injury or equipment damage.

Mechanical Checks

Verify that:
l The robot is mounted level and that all fasteners are properly installed and tightened.

l Any end-of-arm tooling is properly installed.

l All other peripheral equipment is properly installed and in a state where it is safe to
turn on power to the robot system.

System Cable Checks

Verify the following connections:

l Front Panel to the SmartController.

l Pendant to the SmartController, via the pendant adapter cable.

l User-supplied 24 VDC power to the controller.

l User-supplied ground wire between the SmartController and ground.

l One end of the IEEE 1394 cable into the SmartServo port 1.1 connector on the Smart-
Controller, and the other end into a SmartServo connector on the robot interface panel.
l XSYS cable between the XSYS connector on the SmartController and the robot interface
panel XSLV connector (AIB) or eAIB XSLV adapter and XSYSTEM connector (eAIB),
with the latching screws tightened.

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or
eAIB XSYS (eAIB) cable between the robot interface panel XSYSTEM connector and
XSYS connector on the SmartController, and the latching screws tightened.
See Cable Connections from Robot to SmartController on page 27.
l User-supplied 24 VDC power to the robot 24 VDC connector.

l User-supplied 200/240 VAC power to the robot 200/240 VAC connector.

User-Supplied Safety Equipment Checks

Verify that all user-supplied safety equipment and E-Stop circuits are installed correctly.

Turning on Power
After the system installation has been verified, you are ready to turn on AC and DC power to
the system and start up Adept ACE.
1. Manually move the robot joints away from the folded shipping position, see Transport
and Storage on page 19.
2. Turn on the 200/240 VAC power.

DANGER: Make sure personnel are skilled and

instructed—refer to the Adept Robot Safety Guide.

3. Turn on the 24 VDC power to the robot. The Status Panel displays OK. The Robot Status
LED will be off.
4. Verify the Auto/Manual switch on the Front Panel is set to Auto Mode.

5. Turn on the user-supplied PC and start Adept ACE.

l Double-click the Adept ACE icon on your Windows desktop,
or
l From the Windows Start menu bar, select:
Start > Programs > Adept Technology > Adept ACE > Adept ACE.
6. On the Adept ACE Startup menu
l Check Create New Workspace for Controller at Address:
to make the connection to the controller.
l Select the IP address to match the setting being used by your PC.

Starting Adept ACE

The robot should be on, and the status panel should display OK before proceeding.
1. Turn on the PC and start the Adept ACE software.
l Double-click the Adept ACE icon on your Windows desktop
or,

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l from the Windows Start menu bar, select:

Start > Programs > Adept Technology > Adept ACE > Adept ACE.
2. On the Adept ACE Startup menu, click New SmartController Workspace.

3. Click-select the SmartController you want to use, and click OK.

4. Click Open. You will see the message “Working, please wait”.

5. Turn on the user-supplied PC and start Adept ACE.

l Double-click the Adept ACE icon on your Windows desktop,
or
l From the Windows Start menu bar, select:
Start > Programs > Adept Technology > Adept ACE > Adept ACE.
6. On the Adept ACE Getting Started screen:
l Select New SmartController Workspace.

l Select Create New Workspace for Selected Controller

to make the connection to the controller.
l Select the IP address of the controller you wish to connect to, or manually type in
the IP address.
7. Click OK. You will see the message “Working, please wait”.

Enabling High Power

After you have started Adept ACE and connected to the controller, enable high power to the
robot motors.

Using Adept ACE to Enable High Power

1. From the Adept ACE main menu, click the Enable High Power icon.

2. Press and release the blinking High Power button on the Front Panel within 10 seconds.
The Front Panel is shown in Figure 4-3. (If the button stops blinking, you must Enable
Power again.)

NOTE: The use of the blinking High Power button can be configured (or eliminated)
in software. Your system may not require this step.

This step turns on high power to the robot motors and calibrates the robot.
l The Robot Status LED glows amber.

l The code on the Robot Status Panel displays ON. See Status Panel Fault
Codes on page 37.

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Verifying E-Stop Functions

Verify that all E-Stop devices are functional (pendant, Front Panel, and user-supplied). Test
each mushroom button, safety gate, light curtain, etc., by enabling high power and then open-
ing the safety device. The High Power push button/light on the Front Panel should go out for
each.

Verify Robot Motions

Use the pendant (if purchased) to verify that the robot moves correctly. Refer to your Adept
pendant user's guide for complete instructions on using the pendant.
If the optional pendant is not installed in the system, you can move the robot using the Robot
Jog Control in the Adept ACE software. For details, see the Adept ACE User’s Guide.

4.7 Learning to Program the Adept Cobra s-Series Robot

To learn how to use and program the robot, see the Adept ACE User’s Guide, which provides
information on robot configuration, control and programming through the Adept ACE soft-
ware “point and click” user interface.
For V+/eV+ programming information, refer to the V+/eV+ user and reference guides in the
Adept Document Library (ADL) on the Adept website. For more details on the ADL, see Adept
Document Library on page 17.

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 Chapter 5: Maintenance

5.1 Field-replaceable Parts

WARNING: Only qualified service personnel may install or

service the robot system.

The following parts are the only field-replaceable parts:

Table 5-1. Field-replaceable Parts

Part Adept Part Number

Encoder battery 09977-000 (3.6 V, 6.8 Ah)
(This has replaced part number 02704-000)
AIB (Amp-In-Base) 04900-000
eAIB (Amp-In-Base) 11472-000

These parts must only be replaced with the Adept part numbers in the preceding table.

5.2 Periodic Maintenance Schedule

The following table gives a summary of the preventive maintenance procedures and guide-
lines on frequency.
Also, for cleanroom robots, see Maintenance on page 125; for IP-65 robots, see Customer
Requirements on page 116.

Table 5-2. Inspection and Maintenance

Item Period Reference

Check E-Stop, enable and key switches, 6 months See Checking Safety Systems on
and barrier interlocks page 56
Check robot mounting bolts 6 months See Checking Robot Mounting
Bolts on page 56
Check for signs of oil around of harmonic 3 months See Checking Robot for Oil
drive area. Around Harmonic Drive on
page 56.
Lubricate Joint 3 (Z-axis) ball screw 3 months See Lubricating Joint 3 Ball
Screw on page 57

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Item Period Reference

Replace encoder battery 5 to 10 years See Replacing the Encoder Bat-
tery on page 68

NOTE: The frequency of these procedures will depend on the particular system, its
operating environment, and amount of usage. Use the times in this table as guide-
lines and modify the schedule as needed.

WARNING: Lockout and tagout power before servicing.

WARNING: The procedures and replacement of parts men-

tioned in this section should be performed only by skilled or
instructed persons, as defined in the Adept Robot Safety Guide.
The access covers on the robot are not interlocked – turn off
and disconnect power if covers will be removed.

5.3 Checking Safety Systems

These tests should be done every six months.
1. Test operation of:
l E-Stop button on Front Panel

l E-Stop button on pendant

l Enabling switch on pendant

l Auto/Manual switch on Front Panel

NOTE: Operating any of the above switches should disable high power.

2. Test operation of any external (user-supplied) E-Stop buttons.

3. Test operation of barrier interlocks, etc.

5.4 Checking Robot Mounting Bolts

Check the tightness of the base mounting bolts every 6 months. Tighten to 85 N·m
(63 ft-lb). Also check the tightness of all cover plate screws.

5.5 Checking Robot for Oil Around Harmonic Drive

The Adept Cobra s600 and s800 robots use oil in the harmonic drive components for lubri-
cation. Periodically inspect the robot for any signs of oil in areas immediately outside of the
harmonic drive. Check these locations:

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l the area around Joint 1

l the area around Joint 2

l inside the base of the robot, by opening the AIB/eAIB chassis and inspecting internally.

WARNING: Remove all power to the robot before opening the

AIB/eAIB chassis.

Contact Adept if you find any signs of oil in these areas.

5.6 Lubricating Joint 3 Ball Screw

Required Grease for the Robot

Ball Screw/Spline Assembly Grease

LG-2 Lubricating Grease
Lithium Soap, Synthetic Hydrocarbon
Adept part number: 90401-04029

CAUTION: Using improper lubrication products on the Adept

Cobra s600 or s800 robot may cause damage to the robot.

Lubrication Procedure
1. Turn off main power to the controller and robot.

2. Remove the outer link cover by removing screws located on the sides and top of the
cover. Carefully remove the cover.

WARNING: When the outer link cover is removed, you see the

label shown in Figure 6-4. Do not remove the J3-ENC or J4-
ENC encoder cable connectors from their sockets. If they are
removed, the calibration data will be lost and the robot must be
run through a factory recalibration process, which requires spe-
cial software and tools.

For the IP-65 version, refer to Robot Outer Link Cover Removal and Rein-
stallation on page 114 for instructions on removing the link cover, and IP-65 Bel-
lows Replacement on page 119 for instructions on removing the bellows.
For the Cleanroom version, refer to Bellows Replacement on page 125 for instruc-
tions on removing the bellows. The outer link cover is standard.

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3. Switch on 24 VDC power to the robot.

4. Press the brake button and move Joint 3 to the top of its travel.
Remove any existing grease with a clean, lint-free, soft cloth.
5. Using a syringe, apply a small bead of grease to the Joint 3 ball screw grooves, see Fig-
ure 5-1.
Apply grease to the three vertical grooves and the spiral groove.
6. Press the brake button and move Joint 3 to the bottom of its travel.
Remove any existing grease with a clean, lint-free, soft cloth.
7. Apply a small bead of grease to any grooves of the ball screw that are now exposed.

8. Move Joint 3 up and down several times to spread the grease evenly.

9. Remove 24 VDC power from the robot.

10. Reinstall the outer link cover.

For the Cleanroom version, replace the bellows.

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Joint 3 Ball Screw

Lubrication Points

A A

A A
Joint 3 Ball Screw
Lubrication Points

Upper Quill Grease Locations Lower Quill Grease Locations

Quill Shaft
Vertical Groove
Lube Point A Vertical Groove
Lube Point B

Top View Looking Down

NOTE:
Apply grease to the
three vertical grooves Vertical Groove
and the spiral groove Lube Point C

Section A-A

Figure 5-1. Lubrication of Joint 3 Quill

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5.7 Replacing the AIB or eAIB Chassis

This procedure provides details on how to replace the AIB or eAIB chassis on an Adept Cobra
s600 and s800 robot.

CAUTION: Follow appropriate ESD procedures during the

removal/replacement phases.

Removing the AIB or eAIB Chassis

1. Switch off the SmartController.

2. Switch off the 24 VDC input supply to the chassis.

3. Switch off the 200/240 VAC input supply to the chassis.

4. Disconnect the 24 VDC supply cable from the chassis +24 VDC input connector. For the
connector location, see Figure 2-3.
5. Disconnect the 200/240 VAC supply cable from the chassis AC Input connector.

6. Disconnect the XSYS cable from the chassis XSLV connector (AIB) or
Disconnect the eAIB XSYS cable or XSYS cable with eAIB XSLV Adapter from the chas-
sis XSYSTEM connector (eAIB).
7. Disconnect the 1394 cable from the chassis SmartServo connector.

8. Disconnect any other cables, which may be connected to the chassis, such as XIO, RS-
232, or any others.
9. Using a 5 mm Allen wrench, carefully unscrew the chassis securing screw, which is
shown in the following figure. Note that the screw does not need to be completely
removed in order to remove the chassis, as this screw is captured on the chassis heat
sink.

Figure 5-2. Securing Screw on AIB Chassis

10. While holding the chassis heat sink, carefully and slowly lower the chassis down (see
the following figure), so that enough access is available to remove the internal cables.

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The chassis can be laid flat or placed to the right side of the robot for better access.

Figure 5-3. Opening and Removing Chassis

11. Disconnect the “white” amplifier cable from the amplifier connector located on the chas-
sis bracket. See the following figure.

Figure 5-4. Connectors on Chassis and PMAI Board - AIB Shown

12. Carefully disconnect the following cables from their connectors on the PMAI board, by
disengaging the securing latches:
l INT1

l INT2

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l ENC1

l ENC2

NOTE: The inside of the eAIB chassis looks slightly different from the AIB
shown, but the connectors listed are the same.

13. Using a 5 mm Allen wrench, disconnect and remove the ground wire from the chassis.
Keep the screw for reassembly later. See the following figure.

Figure 5-5. Ground Screw on AIB Chassis

14. Carefully remove the chassis from the robot, and place it aside. Tag it with the appro-
priate fault diagnosis faults/errors and robot serial number information.

Installing a New AIB or eAIB Chassis

1. Carefully remove the new chassis from its packaging, check it for any signs of damage,
and remove any foreign packing materials or debris from inside the chassis.
2. Carefully place the chassis next to the robot.

3. Using a 5 mm Allen wrench, carefully connect the ground wire to the chassis.

4. Carefully reconnect the cables you removed from their connectors on the PMAI board,
and engage the securing latches.
5. Carefully connect the “white” amplifier cable to the amplifier connector located on the
chassis bracket.

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Figure 5-6. Installing AIB Chassis in Robot Base

6. Carefully insert the chassis into the robot base in the groove at the bottom of the base—
see Figure 5-6. Tilt the chassis up and into place against the robot, making sure that
none of the cables get trapped or pinched and that the chassis O-ring is not damaged
during installation.
7. Once the chassis is in place, use a 5 mm Allen wrench to tighten the chassis securing
screw. See Figure 5-2 for details.
8. Connect the 200/240 VAC supply cable to the chassis AC input connector.

9. Connect the XSYS cable to the chassis XSLV connector (AIB).

or
Connect the eAIB XSYS cable or XSYS cable with eAIB XSLV Adapter to the chassis
XSYSTEM connector (eAIB).
10. Connect the 1394 cable to the chassis SmartServo connector.

11. Connect any other cables that were connected to the chassis, such as XIO, RS-232, or
any others.
12. Connect the 24 VDC supply cable to the chassis +24 VDC input connector.

13. Switch on the 200/240 VAC input supply to the chassis.

14. Switch on the 24 VDC input supply to the chassis.

15. Switch on the SmartController.

16. Once the system has completed booting, test the system for proper operation.

5.8 Commissioning a System with an eAIB

Commissioning a system involves synchronizing the robot with the eAIB.

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NOTE: This section only applies to robots that have an eAIB amplifier. A robot
with an AIB amplifier does not need the Adept ACE commissioning.

For a new system with an eAIB, the robot and the eAIB will have been commissioned at the
factory and should not need commissioning.
If you are replacing an existing AIB with an eAIB, you will need to commission the system.
In rare cases with a new eAIB robot, you may need to commission the system.
l If the system will not power up, and the robot status display shows SE, you need to
commission the system.
l If the system will not power up in Manual mode, and the robot status display shows
TR, you need to commission the system.

Safety Commissioning Utilities

The Adept eAIB adds two functions that implement safety in hardware:
l E-Stop
This serves as a backup to the standard software E-Stop process. The system will
always try to stop the robot using the software E-Stop first. The hardware E-Stop will
take over in the event of a failure of the software E-Stop.
l Teach Restrict
This limits the maximum speed of the robot when it is operated in Manual mode. As
with the E-Stop, this is a hardware backup to software limits on robot speed. If the soft-
ware fails to limit the robot speed during manual operation, the hardware Teach
Restrict will disable power to the system.
These two functions are only in the eAIB amplifiers. They were not implemented in hardware
in the AIB amplifiers, so these utilities do not apply to those amplifiers.
These two functions are supported by four wizards:
l E-Stop Configuration
This sets the E-Stop hardware delay to factory specifications.
l E-Stop Verification
This verifies that the hardware E-Stop is functioning correctly.
l Teach Restrict Configuration
This sets the hardware Teach Restrict maximum speed to factory specifications.
l Teach Restrict Verification
This verifies that the hardware Teach Restrict is functioning correctly.
The two verification wizards can be run at any time, to ensure that those functions are work-
ing properly.

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Prerequisites
l The robot must be set up and functional.

l The robot must use eAIB amplifiers.

The AIB does not support these hardware functions; these wizards will not run.
l Adept ACE software must be installed.

l The Front Panel keyswitch must be in Auto mode.

Figure 5-7. Adept Front Panel

l No E-Stops can be activated.

l For Configuration (E-Stop and Teach Restrict), the eAIB Commissioning Jumper must be
plugged into the XBELTIO jack on the eAIB.

NOTE: This is the only time that this jumper will be used. It is part number
11901-000, and must be removed for Verification and normal operation.

Figure 5-8. eAIB Commissioning Jumper

l An Adept T1, T2, or T20 pendant is required for the Teach Restrict verification.

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E-Stop Configuration Utility

This utility sets the E-Stop hardware delay to factory specifications.

NOTE: Ensure that the commissioning jumper is plugged into the XBELTIO jack on
the eAIB before you start this procedure.

Procedure

From within the Adept ACE software:

1. Open the robot object editor.

2. Select Configure > Safety Settings > Configure ESTOP Hardware Delay, then click
Next.
This procedure will configure Channel A and then Channel B.
It will then report the delay that it set for each.
3. Reboot the SmartController.
On some systems, the SmartController will reboot automatically.
4. Reboot the eAIB.

E-Stop Verification Utility

This utility verifies that the hardware E-Stop parameters are set correctly and that the hard-
ware E-Stop is working.
The hardware E-Stop must have already been configured for this wizard to run.

NOTE: If the commissioning jumper is plugged into the XBELTIO jack on the eAIB,
remove it before you start this procedure.

Procedure

From within the Adept ACE software:

1. Open the robot object editor.

2. Select Configure > Safety Settings > Verify ESTOP Hardware Delay, then click Next.

3. Enable high power, if not already enabled, then click Next.

4. Press an E-Stop button (on the Front Panel), then click Next.
The utility will confirm that the hardware delay has been verified for this robot, and dis-
play the delay times for channels A and B.
5. Reboot the SmartController.
On some systems, the SmartController will reboot automatically.

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Teach Restrict Configuration Utility

This utility sets the hardware Teach Restrict maximum speed parameter to factory spec-
ifications.

NOTE: Ensure that the commissioning jumper is plugged into the XBELTIO jack on
the eAIB before you start this procedure.

Procedure

NOTE: This procedure takes 2 or 3 minutes to complete.

From within the Adept ACE software:

1. Open the robot object editor.

2. Select Configure > Safety Settings > Configure Teach Restrict, then click Next.

3. From the Prerequisite screen, click Next.

The wizard will go through all of the robot's motors, and display messages that it is con-
figuring Channel A and B for each.
It will then record the configuration, and display the target times that it set.
4. Click Finish.

5. Reboot the SmartController.

On some systems, the SmartController will reboot automatically.

Teach Restrict Verification Utility

This utility verifies that the Teach Restrict parameters are set correctly and that the hardware
Teach Restrict maximum speed control is working.
This is a two-part wizard. The first is run in Auto mode. The second is run in Manual mode.
Before running this verification utility, the Teach Restrict must be configured.

NOTE: If the commissioning jumper is plugged into the XBELTIO jack on the eAIB,
remove it before you start this procedure.

Automatic Mode Procedure

WARNING: The robot will move during this wizard. Ensure

that personnel stay clear of the robot work area.

From within the Adept ACE software:

1. Open the robot object editor.

2. Select Configure > Safety Settings > Verify Teach Restrict, then click Next.

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3. Teach a Start Position.

This can be any position that does not conflict with obstacles or the limits of joint move-
ments.
l If the robot is already in such a position, you can just click Next.

l Otherwise, move the robot to such a position, then click Next.

l The screen will display the number of degrees that each joint is expected to move
during the verification process.
l You can click Preview Motions on this screen to view the motions at slow speed.
The default speed is 10, but you can change that speed with this screen's speed
control.
l You can click Move to Ready, to move the robot to the Ready position.
The robot will move each joint, in succession. It will generate an over-speed con-
dition for each, and verify that the hardware detected the over-speed condition.
4. Click Next, to proceed to the Manual Mode Procedure.
If the Automatic Mode Procedure fails, you will not be allowed to proceed with the Man-
ual Mode.

Manual Mode Procedure

The manual mode of this verification requires the use of an Adept pendant.
For this verification, the Front Panel keyswitch must be in Manual mode.
1. From the Introduction screen, click Next.
l Set the pendant to Joint mode.

l Set the pendant manual control speed to 100.

2. Click Next.

3. Using the pendant, jog any of the robot's joints until power is disabled.
This indicates that the Teach Restrict function is working.
4. Click Next.
The results of the verification will be displayed.
5. Click Finish.

6. Reboot the SmartController.

On some systems, the SmartController will reboot automatically.
7. Reset the Front Panel keyswitch to Auto mode.

5.9 Replacing the Encoder Battery

The data stored by the encoders is protected by a 3.6 V lithium backup battery pack located in
the base of the robot.

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CAUTION: Replace the battery pack only with a 3.6 V, 6.8 Ah

lithium battery pack, Adept P/N 09977-000.

NOTE: The previous battery, P/N 02704-000, has been superseded by this battery
pack. The battery replacement interval and procedure have not changed.

Battery Replacement Time Periods

If the robot is kept in storage and not in production, or the robot is turned off (no 24 VDC
supply) most of the time, then the battery should be replaced every 5 years.
If the robot is turned on with 24 VDC supplied to the robot more than half the time, then you
can increase the replacement interval to a maximum of 10 years.

NOTE: Dispose of the battery according to all local and national environmental reg-
ulations regarding electronic components.

Battery Replacement Procedure

1. Obtain the replacement battery pack.

2. Switch off the SmartController.

3. Switch off the 24 VDC input supply to the robot.

4. Switch off the 200/240 VAC input supply to the robot.

5. Disconnect the 24 VDC supply cable from the robot +24 VDC input connector. For the
connector location, see Figure 2-3.
6. Disconnect the 200/240 VAC supply cable from the robot AC input connector.

7. Using a 5 mm Allen wrench, carefully unscrew the AIB or eAIB chassis securing screw.
See Figure 5-2. Note that the screw does not need to be completely removed in order to
remove the chassis, as this screw is captured on the chassis heat sink.
8. While holding the chassis heat sink, carefully and slowly lower the chassis down, see
Figure 5-3. This provides access to the battery pack, as shown in the following figure.

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Figure 5-9. Location of Encoder Battery Pack

9. The battery cable assembly has two sets of connectors. Locate the secondary (unused)
battery cable in the wire bundle in the base area.
10. Place the new battery pack next to the original one, but do not disconnect the original
one.
11. Connect the new battery pack to the connectors on the secondary battery cable. Make
sure to verify the positive and negative connections are correct.
12. Once the new battery pack is connected, disconnect and remove the original battery
pack.
13. Place the new battery pack in the original location on the base of the robot.

14. Close the robot by reversing the steps in the beginning of this procedure.

15. Reconnect the 200/240 VAC supply cable to the robot AC input connector.

16. Reconnect the 24 VDC supply cable to the robot +24 VDC input connector. For the con-
nector location, see Figure 2-3.

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6.1 Installing End-Effectors

The user is responsible for providing and installing any end-effector or other end-of-arm tool-
ing. End-effectors can be attached to the tool flange using four M6 screws. See Figure 7-4. for a
detailed dimension drawing of the tool flange.
A 6 mm diameter x 12 mm dowel pin (user-supplied) fits in the through hole in the tool flange
and can be used as a keying or anti-rotation device in a user-designed end-effector.
If hazardous voltages are present at the end-effector, you must install a ground connection
from the base of the robot or the outer link to the end-effector. See Grounding Robot-Mounted
Equipment on page 36.

NOTE: A threaded hole is provided on the tool flange. See Figure 7-4. The user may
attach a ground wire through the quill connecting the outer link and the tool flange.

6.2 Removing and Installing the Tool Flange

The tool flange can be removed and reinstalled. If the flange is removed, it must be reinstalled
in exactly the same position to avoid losing the calibration for the system.
There is a setscrew on the flange that holds the rotational position of the flange on the quill
shaft. A steel ball behind the setscrew contacts the shaft in one of the vertical-spline grooves in
the shaft. Follow the procedures below to remove and reinstall the flange assembly.

Removing the Flange

1. Turn off high power and system power to the robot.

2. Remove any attached end-effectors or other tooling from the flange.

3. Use a 2.5 mm Allen wrench to loosen the setscrew. See Figure 6-1. Note the vertical-
spline groove that is in line with the setscrew. You must reinstall the flange in the same
position.
4. Use a socket driver to loosen the two M4 socket-head screws.

5. Slide the flange down slowly until it is off the shaft. Be careful not to lose the steel ball
(3.5 mm) that is inside the flange behind the setscrew.

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Quill shaft
M4 Socket-head
cap screws

User flange
Setscrew
assembly

Figure 6-1. Tool Flange Removal Details

Installing the Flange

1. Make sure the steel ball is in the setscrew hole inside the flange. Hold it in place with
your finger as you get ready to install the flange.
2. Slide the flange up on the quill shaft as far as it will go, and rotate until the setscrew is
lined up with the original vertical groove.
3. Support the flange while using a 2.5 mm Allen wrench to tighten the setscrew to finger
tight. Do not over-tighten the setscrew because this will cause the flange to be off-center
from the quill shaft.
4. Use a socket driver to tighten one of the socket-head screws part of the way, then tighten
the other one the same amount. Alternate between the two screws so there is even pres-
sure on both once they are tight. The torque specification for each screw is 8 N·m (70 in-
lb).

6.3 User Connections on Robot

User Air Lines

There are five user air line connectors on the robot user panel on the back of Joint 1 (see Figure
6-2). The five air lines run through the robot up to another set of five matching connectors on
the top of the outer link. See Figure 6-3.
l The two larger connectors are 6 mm diameter.

l The three smaller connectors are 4 mm diameter.

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Figure 6-2. User Connectors on Joint 1 Figure 6-3. User Connectors on Joint 2

For information on the IO Blox connector, see Connecting Digital I/O to the System
on page 41. Also, refer to the Adept IO Blox User’s Guide for details.

User Electrical Lines

There is a 25-pin male connector (24 conductor) on the robot user panel on the back of Joint 1
for user electrical lines, see Figure 6-2. This connector is wired directly to a 25-pin female con-
nector on the top of the outer link, see Figure 6-3. These connectors can be used to run user
electrical signals from the user panel, through the robot, and up to the outer link.
Wire Specifications: Wire size: 0.1 mm2, Pin Numbers 1-24, 12 pairs, twisted in pairs as 1&2,
3&4, 5&6, . . . 23&24. Maximum current per line: 1 Amp.

6.4 Internal User Connectors

The internal user connectors, OP3/4, EOAPWR, and ESTOP, can be accessed with the Outer
Link cover removed—see Figure 6-4. The SOLND connector is located on the opposite of the
bulkhead area—see Figure 6-5.

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Figure 6-4. Internal User Connectors—OP3/4, EOAPWR, ESTOP

WARNING: When the Outer link cover is removed, you see

the label shown above. Do not remove the J3-ENC or J4-ENC
encoder cable connectors from their sockets. If they are
removed, the calibration data will be lost and the robot must be
run through a factory recalibration process, which requires spe-
cial software and tools.

Figure 6-5. SOLND Connector

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SOLND Connector
This 4-pin connector provides the output signals for the optional Robot Solenoid Kit. See the
previous figure and following table. For installation details, see Installing the Robot Solenoid
Kit on page 79.

Table 6-1. SOLND Connector Pinout

Pin # Description Pin Location

1 Output 3001

2 Ground

3 Output 3002

4 Ground
SOLND Connector
as viewed on robot
Mating Connector:
AMP/Tyco #172167-1, 4-pin Mini-Universal Mate-N-Lok
AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok

OP3/4 Connector
This 4-pin connector provides the output signals for a second set of optional robot hand valve
solenoids, or other user-supplied devices. See the following table and figure. For the connector
location, see Figure 6-4.

Table 6-2. OP3/4 Connector Pinout

Pin # Description Pin Location

1 Output 3003

2 Ground

3 Output 3004

4 Ground
OP3/4 Connector
as viewed on robot
Mating Connector:
AMP/Tyco #172167-1, 4-pin Mini-Universal Mate-N-Lok
AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok

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SOLND Connector Circuit

For optional Robot Solenoid Kit installation, or
+24VDC other user supplied devices.
Pin 1
Signal 3001 Load
(equivalent Pin 2
circuit) GND
Pin 3
Signal 3002 Load
Pin 4
GND

OP3/4 Connector Circuit

For optional second set of solenoids, or
+24VDC other user supplied devices.
Pin 1
Signal 3003 Load
(equivalent Pin 2
circuit) GND
Pin 3
Signal 3004 Load
Pin 4
GND

Figure 6-6. OP3/4 and SOLND Circuits

EOAPWR Connector
This 4-pin connector provides 24 VDC power and ground for user applications. See the fol-
lowing table for the pinouts and Internal User Connector Output Specifications on page 76 for
the output specifications. For the connector location, see Figure 6-4.

Table 6-3. EOAPWR Connector Pinout

Pin # Description Pin Location

1 24 VDC (see the next table for cur-

rent specs)

2 Ground

3 24 VDC (see the next table for cur-

rent specs)
EOAPWR Connector
4 Ground as viewed on robot
Mating Connector:
AMP/Tyco #172167-1, 4-pin Mini-Universal Mate-N-Lok
AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok

Internal User Connector Output Specifications

The output specifications in the following table apply to the EOAPWR, OP3/4, and SOLND
internal user connectors.

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Table 6-4. Internal User Connector Output Circuit Specifications

Parameter Value

Power supply voltage range 24 VDC ± 10%

See Specifications for 24 VDC
Power on page 28.
Operational current range, per channel I ≤ 700 mA
out

Total Current Limitation, all channels ona I ≤ 1.0 A @ 50° C ambient

total

I ≤ 1.5 A @ 25° C ambient

total

On-state resistance (I
out
= 0.5 A) R ≤ 0.32 Ω @ 85° C
on

Output leakage current I ≤ 25 µA

out

Turn-on response time 125 µsec. max., 80 µsec typical

(hardware only)
Turn-off response time 60 µsec. max., 28 µsec typical
(hardware only)
Output voltage at inductive load turnoff (+V - 65) ≤  V ≤ (+V - 45)
demag
(I = 0.5 A, Load = 1 mH)
out
DC short circuit current limit 0.7A ≤ I ≤ 2.5 A
LIM

Peak short circuit current I ≤ 4A

ovpk

aNOTE: Total current is the sum of the output current used by output signals
3001-3004 (SOLND and OP3/4) and any user current drawn from EOAPWR.

ESTOP Connector
The Break-away E-STOP function is provided to enable a high power shutdown from the outer
link area. For example, it would be used if you want a break-away gripper to shut down robot
high power. It lets you disable high power through a user relay circuit inside the robot.
The 2-pin ESTOP connector provides a pair of contacts that can be used for a Break-away E-
Stop function at the end of the arm. See the following table. The function is disabled by default
when the system is shipped. The user must enable this function using the Adept ACE software
(see below), and connect a normally-closed circuit to Pins 1 and 2. When the circuit is opened,
the system will stop in an E-Stop condition. See the following table and figure.

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Table 6-5. ESTOP Connector

Pin # Description Pin Location

1 ESTOP_INPUT

2 24 V

ESTOP Connector
as viewed on robot
Mating Connector:
AMP/Tyco #172165-1, 2-pin Mini-Universal Mate-N-Lock
AMP/Tyco #770985-1, Pin Contact, Mini-Univ. Mate-N-Lok

Typical ESTOP
Connector Circuit
User-supplied normally-closed contact.
Can be connected to a break-away sensor
Pin 1
to cause an E-Stop condition when circuit
is open.
Pin 2
Note: This function is disabled by default - it must
be enabled in software.

Figure 6-7. Internal E-Stop Connector Circuit

NOTE: This circuit will trigger an emergency stop of the local robot only. It does not
link to the E-Stop chain of the host SmartController.

Procedure to Enable the Break-away E-Stop Function

To enable the Break-away E-Stop function, you have to use the Adept ACE software to change
the default configuration:

NOTE: This requires that you have Expert access.

From the Adept ACE software:

To get into Expert mode:
1. Click on Object.

2. Click Expert Access.

You will be asked for a password, to enter Expert Access.
3. Enter the Expert Access password.

To change the Break-away E-Stop parameter:

1. Double-click the robot in the structure pane.
This will open up the object editor for the robot.

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2. Select Break-away E-Stop Enable.

3. Change the value of this field to True.

Figure 6-8. Screen Shot with Break-away E-Stop Parameter Field

NOTE: When the Break-away E-Stop function has been enabled, you must connect
a normally-closed circuit to pins 1 and 2 of the ESTOP connector, as described
above. If this is not done, the system will be in an E-Stop condition and you will
not be able to enable power.

6.5 Mounting Locations for External Equipment

Three locations are provided for mounting user’s external equipment on the robot arm. The
first location is on the J1 Harness Support (top side of the inner link), a second is on the top
side of the outer link, and a third is on the bottom side of the outer link. Each location has a
set of four tapped holes. See Figure 7-5 and Figure 7-6 for the dimensions.

NOTE: The cover on the outer link must be removed for maintenance (lubrication),
so keep this in mind when mounting any external equipment to the outer link
cover.

For information on mounting cameras on the robot, see Installing the Camera Bracket Kit on
page 85.

6.6 Installing the Robot Solenoid Kit

This procedure describes how to mount the 24 V Robot Solenoid option on Adept Cobra s600
and s800 robots. The kit is available as Adept P/N 02853-000.
The robot has been pre-wired to accommodate a bank of two 24 VDC solenoid valves. Power
for the internal mounting is accessible via a connector mounted inside the outer link cover (see
Figure 6-10). The signals actuating the valves are directly switchable from the Adept ACE soft-
ware using software signals 3001 and 3002.

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1. Open the gripper object editor.

2. Select the Open/Close tab.

3. Set the signal values for Open, Close, and Release.

Figure 6-9. Setting Solenoid Signal Values

The Adept-supplied solenoids each draw a nominal 75 mA from 24 VDC.

The solenoid valve assembly consists of two independent valves (Valve #1 and Valve #2) on a
common manifold. The manifold supplies air at the user’s line pressure: minimum 28 psi
(0.19 MPa), to maximum 114 psi (0.786 MPa). Each valve has two output ports, A and B. The
output ports are arranged so that when Port A is pressurized, Port B is not pressurized. Con-
versely, when Port B is pressurized, Port A is not. In the Adept Cobra s600 and s800 robots,
the air lines from Port A on each valve are plugged at the factory (at the solenoid assembly).
The Solenoid Kit for the Adept Cobra s600 and s800 robots is available through Adept. Contact
your Adept Sales Representative for current price and availability.

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Table 6-6. Air Pressure

Air Pressure (Psi) Air Pressure (MPa)

28 - 114 0.19 - 0.786

Tools Required
l Allen drivers

l Cable ties

l Diagonal wire cutters

l Solenoid Valve upgrade Kit (Adept P/N 02853-000)

Procedure
1. Turn off all power to the robot.

2. Remove two screws on s600 (three screws on s800) on each side of the outer link cover.
Remove two screws on top and remove the cover.
3. Connect the Internal Solenoid Valve Cable assembly to the Solenoid Manifold assembly,
by plugging the SOL 1 connector into Valve 1 and SOL 2 into Valve 2.

Figure 6-10. Solenoid Mounting Bracket With Connector and Spare Air Line

4. Cut and discard the cable ties holding the spare air line at the top of the mounting
bracket. Move the air line away to facilitate the mounting of the solenoid manifold. See
Figure 6-10. .
5. Mount the solenoid manifold onto the bracket using the supplied M3 x 25 mm screws
and washers. See Figure 6-11. .

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6. Insert the spare air line into the air intake coupling of the solenoid manifold. Make sure
the air line is pushed in all the way and secured in place by the intake coupling. Con-
firm by gently pulling the air line.

NOTE: If you are installing on a Cleanroom or IP-65 robot, the spare air line is used
for a different purpose in those robots. You will have to provide a piece of 6 mm
tubing to run from one of the 6 mm user air lines at the Joint 2 cover to the air
intake coupling mentioned above.

7. Plug the connector plug into the female connector jack (marked SOLND) on the bracket.

8. Use cable ties to secure air line to the bracket as needed.

Figure 6-11. Solenoid Placement Using Mounting Hardware

9. Install the appropriate lengths of 5/32 inch plastic tubing (supplied) into the two output
ports on the manifold.
l Route the tubing up along the tower bracket next to the quill and down through
the center of the quill.
l Use cable ties as needed to secure the tubing.

10. Loosen the securing screw on the AIB/eAIB chassis, and lower the chassis down flat.
See Figure 5-2 for the location of the securing screw.
11. Remove the cable strap plate by removing two screws and split washers. See Figure 6-
12. . This allows the harness to move when you lift the J1 cover in the next step.

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Figure 6-12. Removing the Cable Strap Plate

12. Remove the four screws for the Joint 1 cover and lift the cover up so you have access to
the tubing under the cover. See Figure 6-13.

Figure 6-13. Connecting Spare Air Line to User Connector

13. Disconnect the tubing from the 6 mm User Air fitting shown in Figure 6-13. Fold the tub-
ing out of the way and restrain using tie-wraps.
14. Locate the spare air line contained in the tubing bundle inside the front end of the
cover. Remove the spare air line from the bundle.
15. Insert the spare air line into the back of the empty 6 mm User Air fitting.

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NOTE: This 6 mm User Air connector and the 6 mm User Air connector at the top
of Figure 6-2 are not available for other uses after this modification.

16. Reinstall the Joint 1 cover, taking care to ensure that all tubing is inside the cover and
nothing gets crimped or pinched while pushing the cover into position. Reinstall four
screws to secure the cover. Tighten the screws to 1.6 N·m (14 in-lb) of torque.
17. Reinstall the cable strap plate that you removed earlier in the procedure.

18. Raise the AIB/eAIB chassis to the closed position and tighten the securing screw.

19. Reinstall the outer link cover and tighten the screws to 1.6 N·m (14 in-lb) of torque.

20. Connect the factory air supply to the 6 mm User Air connector.
For the non-IP-65 robot, this is the air connector just modified.
21. From the Adept ACE software:
a. Click the Digital I/O button in the controller toolbar:

b. The Digital I/O window will open.

c. Check Robot.

d. Select Signal 3001 and Signal 3002 (the first two blocks) to activate the solenoids
one at a time.
e. The selected blocks will turn green, to indicate they are active.

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WARNING: Disconnect robot air pressure until this test has

been done to prevent unsecured pneumatic lines from acci-
dentally injuring personnel.

6.7 Installing the Camera Bracket Kit

The Adept Cobra Robot Camera Bracket Kit provides a convenient way of mounting cameras
to the outer link of the robot. The kit consists of the following:
l One camera plate

l Two camera brackets

l One camera mount slide bracket

l One camera mount channel

l M4 X 12 mm screws

l M4 stainless steel flat washers

l M5 X 12 mm screws

Tools Required
l M4 Allen wrench

l M3 Allen wrench

Procedure
1. Install the camera plate to the outer link with four M5 X 12 mm screws. See Figure 6-14
as you perform this procedure.
2. Install the two camera brackets to the camera plate with two stainless steel washers and
two M4 X 12 mm screws for each bracket. (The camera brackets are not required unless
you are mounting more than one camera.)
3. Mount the camera channel to the camera brackets or camera plate with
M4 x 12 mm screws.
4. Mount the camera to the camera mount.

5. Mount the camera and camera mount to the camera channel using M5 x 12 mm
screws.

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Camera
Mount

Camera Plate

Camera Brackets (optional)

Camera Channel

Figure 6-14. Mounting a Camera on the Robot

6.8 DeviceNet Communication Link

DeviceNet is a communications link that connects industrial I/O devices to a message-pack-
eting network. All nodes connect to the same backbone cable, eliminating the need for individ-
ual wiring for each I/O point.
Adept incorporates the following DeviceNet-ready hardware in the Adept Cobra s600 and s800
robots:
l Male micro-style 12 mm thread DIN connector at the robot base. See Figure 6-2.

l Female micro-style 12 mm thread DIN connector for joint 2 of the robot. See Figure 6-3
and Figure 6-15. .
l A non-standard DeviceNet cable, consisting of two shielded twisted pairs that connect
the base and joint 2 connectors. Adept considers this cabling to be a drop line with a
maximum total length of 6 meters (20 feet) and therefore uses the following wire sizes:

Wire Adept DeviceNet

“thin cable”

Power pairs 24 AWG 22 AWG

Signal pairs 28 AWG 24 AWG

This means that total current on the power pairs must be limited to 2 A instead
of the standard 3 A in a DeviceNet trunk line. Because this is intended to be a
DeviceNet drop line with a maximum of 6 meters (20 feet), the full data rate
should be achievable. However, Adept has tested the internal cable only at 125k
baud.

See the Adept SmartController User's Guide for physical installation.

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Use Adept ACE, controller configuration, for software setup. This assigns the controller signals
to the physical ports of the DeviceNet nodes.

NOTE: The local setting baud rate must match the DeviceNet node’s setting.

From the Adept ACE software:

1. Double-click on the controller in the tree structure pane.
This opens the object editor for the controller.
2. Select Configure > Configure V+ (or eV+).

3. Select DEVICENET.

4. If there is no LOCAL statement, you are prompted to add one before scanning.
The LOCAL statement in the DeviceNet configuration specifies the MAC ID of the
Adept controller on the DeviceNet bus. The default setting is 0. Set the MAC ID so that
all the nodes on the bus have different MAC IDs.
LOCAL = "/MACID n /BAUD n".

This statement also defines the baud rate of the DeviceNet scanner. The baud rate
depends on multiple factors, such as the length of the DeviceNet cable, the DeviceNet
components on the bus, etc.
Syntax of the LOCAL statement:
LOCAL = "/MACID local_id
/BAUD baud_rate"

Parameter Description Range

local_id MACID for the Adept controller on the 0 - 63
bus
baud_rate Baud rate to be used on the DeviceNet 125K, 250K, or 500K

5. Click Scan.
This scans for your physical DeviceNet nodes, and return the MACIDs for them.
6. Use Add or Edit to set the values for DeviceNet.

7. The fields that need to be entered are:

l Index - a unique number for this mapping

l Byte - usually starts at 1

This is the input or output block where mapping starts.
A byte refers to 8 inputs or outputs, so if you are using two 8-channel input
blocks, byte 1 would be the first input block, and byte 2 the second.
l Bit - usually starts at 1
This is the bit within the byte where mapping starts.
To map the first input of an 8-channel input block, this would be 1.

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l Signal - the input or output signal number (e.g. 1013 or 013) where mapping
starts.
l Bit_length - the number of input or output signals to map.

l MACID - the MACID returned by the Scan.

8. When you are finished, click Done.

9. Check that the assignments worked correctly by opening the Digital I/O tab.
The new signals should show up as being mapped now.

Recommended Vendors for Mating Cables and Connectors

A variety of vendors have molded cable assemblies for the Micro-style connector including
Brad Harrison, Crouse Hinds, Lumberg, Turk, and others. In addition, Hirshmann, Phoenix
Contact, and Beckhoff have mating micro connectors that have screw terminals in the plug to
allow the user to make custom cables.

(VIEWED FROM CONTACT END)

4 3

1 2

Male Connector (pins)

Micro-Style
Connector

3 4

LEGEND:
5
1 Drain (bare)
2 V+ (red)
2 1
3 V- (black)
4 CAN_H (white)
5 CAN_L (blue)
Female Connector (sockets)

Figure 6-15. Micro-Style Connector Pinouts for DeviceNet

6.9 Installing Adjustable Hardstops

Adept offers an adjustable hardstop kit for Joint 1 and Joint 2 on the Adept Cobra s600/s800
robots. These are user-installed options that can be used to limit the work envelope of the
robot. The Adept part number for the kit is 02592-000.

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Joint 1 Adjustable Hardstops

The Joint 1 Adjustable Hardstops consist of two black rubber stop cylinders, and the required
screws to install them. There are two locations for the hardstops on each side of the robot, Posi-
tion 1 and Position 2. See the following figure.

Figure 6-16. Joint 1 Adjustable Hardstops

Installation Procedure
1. Remove the plug from desired threaded hole, Position 1 or 2, on each side of the robot.

2. Install the adjustable hardstop into the threaded hole using an 8 mm Allen wrench.
Tighten to a torque of 5.1 N·m (45 in-lbf).
3. Repeat the process on the other side of the robot.

NOTE: The two sides do not have to have a hardstop in the same position, i.e., you
can use Position 1 on one side, and Position 2 (or none) on the other, if you choose.

Modifying Joint Limit Softstop Locations for Joint 1

After installing the adjustable hardstops, you must modify the softstop locations using the
Adept ACE software.
1. From Adept ACE, select the robot in the tree structure pane.

2. Open the robot editor.

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Figure 6-17. Robot Editor, with Joints Collapsed

3. Click the ‘+’ in front of Joints, to display all of the joints.

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Figure 6-18. Robot Editor, with Joints Expanded

4. Click the ‘+’ in front of [1], to open the values for joint 1.

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Figure 6-19. Robot Editor, with Joint 1 Expanded

5. Highlight the current values for joint 1, and replace them with the new values. See the
following table for recommended softstop values for Position 1 or Position 2.

Table 6-7. Joint 1 Ranges for Adjustable Hardstops

Recommended
Hardstop Value Joint Limit Softstop

J1 Hardstop Position 1 ± 50° Lower limit: – 49°

Upper limit: + 49°

J1 Hardstop Position 2 ± 88° Lower limit: – 87°

Upper limit: + 87°

6. Once you have modified the upper and lower joint limit softstops, you must reboot the
system by cycling 24 VDC power to the SmartController. The new joint limits will be in
affect when the system reboot is done.

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Joint 2 Adjustable Hardstops

The Joint 2 Adjustable Hardstop kit (Figure 6-20) consists of two curved plates that are the
adjustable hardstops, a small, black rectangular device that is the fixed hardstop, and the
required screws to install them. The adjustable hardstop plates can be installed in different
locations, depending on how much you need to limit the Joint 2 range of motion.

Figure 6-20. Joint 2 Hardstop Kit

Installation Procedure

1. Slide the two adjustable hardstop plates into the space between inner and outer links.
See Figure 6-21. Looking up at the inner link from underneath, align the holes in the
plates with the holes in the inner link. See Figure 6-22.

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Figure 6-21. Joint 2 Adjustable Hardstop Locations

Joint 2 Left Hardstop Plate,

installed in +81 degree position

Joint 2 Fixed
Hardstop Device

Joint 2 +
Positive
direction

Joint 2
Negative
direction _

12 thru holes for M5 x 10 screws,

for installing Joint 2 hardstops, located
30 degrees apart Joint 2 Right Hardstop Plate,
installed in -81 degree position
View of under side of Inner Link, looking up

Figure 6-22. Screw Locations for Joint 2 Adjustable Hardstops

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2. Use a 4 mm Allen wrench to install three supplied M5 x 10 screws to secure the plate.
Tighten the screws to a torque of 4.5 N·m (40 in-lb). Repeat the process for the second
plate. Note that the plates can be installed in a number of different positions, depending
on how much you need to limit the range of Joint 2.

NOTE: The two sides do not have to have the hardstop in the same position, so the
workspace does not have to be symmetrical.

3. Slide the fixed hardstop device into the slot on the underside of the outer link. See Fig-
ure 6-23.

Figure 6-23. Fixed Hardstop Block for Joint 2

4. Use a 3 mm Allen wrench to install two supplied M4 x 10 screws to secure the hard-
stop device. Tighten the screws to a torque of 2.5 N·m (22 in-lb).

Modifying Joint Limit Softstop Locations for Joint 2

After installing the adjustable hardstops, you must modify the softstop locations using the
Adept ACE software.
1. From the Adept ACE software, select the robot in the tree structure pane.

2. Open the robot editor.

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Figure 6-24. Robot Editor, with Joints Closed

3. Click the ‘+’ in front of Joints, to display all of the joints.

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Figure 6-25. Robot Editor, with Joints Expanded

4. Click the ‘+’ in front of [2], to open the values for joint 2.

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Figure 6-26. Robot Editor, with Joint 2 Expanded

5. Highlight the current values for joint 2, and replace them with the new values. See the
following table for recommended softstop values.

Table 6-8. Joint 2 Ranges for Adjustable Hardstops

Recommended
Hardstop Value Joint Limit Softstop

J2 Hardstop Position 1 ± 81° Lower limit: – 80°

Upper limit: + 80°

J2 Hardstop Position 2 ± 51° Lower limit: – 50°

Upper limit: + 50°

J2 Hardstop Position 3 ± 21° Lower limit: – 20°

Upper limit: + 20°

Note: J2 Hardstops can be installed in a number of positions, depending on how

the robot workcell needs to be configured. The positions are spaced 30° apart.

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6. Once you have modified the upper and lower joint limit softstops, you must reboot the
system by cycling 24 VDC power to the SmartController. The new joint limits will be in
affect when the system reboot is done.

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 Chapter 7: Technical Specifications

7.1 Dimension Drawings

417
183

200

Required
clearance
to open 918
AIB Chassis
894

46
37

398

342

31
Required
cable
188
clearance

0
425

800
234

Figure 7-1. Adept Cobra s600 Robot Top and Side Dimensions

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 Chapter 7: Technical Specifications

417
183

200

Required
clearance
to open 918
AIB Chassis
894

46
37

394

342

31
Required
cable
184
clearance

0
425

800
234

Figure 7-2. Adept Cobra s800 Robot Top and Side Dimensions

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 Chapter 7: Technical Specifications

2X M4x0.7-6H 10

+.10
54 2X 3.0 6
-.03

45
10

457 to
base of
robot
2X M4x0.7-6H 10

All dimensions in mm

Figure 7-3. Dimensions of the Camera Bracket Mounting Pattern

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 Chapter 7: Technical Specifications

12.0 mm
(0.47 in.)
20.0 mm See Detail A
3.0 mm (0.79 in.)
(0.12 in.)

43 mm
(1.69 in.)

∅ 41.15 mm +.03 mm -A-

–.00 mm
45°
(∅ 1.620 in.) (+.001 in.)
(–.000 in.)
Dowel Pin Hole
∅ 6.0 mm +.01 mm ∅ 63.0 mm (2.48 in.)
– 0 mm

(0.2362 in.) (+.0005 in.)

(– 0 in.)
-C-
30°
BC ∅ 50.0 mm (1.9685 in.)

4X M6 x 1- 6H Thru
∅.10 mm (.004 in.) M A M B C M User Ground
R 3.56mm (R 0.140in)
5.08mm (0.20in)
M3 X 0.5-6H Thru

Units in mm

4.14 mm
(0.163 in.)

1.5 mm
(0.059 in.)

6.80 mm
(0.268 in.)

-B-
25°
Detail A

Figure 7-4. Tool Flange Dimensions for Adept Cobra Robots

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 Chapter 7: Technical Specifications

25 4X M4x0.7 - 6H 6

Inner Link
External Mounting
105 Locations

60 4X M4x0.7 - 6H 8
Units in mm

Outer Link
105
External Mounting
Locations

Figure 7-5. External Tooling on Top of Robot Arm

76 - Cobra s/i600
135 - Cobra s/i800
34

90
Outer Link - Bottom View

4X M4x0.7-6H 8 Units in mm

Figure 7-6. External Tooling on Underside of Outer Link

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 Chapter 7: Technical Specifications

Figure 7-7. Adept Cobra s600 Robot Working Envelope

Maximum Intrusion Maximum Radial Reach

Contact Radius Functional Area
847.3 mm (33.36 in.) 800 mm (31.50 in.)

Minimum
Radial
Reach
163.6 mm
105˚ (6.44 in.)

105˚

157.5˚ 157.5˚

Cartesian Limits
300 mm (11.8 in.)

Figure 7-8. Adept Cobra s800 Robot Working Envelope

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7.2 Cobra s600/s800 Internal Connections

Cobra s600/s800 SmartController

Internal Connections Connections

Man 1 XSLV-2
Man 2 XSLV-3
Auto 1 XSLV-6
Auto 2 XSLV-7

To XSYS on
ESTOPSRC XSLV-9 SmartController
Force-Guided Relay
Cyclic Check ESTOPGND XSLV-1
Control Circuit
HPWRREQ XSLV-5

Single-Phase
AC Input High Power to
200-240VAC Amplifiers

Force-Guided Force-Guided

Figure 7-9. Adept Cobra s600/s800 Internal Connections Diagram

7.3 XSLV Connector

Table 7-1. XSLV Connector Pinout (AIB only)

Pin # Description Comment Pin Location

1 ESTOPGND ESTOP System Ground
2 MAN1 ESTOP Manual Input Ch 1 Pin 5 Pin 1

3 MAN2 ESTOP Manual Input Ch 2

4 HIPWRDIS High Power Disable
Pin 9 Pin 6
5 ESTOP_RESET Normally Closed Check Contacts
6 AUTO1 ESTOP Auto Input Ch 1
XSLV1/2 Connector
7 AUTO2 ESTOP Auto Input Ch 2
as viewed on Cobra
8 N/C
9 ESTOP_SRC ESTOP System +24 V
Mating Connector:
AMP/Tyco #747904-2, 9-pin D-Sub
AMP/Tyco #748676-1, D-Sub Cable Clamp

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7.4 Robot Specifications

Table 7-2. Adept Cobra s600/s800 Robot Specificationsa

Description s600 Robot s800 Robot

Reach 600 mm (23.6 in) 800 mm (31.5 in)
Payload—rated 2.0 kg (4.4 lb) 2.0 kg (4.4 lb)
Payload—maximum 5.5 kg (12.1 lb) 5.5 kg (12.1 lb)
Moment of Inertia Joint 4 - 450 kg-cm² Joint 4 - 450 kg-cm²
(150 lb-in²) - max (150 lb-in²) - max
Downward Push Force— 343 N (77 lb) - maximum 298 N (67 lb) - maximum
Burst, (no load)
Lateral/Side Push Force— 178 N (40 lb) - maximum 133 N (30 lb) - maximum
Burst
Adept Cycle—Sustained (no J4 rotation)
0 kg 0.42 sec at 20° C 0.48 sec at 20° C
0.48 sec at 40° C 0.51 sec at 40° C
2 kg 0.45 sec at 20° C 0.54 sec at 20° C
0.51 sec at 40° C 0.54 sec at 40° C
5.5 kg 0.58 sec at 20° C 0.70 sec at 20° C
0.64 sec at 40° C 0.70 sec at 40° C
Adept Cycle—Sustained (180° J4 rotation)
0 kg 0.42 sec at 20° C 0.48 sec at 20° C
0.48 sec at 40° C 0.48 sec at 40° C
2 kg 0.45 sec at 20° C 0.54 sec at 20° C
0.51 sec at 40° C 0.61 sec at 40° C
5.5 kg 0.80 sec at 20° C 0.77 sec at 20° C
0.86 sec at 40° C 0.91 sec at 40° C
Repeatability
X, Y ±0.017 mm (±0.00067 in.) ±0.017 mm (±0.00067 in.)
Z ±0.003 mm (±0.00012 in.) ±0.003 mm (±0.00012 in.)
Theta ±0.019° ±0.019°
Joint Range
Joint 1 ±105° ±105°
Joint 2 ±150° ±157.5°
Joint 3 210 mm (8.3 in.) 210 mm (8.3 in.)

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Description s600 Robot s800 Robot

Joint 4 ±360° ±360°
Joint Speed (maximum)
Joint 1 386°/sec 386°/sec
Joint 2 720°/sec 720°/sec
Joint 3 1,100 mm/sec (43 in/sec) 1,100 mm/sec (43 in/sec)
Joint 4 1200°/sec 1200°/sec
Encoder type Absolute
Robot Brakes Joints 1, 2, and 4: Dynamic
Joint 3: Electric
Airline pass-through (quan- 6 mm diameter (2), 4 mm diameter (3)
tity)
Electrical pass-through 24 conductors (12 twisted pair)
DeviceNet pass-through One available
Weight (without options) 41 kg (90 lb) 43 kg (95 lb)
aSpecifications subject to change without notice.

Table 7-3. Softstop and Hardstop Specifications

Joint Cobra s600 Cobra s800

Softstop Hardstop – Softstop Hardstop –
Approximate Approximate
Joint 1 ± 105 ± 108 ± 105 ± 108

Joint 2 ± 150 ± 151 ± 157.5 ± 160

Joint 3 0 to 210 mm -5 to 215 mm 0 to 210 mm -5 to 215 mm

Joint 4 ± 360 not applicable ± 360 not applicable

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8.1 Cobra s800 IP-65 Classification

The factory installed IP-65 option kit provides an improved level of dust and water protection.
IP-65 means “dust-tight and protection against water jetting.”
l Dust Resistance—protection of the equipment inside the robot shell against ingress of
solid foreign objects
l Specifically for IP-65 Dust Protection—“No ingress of dust is allowed.”

l Water Resistance—protection of the equipment inside the robot shell against harmful
effects due to the ingress of water
l Specifically for IP-65 Water Protection—“Water projected in jets against the robot enclo-
sure from any direction shall have no harmful effects”

NOTE: The IP-65 Option is available only for the Cobra s800 robot.

Figure 8-1. Adept Cobra s800 Robot—IP-65 Version

8.2 Installing Cable Seal Assembly

Cable Seal Identification

The cable seal assembly (04813-000) must be mounted on the back of the robot during the
robot installation process. The cable seal assembly is shipped separately from the robot. See the
following figure to identify the cable seal parts.

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Cable Seal Housing

Figure 8-2. Cable Seal Parts

Installation Procedure
1. Disassemble the cable seal assembly into separate pieces by removing all screws.

2. Install the cable seal housing on the back of the robot using four M4x50 screws, four M4
lock washers, and four M4 flat washers. Note that the centered M6 threaded hole must
be at the top. See the following figure.

Figure 8-3. Cable Seal Housing Installed

3. Attach all system cables to the robot. See Figure 3-1.

4. Install the lower cable seal flange onto the housing. The lower flange fits into the groove
at the bottom of the housing.
a. Tilt the flange away from the robot as you install it—see Figure 8-4.

b. Then pull up on the flange and push it toward the robot.

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c. Finally push down on the flange to secure it against the housing. See Figure 8-5
for the lower flange in the installed position.

Figure 8-4. Installing Lower Flange Figure 8-5. Lower Flange in Position

5. Seat all of the cables by pushing down into the foam on the lower flange.

6. Attach the upper flange to the lower flange using two M6 x 20 screws, two M6 lock
washers, and two M6 flat washers. Make sure none of the cable are pinched or crimped
when installing the upper flange.
7. Attach the flange assembly using one M6 x 20 screw, one M6 lock washer, and one M6
flat washer. See Figure 8-6.

Figure 8-6. Upper Flange Installed Figure 8-7. Splash Guard Installed

8. Install the splash guard using two M6 x 20 screws, two M6 lock washers, and two M6
flat washers. See Figure 8-7.

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8.3 Robot Outer Link Cover Removal and Reinstallation

The robot outer link cover has special sealing hardware to ensure nothing can enter the inside
of the robot. If you need to remove the outer link cover from the robot for any reason, please fol-
low the procedures below.

Cover Removal Procedure

1. Turn off main power to the controller and power chassis.

2. Turn off the air supply to the robot. Clean the exterior of the outer link thoroughly to
remove any dust or particles that might fall inside the robot when the cover is removed.
3. Unscrew the collar nut on the top of the outer link. See Figure 8-8.

4. Remove 2 screws and nylon washers on the top of the outer link.

5. Remove 2 screws (one on each side) at the front of the outer link. Make sure the O-ring
on each screw stays in place and is not lost.
6. For the 8 screws along the side of the cover (4 on each side; see Figure 8-8), loosen only
1 to 2 turns, just enough to loosen the inside clamp nuts. You do not want to completely
remove the screws. See the label on the side of the outer link cover.

CAUTION: Do not loosen these screws any more than 2 turns,

because the special clamp nut on the inside of the cover might
come loose and fall inside the robot.

Remove this screw

(one on each side)

Collar
Nut

Caution: loosen these screws only 1-2 turns. (Four screws on each side.)
Remove this screw If you loosen more than that, the internal clamp nut could come loose
(one on each side) and fall inside the robot.

Figure 8-8. Cover Removal Instructions

7. When all 8 screws are loose (but not removed), lift the cover up and slide it back along
the cable track and out of the way. Protect the cover with a soft cloth or other padding

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material so the cover does not get scratched. See Figure 8-9.

Figure 8-9. IP-65 Robot with Outer Link Cover Removed

Cover Reinstallation Procedure

1. Check the cover O-ring around the inner groove of the cover to make sure it is in place
and not crimped when installing cover.
2. Hold the cover over the outer link and check to see that the clamp nuts attached to the 8
side screws are positioned so they will slip into place when the cover is lowered down
onto the outer link.
3. Slowly lower the cover down onto the outer link, making sure the O-ring does not fall
out or get pinched as the cover presses down to make the seal.

NOTE: As you lower the cover down onto the outer link, make sure the 8
side screws are pushed all the way in, so the clamp nuts will slide into the
correct position.

4. Reinstall the 2 screws and nylon washers at the top of the outer link and tighten to 5 in-
lb (0.56 N-m).
5. Reinstall the 2 screws (check for O-ring on screw) near the front of the outer link and
tighten to 10 in-lb (1.1 N-m).
6. Tighten the 8 side screws to 10 in-lb (1.1 N-m). Be careful to not over-tighten. Begin with
the two screws (one on each side) at the back of the outer link, then move forward to the
next two, and so on, until all eight are tightened. This pattern is recommended to
achieve a balanced secure fit around the cover.
7. Reinstall the collar nut and tighten until secure.

8. Remember to turn on the compressed air supply to the system before restarting the
robot.

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8.4 Customer Requirements

The IP-65 robot provides most of the hardware needed to achieve an IP-65 protection level, but
customers must provide a way of sealing the tool flange and pressurizing the robot through
the compressed air attachment fitting (located at the top of the robot). These two requirements,
sealing the tool flange and pressurizing the robot, are critical to achieving the IP-65 level of pro-
tection.
In addition, the robot must be inspected periodically to make sure these requirements are being
met, as part of a periodic maintenance program.

Sealing the Tool Flange

The tool flange must be sealed so that the robot shell can be positively pressurized. The pos-
itive pressure reinforces the sealing properties of the gaskets and seals provided in the IP-65
robot.
The tool flange for the IP-65 robot has an additional protective shield on the outer edge that is
not present on the standard robot tool flange. See Figure 8-10 for the side view dimensions.
The bottom face of the flange (mounting surface) is the same as the standard flange, so the
dimensions in Figure 7-4 are correct.

20.0

12.0

72.2

3.8 6.8

41.15

76.2

Figure 8-10. Cobra IP-65 Tool Flange

Pressurizing the Robot

The user must supply compressed air to keep a positive airflow pressure in the robot cavity.

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1. Remove the red shipping plug from the compressed air fitting on the top of the robot.
See Figure 8-11. .

Figure 8-11. Compressed Air Fitting on Robot

2. Connect a compressed air source to the air fitting. The specification for the regulated air
supply is shown in Table 8-1.

Table 8-1. Compressed Air Specifications

Required Air Pressure Required Air Flow, Minimum
3 bar, ± 10% 57 liters per minute
(44 PSI, ± 10%) (2 cubic feet per minute)

CAUTION: The compressed air supply must be clean and dry

and it must be turned on continuously to maintain a positive air
pressure inside the robot. Failure to do this could result in mois-
ture or particle buildup inside the robot and lead to reduced per-
formance or damage to the robot. This will also void your
warranty.

8.5 User Connectors

User Electrical and DeviceNet

On the back of the Joint 1 cover, the user electrical, IO Blox, and DeviceNet connectors are
filled with removable plugs at the factory. See Figure 8-12. If you use any of these connectors,
you must provide a seal (see note below) at the connection to prevent moisture from entering
the robot.

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NOTE: The user electrical connector (DB-25) and the IO Blox connector (DB-9) on
the back of the Joint 1 cover require a gel seal gasket to maintain an adequate seal.
The gaskets are supplied in the accessory kit.

Figure 8-12. User Connectors on Joint 1 Cover

The user electrical and DeviceNet connectors on the outer link are accessible with the cover
removed. See Figure 8-13 for locations of the internal connectors.

Figure 8-13. IP-65 Internal Connectors with Outer Link Cover Removed

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 Chapter 8: IP-65 Option

User Air Lines

On the back of the Joint 1 cover, the user air line connectors are fitted with removable plugs at
the factory. See Figure 8-12.
The user air line connectors on the outer link are accessible with the cover removed. See Figure
8-13 for locations of the internal connectors.
When routing air lines outside of the robot, any fittings you use must maintain an adequate
seal in the cover to prevent moisture from entering the outer link.

CAUTION: Failure to prevent water intrusion through improp-

erly-sealed external fittings could void your warranty.

Robot Solenoid Option

In an IP-65 robot, if you are installing the internally-mounted solenoid hand valves (Adept
Option Kit P/N 02853-000), you must use a different air line than described in Installing the
Robot Solenoid Kit on page 79.
The internal air line normally used to supply the solenoid manifold is instead used to provide
positive airflow pressure to the bellows/outer link. You can use one of the passive 6 mm user
air lines shown in Figure 8-12 and Figure 8-13.

8.6 Maintenance

IP-65 Bellows Replacement

Check the bellows, Adept P/N 04625-000, periodically for cracks, wear, or damage. Replace bel-
lows, if necessary, using the procedure below.
1. Remove the lower bellows clamp by removing two M3 screws and pulling the clamp
apart. See Figure 8-14.
2. Remove the tool flange. For the tool flange removal procedure, refer to Removing and
Installing the Tool Flange on page 71.
3. Remove the upper bellows clamp by removing two M3 screws and pulling the clamp
apart.
4. Slide the old bellows down off of the quill.

5. Install a new bellows by sliding it up onto the quill.

6. Re-install the upper bellows clamp. You must align mating surface of the clamp half-
rings with the bellows seam—see Figure 8-15. Tighten the screw to secure the bellows.
7. Re-install the tool flange.

8. Place new gaskets in the lower bellows clamp—extra gaskets are shipped in the acces-
sory kit. Then install the clamp over the bottom of the bellows, on the bearing ring just
above the tool flange. Align the mating surfaces of the clamp half-rings with the bellows
seam—see Figure 8-15. Tighten the screw to secure the clamp.

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NOTE: Align the bellows clamps with the

bellows seam, on both upper and lower
clamps.

Bellows Seam

Bellows Bellows
Clamp Clamp

Bellows

Cross-section View

Figure 8-14. Bellows Replacement Figure 8-15. Bellows Clamp Alignment

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8.7 Dimension Drawing for Cable Seal Assembly

432
208

Required
clearance
to open AIB
controller
with the IP-65
connector

Cable sealing box on

IP-65 version only

74
308 Units in mm

Figure 8-16. Cable Seal Assembly Dimensions

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 Chapter 9: Cleanroom Robots

The Adept Cobra s600/s800 Cleanroom Option is a modification to the standard robot that cer-
tifies the robot to meet the Class 3 Airborne Particulate Cleanliness Limits as defined by ISO
Standard 14644 (Class 10 for Federal Standard 209E).

NOTE: Class 1 Limits can be achieved by maintaining the robot speed at Speed 50

or below.

This option is a factory-installed configuration. Changes to the robot include the addition of a
bellows assembly mounted at the Joint 3 quill, fully sealed access covers, and a two-stage vac-
uum system to evacuate the arm. This vacuum system incorporates a compressed air vacuum
generator mounted in the base of the robot to provide a high vacuum in the outer link and bel-
lows area. An additional high flow rate vacuum source is required to evacuate in the inner
link and base.

Figure 9-1. Adept Cobra s600 Cleanroom Robot

Specifications

Table 9-1. Adept Cobra Cleanroom Robot Specifications

Robot Performance Specification See Robot Specifications on page 108.

Ambient Temperature Specification 5–35° C (41–95° F)

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9.1 Connections

Figure 9-2. Cleanroom Connections

9.2 Requirements

Table 9-2. Cleanroom Robot Requirements

Vacuum source 0.80 m 3/min (28 ft3/min) minimum volumetric flow rate

6 mm of water (0.2 inches of water) differential pressure

measured between the robot and the vacuum source

3/4 inch NPT female thread pipe fitting at the back of the
robot

Compressed air source Clean, dry, oil-free compressed air

75 psi (0.52 MPa)

1.4 SCFM (.04 m 3/min.) flow rate

3/8 inch NPT female thread pipe fitting at the back of the
robot, flow regulator not supplied

Quill inside diameter The inside diameter of the quill must be plugged by the
user’s end-effector in order for sufficient vacuum to
develop in the outer link.

9.3 Exclusions and Incompatibilities

Table 9-3. Internally Mounted Hand Valves

Installation considerations The internal air line normally used to supply the inter-
nally-mounted hand valves (Adept Option Kit P/N
02853-000) is instead used to provide vacuum to the bel-
lows/outer link. One of the passive 6 mm user air lines
would need to be used instead.

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Performance considerations The air exhausting from the internally-mounted hand

valves (Adept Option Kit P/N 02853-000) may be of suf-
ficient quantity/ quality to cause the robot to exceed
Class 10 Particulate Limits.

Recommendation For these reasons, Adept recommends mounting hand

valves externally.

9.4 Maintenance

Bellows Replacement
Check the bellows periodically for cracks, wear, or damage. Replace bellows (Adept P/N 04625-
000) if necessary, using the procedure below.
1. Remove the lower bellows clamp ring from the bearing ring by loosening the screw on
the clamp. See Figure 9-3.
2. Remove the tool flange.
For the tool flange removal procedure, refer to Removing and Installing the Tool Flange
on page 71.
3. Remove the upper bellows clamp ring by loosening the screw on the clamp.

4. Slide the old bellows down off of the quill.

5. Install a new bellows, and reverse the steps listed above.

Figure 9-3. Cleanroom Bellows Replacement

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Lubrication
The upper and lower quill requires lubrication in the same manner as the standard Cobra
s600/s800 robots. See Lubricating Joint 3 Ball Screw on page 57.

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 5960 Inglew ood D riv e
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