Download Adept Cobra i600 User's Guide - pulsar.com.tr

<strong>Adept</strong> <strong>Cobra</strong> 

<strong>i600</strong>/i800 Robot 

User’s <strong>Guide</strong>



User’s <strong>Guide</strong> 

P/N: 03589-000, Rev B 

July 2004 

3011 Triad Drive • Livermore, CA 94551 • USA • Phone 925.245.3400 • Fax 925.960.0452 

Otto-Hahn-Strasse 23 • 44227 Dortmund • Germany • Phone 49.231.75.89.40 • Fax 49.231.75.89.450 

41, rue du Saule Trapu • 91300 • Massy • France • Phone 33.1.69.19.16.16 • Fax 33.1.69.32.04.62

The information contained herein is the property of <strong>Adept</strong> Technology, Inc., and shall not be reproduced 

in whole or in part without prior written approval of <strong>Adept</strong> Technology, Inc. The information herein is subject 

to change without notice and should not be construed as a <strong>com</strong>mitment by <strong>Adept</strong> Technology, Inc. This 

manual is periodically reviewed and revised. 

<strong>Adept</strong> Technology, Inc., assumes no responsibility for any errors or omissions in this document. Critical 

evaluation of this manual by the user is wel<strong>com</strong>ed. Your <strong>com</strong>ments assist us in preparation of future documentation. 

Please email your <strong>com</strong>ments to: techpubs@adept.<strong>com</strong>. 

Copyright ©2004 by <strong>Adept</strong> Technology, Inc. All rights reserved. 

The <strong>Adept</strong> logo, <strong>Adept</strong>Vision, AIM, HexSight, and HexaVision 

are registered trademarks of <strong>Adept</strong> Technology, Inc. 

ActiveV, <strong>Adept</strong>, <strong>Adept</strong> 1060, <strong>Adept</strong> 1060+, <strong>Adept</strong> 1850, <strong>Adept</strong> 1850 XP, <strong>Adept</strong> 540, <strong>Adept</strong> 560, <strong>Adept</strong> C40, 

<strong>Adept</strong> C60, <strong>Adept</strong> CC, <strong>Adept</strong> <strong>Cobra</strong> 550, <strong>Adept</strong> <strong>Cobra</strong> 550 CleanRoom, <strong>Adept</strong> <strong>Cobra</strong> 600, <strong>Adept</strong> <strong>Cobra</strong> 800, 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>, <strong>Adept</strong> <strong>Cobra</strong> i800, <strong>Adept</strong> <strong>Cobra</strong> s600, <strong>Adept</strong> <strong>Cobra</strong> s800, <strong>Adept</strong> DeskTop, <strong>Adept</strong> Digital 

Workcell, <strong>Adept</strong> FFE, <strong>Adept</strong> FlexFeeder 250, <strong>Adept</strong> IC, <strong>Adept</strong> Impulse Feeder, <strong>Adept</strong> LineVision, <strong>Adept</strong> 

MC, <strong>Adept</strong> MV, <strong>Adept</strong> MV-10, <strong>Adept</strong> MV-19, <strong>Adept</strong> MV4, <strong>Adept</strong> MV-5, <strong>Adept</strong> MV-8, <strong>Adept</strong> NanoBonder 

EBS, <strong>Adept</strong> NanoBonder LWS, <strong>Adept</strong> NanoCell, <strong>Adept</strong> NanoStage L1P2, <strong>Adept</strong> NanoStage L3, <strong>Adept</strong> 

NanoStage L3P2, <strong>Adept</strong> OC, <strong>Adept</strong> SmartAmp, <strong>Adept</strong> SmartAxis, <strong>Adept</strong> SmartController CS, <strong>Adept</strong> 

SmartController CX, <strong>Adept</strong> SmartModule, <strong>Adept</strong> SmartMotion, <strong>Adept</strong> SmartServo, <strong>Adept</strong> sDIO, <strong>Adept</strong> 

Servo Kit, <strong>Adept</strong> sMI6, <strong>Adept</strong> SMIF-EZ, <strong>Adept</strong>Align 650, <strong>Adept</strong>Atlas, <strong>Adept</strong>Cartesian, <strong>Adept</strong>Force, 

<strong>Adept</strong>FTP, <strong>Adept</strong>GEM, <strong>Adept</strong>Modules, <strong>Adept</strong>Motion, <strong>Adept</strong>Motion Servo, <strong>Adept</strong>Motion VME, 

<strong>Adept</strong>Net, <strong>Adept</strong>NFS, <strong>Adept</strong>One, <strong>Adept</strong>One-MV, <strong>Adept</strong>One-XL, <strong>Adept</strong>RAPID, <strong>Adept</strong>Six 300, <strong>Adept</strong>Six 

300CL, <strong>Adept</strong>Six 600, <strong>Adept</strong>TCP/IP, <strong>Adept</strong>Three, <strong>Adept</strong>Three-MV, <strong>Adept</strong>Three-XL, <strong>Adept</strong>Two, 

<strong>Adept</strong>Vicron, <strong>Adept</strong>Vicron 300S, <strong>Adept</strong>Vicron 310D, <strong>Adept</strong>Vision AVI, <strong>Adept</strong>Vision AGS, <strong>Adept</strong>Vision 

GV, <strong>Adept</strong>Vision I, <strong>Adept</strong>Vision II, <strong>Adept</strong>Vision VME, <strong>Adept</strong>Vision VXL, <strong>Adept</strong>Vision XGS, <strong>Adept</strong>Vision 

XGS II, <strong>Adept</strong>Windows, <strong>Adept</strong>Windows Controller, <strong>Adept</strong>Windows DDE, <strong>Adept</strong>Windows Offline Editor, 

<strong>Adept</strong>Windows PC, AIM Command Server, AIM Dispense, AIM PCB, AIM VisionWare, A-Series, 

AutoCal, AutoTune, AutoWidth, CCM, CCMII, CGM, FlexFeedWare, HyperDrive, Microenvironment, 

MicroV + , MotionWare, ObjectFinder, ObjectFinder 2000, PackOne, PalletWare, SMIF-C, SMIF-EZX, 

SMIF-Z, SMIF-ZX, S-Series, UltraOne, V, V + , and VisionTeach are trademarks of <strong>Adept</strong> Technology, Inc. 

Any trademarks from other <strong>com</strong>panies used in this publication 

are the property of those respective <strong>com</strong>panies. 

Printed in the United States of America

Table of Contents 

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

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

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

<strong>Adept</strong> SmartAmp AIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

1.2 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

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

<strong>Adept</strong> Document Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

2.1 Warnings, Cautions, and Notes in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

2.2 Warning Labels on the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

2.3 Precautions and Required Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

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

Impact and Trapping Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

Additional Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

2.4 Intended Use of the Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 

2.5 Robot Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

Acceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

Unacceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

2.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

2.7 Safety Requirements for Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 24 

2.8 Sound Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

2.9 Thermal Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 

2.10 Working Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 

2.11 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 

2.12 Safety Equipment for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 

2.13 Protection Against Unauthorized Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 26 

2.14 Safety Aspects While Performing Maintenance . . . . . . . . . . . . . . . . . . . . . . . 26 

2.15 Risks Due to Incorrect Installation or Operation. . . . . . . . . . . . . . . . . . . . . . . . 27 

2.16 What to Do in an Emergency Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 

3 Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

3.1 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

3.2 Unpacking and Inspecting the <strong>Adept</strong> Equipment. . . . . . . . . . . . . . . . . . . . . . . 30 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot User’s <strong>Guide</strong>, Rev B 5


Before Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

Upon Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

3.3 Repacking for Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

3.4 Environmental and Facility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

3.5 Mounting the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

Robot Mounting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

3.6 Description of Connectors on Robot Interface Panel . . . . . . . . . . . . . . . . . . . . 34 

4 System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

4.1 System Cable Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

4.2 Cable and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 

4.3 Optional Starter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 

4.4 Cable Connections to the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 

Installing AIB XPANEL Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 

Installing Peripherals and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 

4.5 Connecting User-Supplied PC to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

PC Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

Installing Serial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

4.6 Installing Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 

4.7 Connecting 24 VDC Power to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 

Specifications for 24 VDC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 

Details for 24 VDC Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

Procedure for Creating 24 VDC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

Installing 24VDC Robot Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

4.8 Connecting 200-240 VAC Power to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 

Specifications for AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 

Facility Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 

AC Power Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 

Details for AC Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 

Procedure for Creating 200-240 VAC Cable . . . . . . . . . . . . . . . . . . . . . . . . . 45 

Installing AC Power Cable to Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 

4.9 Grounding the <strong>Adept</strong> Robot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

Ground Point on Robot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

Ground Point on AIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

Robot-Mounted Equipment Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 

4.10 Installing User-Supplied Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 

5 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 

5.1 Robot Status LED Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 

5.2 Diagnostic Panel Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 

6 <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot User’s <strong>Guide</strong>, Rev B


5.3 Using the Brake Release Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 

Brake Release Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 

5.4 Front Panel Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

5.5 Using Digital I/O on Robot XIO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 

XIO Connector Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 

Optional I/O Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 

XIO Input Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 

XIO Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 

Typical Input Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 

XIO Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 

XIO Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 

Typical Output Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 

XIO Breakout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 

5.6 Connecting Customer-Supplied Safety and Power Control Equipment . . . . . 59 

Connecting Equipment to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 

Emergency Stop Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 

Muted Safety Gate E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 64 

Remote Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 

Remote High Power On/Off Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 

High Power On/Off Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 

Remote Front Panel or User-Supplied Replacement . . . . . . . . . . . . . . . . . . 65 

5.7 Turning On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

Verifying Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

System Installation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

User-Supplied Safety Equipment Checks . . . . . . . . . . . . . . . . . . . . . 66 

Turning on Power and Starting <strong>Adept</strong> DeskTop . . . . . . . . . . . . . . . . . . . . . . 67 

Enabling High Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 

Option 1: Using the Diagnostics Wizard to Enable High Power . . 68 

Option 2: Using <strong>Adept</strong> DeskTop to Enable High Power . . . . . . . . . 70 

Verifying E-Stop Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 

5.8 Learning to Program the <strong>Adept</strong> <strong>Cobra</strong> I-Series Robot. . . . . . . . . . . . . . . . . . . . 71 

6 Optional Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

6.1 Installing End-Effectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

6.2 Removing and Installing the User Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

Removing the Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 

Installing the Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 

6.3 User Connections on Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 

User Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 

User Electrical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 

6.4 Mounting Locations for External Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 



6.5 Installing Robot Solenoid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 

6.6 Installing Adjustable Hardstops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 

Joint 1 Adjustable Hardstops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 

Modifying Joint Limit Softstop Locations for Joint 1 . . . . . . . . . . . . . 81 

Joint 2 Adjustable Hardstops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 

Modifying Joint Limit Softstop Locations for Joint 2 . . . . . . . . . . . . . 85 

7 Using the Manual Control Pendant (MCP) . . . . . . . . . . . . . . . . . . . . . . . 87 

7.1 Manual Control Pendant Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 

MCP-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 

MCP Enable Switch Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 

3-Position Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 

Connecting the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 

MCP Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 

Mode Control and Joint/Axis Control Buttons . . . . . . . . . . . . . . . . . 91 

Speed Bars and Slow Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 

Data Entry Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 

Soft Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 

Function Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 

Emergency Stop From the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 

Re-Enabling Power After Enable Switch Released . . . . . . . . . . . . . . . . . . . . 93 

In Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 

In Manual Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 

Background Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 

7.2 MCP Predefined Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

Edit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

Clear Error Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

CMD Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

Prog Set Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

7.3 Moving a Robot or Motion Device With the MCP . . . . . . . . . . . . . . . . . . . . . . . . 95 

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

Mode Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

COMP/PWR Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

MAN/HALT Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 

DIS PWR Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 

RUN/HOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 

Joint/Axis Control Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

STEP Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 



Speed Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

In World, Tool, and Joint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

Slow Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

Robot States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 

World State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 

Tool State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 

Joint State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 

Free State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 

8.1 Periodic Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 

8.2 Checking of Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 

8.3 Checking Robot Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 

8.4 Check Robot for Oil Around Harmonic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 102 

8.5 Lubricate Joint 3 Ball Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 

Required Grease for the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 

Lubrication Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 

8.6 Replacing the SmartAmp AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 

Removing the SmartAmp AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 

Installing a New SmartAmp AIB Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 

8.7 Replacing Encoder Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 

Battery Replacement Time Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 

Battery Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 

9 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 

9.1 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 

9.2 Robot Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 




List of Figures 

Figure 1-1. <strong>Adept</strong> <strong>Cobra</strong> i800 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

Figure 1-2. Robot Joint Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

Figure 1-3. <strong>Adept</strong> SmartAmp AIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

Figure 2-1. Electrical and Thermal Warning Labels on AIB Chassis . . . . . . . . . . . . . . . . . 18 

Figure 2-2. Thermal Warning Label on Underside of Inner Link . . . . . . . . . . . . . . . . . . . . 18 

Figure 2-3. Warning Label on Encoder Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 

Figure 3-1. <strong>Cobra</strong> Robot on a Transportation Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

Figure 3-2. Mounting Hole Pattern for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

Figure 3-3. Robot Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 

Figure 4-1. System Cable Diagram for <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robots . . . . . . . . . . . . . 35 

Figure 4-2. <strong>Adept</strong> Software CD-ROM Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 

Figure 4-3. <strong>Adept</strong> Desktop Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 

Figure 4-4. User-Supplied 24VDC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 

Figure 4-5. Typical AC Power Installation with Single-Phase Supply . . . . . . . . . . . . . . . . 44 

Figure 4-6. Single-Phase AC Power Installation from a Three-Phase AC Supply . . . . . . 44 

Figure 4-7. AC Power Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 

Figure 4-8. Ground Point on Robot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

Figure 4-9. User Ground Location on AIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

Figure 5-1. Robot Status LED Indicator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 

Figure 5-2. Diagnostic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 

Figure 5-3. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

Figure 5-4. Typical User Wiring for XIO Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 

Figure 5-5. Typical User Wiring for XIO Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 

Figure 5-6. Optional XIO Breakout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 

Figure 5-7. <strong>Cobra</strong> <strong>i600</strong>/i800 E-Stop Circuit Connections . . . . . . . . . . . . . . . . . . . . . . . . . 62 

Figure 5-8. Front Panel Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 

Figure 5-9. Connect to Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 

Figure 5-10. Connection Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 

Figure 5-11. Main Screen in Diagnostics Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 

Figure 5-12. High Power Button on Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 

Figure 5-13. Diagnostics Wizard Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 

Figure 5-14. Steps to Enable Power and Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 

Figure 5-15. Jog Pendant Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 

Figure 6-1. User Flange Removal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 

Figure 6-2. User Connectors on Joint 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 

Figure 6-3. User Connectors on Joint 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 

Figure 6-4. Solenoid Mounting Bracket With Connector and Spare Air Line . . . . . . . . 78 

Figure 6-5. Solenoid Placement Using Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . 79 

Figure 6-6. Connecting Spare Air Line to User Connector . . . . . . . . . . . . . . . . . . . . . . . 79 


List of Figures 

Figure 6-7. Joint 1 Adjustable Hardstops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 

Figure 6-8. Configuration Manager - Modifying Joint 1 Limits . . . . . . . . . . . . . . . . . . . . . 82 

Figure 6-9. Configuration Manager - Apply Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 

Figure 6-10. Joint 2 Hardstop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 

Figure 6-11. Joint 2 Adjustable Hardstop Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 

Figure 6-12. Screw Locations for Joint 2 Adjustable Hardstops . . . . . . . . . . . . . . . . . . . . . 84 

Figure 6-13. Fixed Hardstop Device for Joint 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 

Figure 6-14. Configuration Manager - Modifying Joint 2 Limits . . . . . . . . . . . . . . . . . . . . . 85 

Figure 7-1. 3-Position Enable Switch on MCP-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 

Figure 7-2. Holding the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 

Figure 7-3. Cradling the MCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 

Figure 7-4. MCP Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 

Figure 7-5. Data Entry Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 

Figure 7-6. MCP Predefined Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 

Figure 7-7. Mode Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 

Figure 7-8. Speed Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

Figure 7-9. WORLD State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 

Figure 7-10. TOOL State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 

Figure 7-11. JOINT State (Four-Axis SCARA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 

Figure 8-1. Lubrication of Joint 3 Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 

Figure 8-2. Securing Screw on SmartAmp AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 105 

Figure 8-3. Opening and Removing AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 

Figure 8-4. Connectors on AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 

Figure 8-5. Ground Screw on AIB Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 

Figure 8-6. Installing AIB Chassis in Robot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 

Figure 8-7. Location of Encoder Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 

Figure 9-1. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/s600 Top and Side Dimensions . . . . . . . . . . . . . . . . . . . 111 

Figure 9-2. <strong>Adept</strong> <strong>Cobra</strong> i800/s800 Top and Side Dimensions . . . . . . . . . . . . . . . . . . . 112 

Figure 9-3. Dimensions of the Camera Bracket Mounting Pattern . . . . . . . . . . . . . . . . 113 

Figure 9-4. Tool Flange Dimensions for <strong>Adept</strong> <strong>Cobra</strong> Robots . . . . . . . . . . . . . . . . . . . . 114 

Figure 9-5. External Tooling on Top of Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 

Figure 9-6. External Tooling on Underside of Outer Link . . . . . . . . . . . . . . . . . . . . . . . . . 116 

Figure 9-7. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/s600 Robot Working Envelope . . . . . . . . . . . . . . . . . . . 117 

Figure 9-8. <strong>Adept</strong> <strong>Cobra</strong> i800/s800 Robot Working Envelope . . . . . . . . . . . . . . . . . . . 118 


Introduction 1 

1.1 Product Description 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robots 

The <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> and i800 robots are four-axis SCARA robots (Selective Compliance 

Assembly Robot Arm). See Figure 1-1. Joints 1, 2, and 4 are rotational; Joint 3 is 

translational. See Figure 1-2 on page 14 for a description of the robot joint locations. 

The <strong>Adept</strong> <strong>Cobra</strong> i-series robots are programmed and controlled using the <strong>Adept</strong> 

DeskTop software, running on a user-supplied PC. Mechanical specifications for the 

<strong>Adept</strong> <strong>Cobra</strong> i-series robots are provided in Chapter 9. 

NOTE: The descriptions and instructions in this manual apply to both the 

<strong>Cobra</strong> <strong>i600</strong> and the <strong>Cobra</strong> i800, except for instances where there is a 

difference, as in dimension and work envelope drawings. In those cases 

the information is presented for both robots. 

Figure 1-1. <strong>Adept</strong> <strong>Cobra</strong> i800 Robot 


Chapter 1 - Introduction 

Joint 2 

Joint 1 

Joint 3 

Inner 

Link 

Outer 

Link 

Joint 4 

Figure 1-2. Robot Joint Motions 

<strong>Adept</strong> SmartAmp AIB 

The amplifiers for the <strong>Adept</strong> <strong>Cobra</strong> s-series and i-series robots are embedded in the base 

of the robot. This amplifier section is known as the SmartAmp AIB (amp-in-base), and it 

provides power amplifiers and full servo control. 

<strong>Adept</strong> SmartAmp AIB features: 

• On-board digital I/O 

• Low EMI for use with noise sensitive equipment 

• No external fan for quiet robot operation 

• 8 kHz servo rate delivers low positional errors and superior path following 

• Sine wave <strong>com</strong>mutation lowers cogging torque and improves path following 

• Digital feed forward design maximizes efficiency, torque, and velocity 

• Temperature sensors on all amplifiers and motors for maximum reliability and 

easy troubleshooting 

SmartAmp AIB on 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> Robot 

Figure 1-3. <strong>Adept</strong> SmartAmp AIB 


Installation Overview 

1.2 Installation Overview 

The system installation process is summarized in the following table. Refer also to the 

system cable diagram in Figure 4-1 on page 35. 

NOTE: The <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot Quick Setup <strong>Guide</strong> also provides 

information on installing your robot system. 

Table 1-1. Installation Overview 

Task to be Performed 

Reference Location 

1. Mount the robot on a flat, secure mounting surface. See Section 3.5 on page 32. 

2. Install the system cables and options. See Section 4.4 on page 37. 

3. Connect the PC to the robot See Section 4.5 on page 38. 

4. Install <strong>Adept</strong> DeskTop software on the PC. See Section 4.6 on page 39. 

5. Create a 24VDC cable and connect it between the 

robot and the 24VDC power supply. 

6. Create a 200-240 VAC cable and connect it 

between the robot and the facility AC power source. 

See Section 4.7 on page 40. 


7. Install user-supplied safety barriers in the workcell. See Section 4.10 on page 48. 

8. Read Chapter 5 to learn about connecting digital 

I/O through the XIO connector on the robot. 

9. Read Chapter 5 to learn about turning on the 

system, and testing operation. 

10.Read Chapter 6 if you need to install optional 

equipment, including end-effectors, user air and 

electrical lines, external equipment, solenoids, etc. 





Chapter 1 - Introduction 

1.3 How Can I Get Help? 

Refer to the How to Get Help Resource <strong>Guide</strong> (<strong>Adept</strong> P/N 00961-00700) for details on 

getting assistance with your <strong>Adept</strong> software and hardware. Additionally, you can access 

information sources on <strong>Adept</strong>’s corporate web site: 

http://www.adept.<strong>com</strong> 

<strong>Adept</strong> Document Library 

The <strong>Adept</strong> Document Library (ADL) contains documentation for <strong>Adept</strong> products. You 

can access a local copy of the ADL from the <strong>Adept</strong> Software CD shipped with your 

system, or from the separate ADL CD. Additionally, an Internet version of the ADL can be 

accessed by going to the <strong>Adept</strong> Web site and selecting Document Library from the home 

page. 

To locate information on a specific topic, use the Document Library search engine on the 

ADL main page. To view a list of available product documentation, select the Document 

Titles option. 


Safety 2 

2.1 Warnings, Cautions, and Notes in Manual 

There are four levels of special alert notation used in this manual. In descending order of 

importance, they are: 

DANGER: This indicates an imminently hazardous 

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

serious injury. 

WARNING: This indicates a potentially hazardous 

situation which, if not avoided, could result in serious 

injury or major damage to the equipment. 

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

could result in minor injury or damage to the equipment. 

NOTE: This provides supplementary information, emphasizes a point or 

procedure, or gives a tip for easier operation. 


Chapter 2 - Safety 

2.2 Warning Labels on the Robot 

Figure 2-1, Figure 2-2, and show the warning labels on the <strong>Adept</strong> <strong>Cobra</strong> i-series and 

s-series robots. 

Figure 2-1. Electrical and Thermal Warning Labels on AIB Chassis 

Figure 2-2. Thermal Warning Label on Underside of Inner Link 


Warning Labels on the Robot 

Figure 2-3. Warning Label on Encoder Cables 

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 special software and tools. 



2.3 Precautions and Required Safeguards 

This manual must be read by all personnel who install, operate, or maintain <strong>Adept</strong> 

systems, or who work within or near the workcell. 

WARNING: <strong>Adept</strong> Technology strictly prohibits 

installation, <strong>com</strong>missioning, or operation of an <strong>Adept</strong> 

robot without adequate safeguards according to 

applicable local and national standards. Installations in EU 

and EEA countries must <strong>com</strong>ply with EN 775/ISO 10218, 

especially sections 5,6; EN 292-2; and EN 60204-1, 

especially section 13. 

Safety Barriers 

Safety barriers must be an integral part of robot workcell design. <strong>Adept</strong> systems are 

<strong>com</strong>puter-controlled and may activate remote devices under program control at times or 

along paths not anticipated by personnel. It is critical that safeguards be in place to 

prevent personnel from entering the workcell whenever equipment power is present. 

The robot system integrator, or end user, must ensure that adequate safeguards, safety 

barriers, light curtains, safety gates, safety floor mats, etc., will be installed. The robot 

workcell must be designed according to the applicable local and national standards (see 

Section 2.7 on page 24). 

The safe distance to the robot depends on the height of the safety fence. The height and 

the distance of the safety fence from the robot must ensure that personnel cannot reach the 

danger zone of the robot. 

The <strong>Adept</strong> control system has features that aid the user in constructing system safeguards, 

including customer emergency stop circuitry and digital input and output lines. See 

Chapter 5 for information on safe and effective use of the robot. 

Impact and Trapping Points 

<strong>Adept</strong> robots are capable of moving at high speeds. If a person is struck by a robot 

(impacted) or trapped (pinched), death or serious injury could occur. Robot configuration, 

joint speed, joint orientation, and attached payload all contribute to the total amount of 

energy available to cause injury. 


Precautions and Required Safeguards 

Additional Safety Information 

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

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

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

Table 2-1. Sources for International Standards and Directives 

SEMI International Standards 

3081 Zanker Road 

San Jose, CA 95134 

USA 

American National Standards Institute (ANSI) 

11 West 42nd Street, 13th Floor 

New York, NY 10036 

USA 

Phone: 1.408.943.6900 

Fax: 1.408.428.9600 

http://www.semi.org/web/wstandards.nsf 

BSI Group (British Standards) 

389 Chiswick High Road 

London W4 4AL 

United Kingdom 

Phone 212-642-4900 

Fax 212-398-0023 

http://www.ansi.org 

Document Center, Inc. 

1504 Industrial Way, Unit 9 

Belmont, CA 94002 

USA 

Phone +44 (0)20 8996 9000 

Fax +44 (0)20 8996 7400 

http://www.bsi-global.<strong>com</strong> 

DIN, Deutsches Institut für Normung e.V. 

German Institute for Standardization 

Burggrafenstrasse 6 

10787 Berlin 

Germany 

Phone.: +49 30 2601-0 

Fax: +49 30 2601-1231 

Phone 415-591-7600 

Fax 415-591-7617 

http://www.document-center.<strong>com</strong> 

Global Engineering Documents 

15 Inverness Way East 

Englewood, CO 80112 

USA 

Phone 800-854-7179 

Fax 303-397-2740 

http://global.ihs.<strong>com</strong> 

http://www.din.de 

http://www2.beuth.de/ (publishing) 

IEC, International Electrotechnical Commission 

Rue de Varembe 3 

PO Box 131 

CH-1211 Geneva 20 

Switzerland 

Phone 41 22 919-0211 

Fax 41 22 919-0300 

http://www.iec.ch 

Robotic Industries Association (RIA) 

900 Victors Way 

PO Box 3724 

Ann Arbor, MI 48106 

USA 

Phone 313-994-6088 

Fax 313-994-3338 

http://www.robotics.org 



2.4 Intended Use of the Robots 

The installation and use of <strong>Adept</strong> products must <strong>com</strong>ply with all safety instructions and 

warnings in this manual. Installation and use must also <strong>com</strong>ply with all applicable local 

and national requirements and safety standards (see Section 2.7 on page 24). 

The <strong>Adept</strong> <strong>Cobra</strong> s600/<strong>i600</strong> and s800/i800 robots are intended for use in parts assembly 

and material handling for payloads less than 5.5 kg (12.1 lb). 

WARNING: For safety reasons, it is prohibited to make 

certain modifications to <strong>Adept</strong> robots (see Section 2.5). 

The <strong>Adept</strong> <strong>Cobra</strong> i-series and s-series robots are <strong>com</strong>ponent subassemblies of a <strong>com</strong>plete 

industrial automation system. The standard <strong>Adept</strong> <strong>Cobra</strong> i-series and s-series robots must 

not <strong>com</strong>e into contact with liquids. 

The <strong>Adept</strong> equipment is not intended for use in any of the following situations: 

• In hazardous (explosive) atmospheres 

• In mobile, portable, marine, or aircraft systems 

• In life-support systems 

• In residential installations 

• In situations where the <strong>Adept</strong> equipment will be subject to extremes of heat or 

humidity. See Table 3-1 on page 31 for allowable temperature and humidity 

ranges. 

WARNING: The instructions for installation, operation, 

and maintenance given in this User’s <strong>Guide</strong> must be 

strictly observed. 

Non-intended use of an <strong>Adept</strong> <strong>Cobra</strong> i-series or s-series robot can: 

• Cause injury to personnel 

• Damage the robot or other equipment 

• Reduce system reliability and performance 

All persons that install, <strong>com</strong>mission, operate, or maintain the robot must: 

• Have the necessary qualifications 

• Read and follow exactly the instructions in this User’s <strong>Guide</strong> 

If there is any doubt concerning the application, ask <strong>Adept</strong> to determine if it is an 

intended use or not. 


Robot Modifications 

2.5 Robot Modifications 

It is sometimes necessary to modify the robot in order to successfully integrate it into a 

workcell. Unfortunately, many seemingly simple modifications can either cause a robot 

failure or reduce the robot’s performance, reliability, or lifetime. The following 

information is provided as a guideline to modifications. 

Acceptable Modifications 

In general, the following robot modifications will not cause problems, but may affect 

robot performance: 

• Attaching tooling, utility boxes, solenoid packs, vacuum pumps, screwdrivers, 

cameras, lighting, etc., to the inner link, outer link, or J1 harness support. 

• Attaching hoses, pneumatic lines, or cables to the robot. These should be designed 

so they do not restrict joint motion or cause robot motion errors. 

Unacceptable Modifications 

The modifications listed below may damage the robot, reduce system safety and 

reliability, or shorten the life of the robot. 

CAUTION: Making any of the modifications outlined 

below will void the warranty of any <strong>com</strong>ponents that 

<strong>Adept</strong> determines were damaged due to the modification. 

You must contact <strong>Adept</strong> Customer Service if you are 

considering any of the following modifications. 

• Modifying any of the robot harnesses or robot cables. 

• Modifying any robot access covers or drive system <strong>com</strong>ponents. 

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

• Modifying any robot electrical <strong>com</strong>ponent or printed-circuit board. 

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

• Modifications that <strong>com</strong>promise EMC performance, including shielding. 



2.6 Transport 

Always use adequate equipment to transport and lift <strong>Adept</strong> products. See Chapter 3 for 

more information on transporting, lifting, and installing. 

WARNING: Stay clear of the robot while it is transported. 

2.7 Safety Requirements for Additional Equipment 

Additional equipment used with the <strong>Adept</strong> <strong>Cobra</strong> i-series/s-series robot (grippers, 

conveyor belts, etc.) must not reduce the workcell safeguards. 

All emergency stop switches must always be accessible. 

If the robot is to be used in an EU or EEA member country, all <strong>com</strong>ponents in the robot 

workcell must <strong>com</strong>ply with the safety requirements in the European Machine Directive 

89/392/EEC (and subsequent amendments) and related harmonized European, 

international, and national standards. For robot systems, these include: EN 775/ISO 

10218, sections 5,6; EN 292-2; and EN 60204. For safety fences, see EN 294. 

In other countries, <strong>Adept</strong> strongly re<strong>com</strong>mends, in addition to <strong>com</strong>plying with the 

applicable local and national regulations, that a similar level of safety be obtained. 

In the USA, applicable standards include ANSI/RIA R15.06 and ANSI/UL 1740. 

In Canada, applicable standards include CAN/CSA Z434. 

2.8 Sound Emissions 

The sound emission level of the <strong>Adept</strong> <strong>Cobra</strong> i-series and s-series robot depends on the 

speed and payload. The maximum value is 90dB. (This is at maximum AUTO-mode 

speed.) 

WARNING: Acoustic emission from this robot may be up 

to 90dB (A) under worst-case conditions. Typical values 

will be lower, depending on payload, speed, acceleration, 

and mounting. Appropriate safety measures should be 

taken, such as ear protection and display of a warning 

sign. 


Thermal Hazard 

2.9 Thermal Hazard 

WARNING: You can burn yourself. Do not touch the robot 

base or outer link shortly after the robot has been running 

at high ambient temperatures (40-50°C) (104-122°F) or at 

fast cycle times (over 60 cycles per minute). The robot 

skin/surface temperature can exceed 85°C (185°F). 

2.10 Working Areas 

<strong>Adept</strong> robots have a Manual and an Automatic (AUTO) operating mode. While in 

Automatic Mode, personnel are not allowed in the workcell. 

In Manual Mode, operators with additional safety equipment (see Section 2.12 on page 

26) are allowed to work in the robot workcell. For safety reasons the operator should, 

whenever possible, stay outside of the robot work envelope to prevent injury. The 

maximum speed and power of the robot is reduced but it could still cause injury to the 

operator. 

Before performing maintenance in the working envelope of the robot, High Power must 

be switched off and the power supply of the robot must be disconnected. After these 

precautions, a skilled person is allowed to maintain the robot. See Section 2.11 for the 

specifications. 

WARNING: Never remove any safeguarding and never 

make changes in the system that will de<strong>com</strong>mission a 

safeguard. 

2.11 Qualification of Personnel 

This manual assumes that all personnel have attended an <strong>Adept</strong> training course and have 

a working knowledge of the system. The user must provide the necessary additional 

training for all personnel who will be working with the system. 

As noted in this user’s guide, certain procedures should be performed only by skilled or 

instructed persons. For a description of the level of qualification, <strong>Adept</strong> uses the standard 

terms: 

• Skilled persons have technical knowledge or sufficient experience to enable them 

to avoid the dangers, electrical and/or mechanical. 

• Instructed persons are adequately advised or supervised by skilled persons to 

enable them to avoid the dangers, electrical and/or mechanical. 



All personnel must observe sound safety practices during the installation, operation, and 

testing of all electrically powered equipment. To avoid injury or damage to equipment, 

always remove power by disconnecting the AC power from the source before attempting 

any repair or upgrade activity. Use appropriate lockout procedures to reduce the risk of 

power being restored by another person while you are working on the system. 

WARNING: The user must get confirmation from every 

entrusted person before they start working with the robot 

that the person: 

1. Has received the user’s guide. 

2. Has read the user’s guide. 

3. Understands the user’s guide and 

4. Will work in the manner specified by the user’s guide. 

2.12 Safety Equipment for Operators 

<strong>Adept</strong> advises operators to wear extra safety equipment in the workcell. For safety 

reasons operators must wear the following when they are in the robot workcell. 

• Safety glasses 

• Protective headgear (hard hats) 

•Safety shoes 

Install warning signs around the workcell to ensure that anyone working around the 

robot system knows they must wear safety equipment. 

2.13 Protection Against Unauthorized Operation 

The system must be protected against unauthorized use. Restrict access to the keyboard 

and the Manual Control Pendant by locking them in a cabinet or use another adequate 

method to prevent access to them. 

2.14 Safety Aspects While Performing Maintenance 

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

equipment are allowed to maintain the robot. 

WARNING: During maintenance and repair, the power to 

the robot must be turned off. Unauthorized third parties 

must be prevented from turning on power through the use 

of lockout measures. 


Risks Due to Incorrect Installation or Operation 

2.15 Risks Due to Incorrect Installation or Operation 

• Purposely defeating any aspect of the safety E-Stop system 

• Improper installation or programming of the robot system 

• Unauthorized use of cables other than those supplied or use of modified 

<strong>com</strong>ponents in the system 

• Defeating interlock so that operator can enter workcell with High Power ON 

Take precautions to ensure that these situations do not occur. 

2.16 What to Do in an Emergency Situation 

Press any E-Stop button (a red push-button on a yellow background/field) and then 

follow the internal procedures of your <strong>com</strong>pany or organization for an emergency 

situation. If a fire occurs, use CO 2 to extinguish the fire. 




® 

Robot Installation 3 

3.1 Transport and Storage 

This equipment must be shipped and stored in a temperature-controlled environment, 

within the range –25°C to +55°C. The re<strong>com</strong>mended humidity range is 5 to 90 percent, 

non-condensing. It should be shipped and stored in the <strong>Adept</strong>-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 and store the packaged equipment 

(see Figure 3-1). 

NOTE: The robot weighs 34 kg (75 lb) with no options installed. 

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 damage the robot. 

Eyebolt for lifting robot 

after robot has been 

unbolted from the 

transportation pallet. 

Place forklift or pallet-jack here. 

Figure 3-1. <strong>Cobra</strong> Robot on a Transportation Pallet 


Chapter 3 - Robot Installation 

3.2 Unpacking and Inspecting the <strong>Adept</strong> Equipment 

Before Unpacking 

Carefully inspect all shipping crates for evidence of damage during transit. Pay special 

attention to tilt and shock indication labels on the exteriors of the containers. If 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 <strong>com</strong>pare the actual items received (not 

just the packing slip) with your equipment purchase order and verify that all items are 

present and that the shipment is correct and free of visible damage. 

If the items received do not match the packing slip, or are damaged, do not sign the 

receipt. Contact <strong>Adept</strong> as soon as possible. 

If the items received do not match your order, please contact <strong>Adept</strong> immediately. 

Inspect each item for external damage as it is removed from its container. If any damage is 

evident, contact <strong>Adept</strong> (see Section 1.3 on page 16). 

Retain all containers and packaging materials. These items may be necessary to settle 

claims or, at a later date, to relocate equipment. 

3.3 Repacking for Relocation 

If the robot or other equipment needs to be relocated, reverse the steps in the installation 

procedures that follow this chapter. Reuse all original packing containers and materials 

and follow all safety notes used for installation. Improper packaging for shipment will 

void your warranty. Before unbolting the robot from the mounting surface, fold the outer 

arm against the Joint 2 hardstops to help centralize the center of gravity. The robot must 

always be shipped in an upright orientation. Specify this to the carrier if the robot is to be 

shipped. 


Environmental and Facility Requirements 

3.4 Environmental and Facility Requirements 

The <strong>Adept</strong> robot system installation must meet the operating environment requirements 

shown in Table 3-1. 

Table 3-1. Robot System Operating Environment Requirements 

Ambient temperature 

Humidity 

Altitude 

5°C to 40°C (41°F to 104°F) 

5 to 90%, noncondensing 

up to 2000 m (6500 ft.) 

Pollution degree 2 (IEC 1131-2/EN 61131-2) 

Robot protection class IP20 (NEMA Type 1) 

Note: See Section 9.1 on page 111 for robot dimensions. 



3.5 Mounting the Robot 

Mounting Surface 

The <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> and i800 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. <strong>Adept</strong> re<strong>com</strong>mends a 25 mm (1 in.) thick steel plate mounted to a 

rigid steel tube frame. Excessive vibration or mounting flexure will degrade robot 

performance. Figure 3-2 shows the mounting hole pattern for the <strong>Adept</strong> <strong>Cobra</strong> i-series 

and s-series 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 Figure 3-2. Using locating pins could improve the ability to 

remove and reinstall the robot in the same position. 

+0.015 

2x R4 0 

45 

6 

80 

160 

4X Ø 14 THRU 

10 

50 

160 

200 

+0.015 

Ø 8 

0 

6 

90 

234 

338 

Robot Mounting Procedure 

Figure 3-2. Mounting Hole Pattern for Robot 

1. Using the dimensions shown in Figure 3-2, drill and tap the mounting surface for 

four M12 - 1.75 x 36 mm (or 7/16 - 14 UNC x 1.50 in.) machine bolts (bolts not 

provided). See Table 3-2 for bolt and torque specifications. 


Mounting the Robot 

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 3-1 on page 29). 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 <strong>com</strong>ply 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 

possible 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. Verify that the robot is 

mounted squarely (will not rock back and forth) before tightening the 

mounting bolts. 

6. Install the user-supplied mounting bolts and washers. Tighten bolts to torque 

specified in Table 3-2. 

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 8 for periodic 

maintenance. 

Table 3-2. 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 SAE Grade 5 50 ft-lb 



3.6 Description of Connectors on Robot Interface Panel 

200-240 VAC 

Input 

XSLV 

Ground 

Pin 

24 VDC 

Input 

SmartServo Port 1 

SmartServo Port 2 

+24 VDC 

Pin 

RS-232 

XIO 

XPANEL 

Figure 3-3. Robot Interface Panel 

24VDC - for connecting user-supplied 24VDC power to the robot. The mating connector 

is provided. 

200/240VAC - for connecting 200-240 VAC, single-phase, input power to the robot. The 

mating connector is provided. 

XSLV - not used in a <strong>Cobra</strong> <strong>i600</strong>/i800 robot system. 

SmartServo 1/2 - not used in a <strong>Cobra</strong> <strong>i600</strong>/i800 robot system. 

RS-232 - for connecting a user-supplied <strong>com</strong>puter, running <strong>Adept</strong> DeskTop software. 

(DB-9, male) 

XPANEL - for connecting the AIB XPANEL cable. The AIB XPANEL cable has connectors 

for the Front Panel, MCP, and XUSR. (DB26, high density, male) 

XIO - for user I/O signals for peripheral devices. This connector provides 8 outputs and 

12 inputs. See Section 5.5 on page 53 for connector pin allocations for inputs and outputs. 

That section also contains details on how to access these I/O signals via MicroV+. (DB26, 

high density, female) The optional XIO Termination Block connects here. This device 

provides a termination block for IO connections, plus status LEDs and switches to test 

I/O signals. 


R 

GND 

+24V 

DC INPUT 

(24 VDC) 

AC INPUT 

(200-240 VAC 1Φ) XIO 

XSLV 

XPANEL 

1 

2 

SmartServo 

RS-232 

4.1 System Cable Diagram 

System Installation 4 

Installation Procedure 

1. Connect AIB XPANEL cable to XPANEL on Interface Panel. 

2. Verify XUSR jumper plug is installed on XUSR connector. 

3. Connect Front Panel cable to Front Panel and XFP connector. 

4. If no MCP, install MCP jumper plug on XMCP connector. Skip to 5. 

4a. If you have MCP, install MCP cable assembly on XMCP connector. 

5. Connect optional user-supplied ground wire. See Section 4.9 for locations. 

6. Connect 200-240 VAC to AC Input on Interface Panel, secure with clamp. 

7. Connect 24VDC to DC Input on Interface Panel. 

8. Connect null modem serial cable to Interface Panel and serial port on PC. 

XUSR for: 

- User E-Stop/Safety Gate 

- Muted Safety Gate 

- Jumper plug required 

when not used 

STOP 

Front Panel 

XUSR 

Jumper 

Plug 

3 

Front Panel 

Cable 

2 

XUSR 

XFP 



1 

AIB XPANEL 

Cable 

Robot Interface 

Panel 

1 

GND 

XSLV 

2 

-+ 

MCP Power 

Adapter 

4a 

+24V 

DC INPUT 

(24 VDC) 

AC INPUT 

(200-240 VAC 1Φ) 

XIO 

SmartServo 

XPANEL RS-232 

MCP - Optional 

MCP Adapter 

Cable 

See Table 4-1 on page 36 for Cable 

and Parts List. 

4 

XMCP 

MCP Jumper Plug 

Install if MCP 

not used 

7 

DC Power 

Cable 

24VDC, 6A 

Power Supply 

6 

AC Power 

Cable 

200-240 VAC, 

10A, single phase 

User-Supplied 

Ground Wire, 

optional 

RS-232 Null Modem Cable 

for Robot to PC Connection 

5 

8 

PC running <strong>Adept</strong> DeskTop 

Figure 4-1. System Cable Diagram for <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robots 


Chapter 4 - System Installation 

4.2 Cable and Parts List 

Table 4-1. Cable and Parts List 

Part Description Part Number Notes 

AIB XPANEL Cable - for connecting 

XUSR, Front Panel, and optional MCP 

to the robot 

02963-000 (or 04715-000 for 

cable with molded plugs) 

Standard cable - 

supplied with system 

RS-232 Null Modem Serial Cable, 

5 meter, for connecting user-supplied 

PC to robot. 

04116-000 Standard cable - 


XUSR Jumper Plug 

00946-000 (or 04736-000 for 

molded plug) 

Standard plug - 


Front Panel Cable 10356-10500 Supplied with Front 

Panel 

MCP Adapter Cable 10356-10400 Supplied with MCP 

MCP Power Adapter 02721-000 Supplied with MCP 

MCP Jumper Plug 

00947-000 (or 04737-000 for 

molded plug) 

Standard plug - 


24VDC Power Cable - to supply 

24 VDC to robot 

AC Power Cable - to supply 

AC power to robot 

04120-000 Available in Starter 

Kit 


Kit 

24 VDC power supply, 150W, 6A 04117-000 Available in Starter 

Kit 

XIO Breakout Cable, 12 inputs/ 

8 outputs, 5 meter 


Kit - see page 57. 

4.3 Optional Starter Kit 

The optional Starter Kit contains a 24 VDC power supply and various premanufactured 

cables for quickly bringing up your system. If you have ordered this kit, you do not have 

to create the DC and AC power cables specified later in this chapter. The kit includes: 

• 24VDC Power Supply (with AC cable) 

• 24VDC Power Cable (to robot) 

• AC Power Cable (to robot) 

• XIO Breakout Cable, 12-8, 5 meter 

The individual items in the Starter Kit, except for the power supply, can also be ordered 

separately - see Table 4-1 for part numbers. 


Cable Connections to the Robot 

4.4 Cable Connections to the Robot 

Installing AIB XPANEL Cable 

1. Locate the AIB XPANEL cable. It is typically shipped in the cable/accessories box. 

2. Install the single end of the AIB XPANEL cable into the XPANEL connector on the 

robot interface panel. See Figure 4-1 on page 35. The AIB XPANEL cable has these 

connectors on the opposite end: XUSR, XFP, and XMCP. 

Installing Peripherals and Options 

See Figure 4-1 on page 35 while installing these items. 

1. Verify that the XUSR jumper plug is installed on the XUSR connector, or that 

user-supplied E-stop devices are installed. See Section 5.6 on page 59 for 

information on connecting user-supplied E-Stop devices and safety circuits to the 

XUSR connector. 

2. Connect the Front Panel cable to the XFP connector on the AIB XPANEL cable. 

3. Connect the Front Panel by plugging the Front Panel cable into the XFP connector 

on the side of the Front Panel. 

4. If you are not using the optional MCP, then verify the MCP jumper plug is 

installed on the XMPC connector. If your system contains the optional MCP, go to 

step 5 below. 

5. If your system contains the optional Manual Control Pendant (MCP), follow these 

steps. 

a. Remove the MCP jumper plug from the XMCP connector on the AIB 

XPANEL cable. 

b. Install the MCP Adapter cable assembly onto the XMCP connector on the 

AIB XPANEL cable. (The MCP Adapter cable assembly consists of the MCP 

Adapter cable and the MCP Power Adapter device.) 

c. Install the MCP circular connector to the matching connector on the MCP 

Adapter cable. 



4.5 Connecting User-Supplied PC to Robot 

The <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 robots must be connected to a user-supplied PC for setup, 

control, and programming. The user loads the <strong>Adept</strong> DeskTop software onto the PC and 

connects it to the robot via an RS-232 serial cable. 

PC Requirements 

In order to use <strong>Adept</strong> DeskTop software, your PC should be configured with: 

• IBM-<strong>com</strong>patible PC with a Pentium-II 400 Mhz or higher processor 

• Windows 98, Windows NT 4.0 (Service Pack 6a or later), Windows 2000 (Service 

Pack 3 or later) or Windows XP (Service Pack 1 or later) operating system 

• 500 MB hard disk (re<strong>com</strong>mended minimum) 

• Minimum of 128 MB RAM (more memory may be required to run Windows NT or 

Windows 2000/XP) 

•SVGA monitor 

•CD-ROM drive 

• For the serial option, a standard, null modem, shielded, RS-232 data transfer serial 

cable, DB-9 female connectors on both ends (supplied by <strong>Adept</strong>). 

Installing Serial Cable 

1. Locate the RS-232 null modem serial cable that is included in the Accessory Box. 

2. Connect one end of the serial cable to the RS-232 connector on the robot interface 

panel. See Figure 4-1 on page 35. 

3. Connect the other end of the cable to a serial port on the PC. Serial ports are often 

known as COM ports. 


Installing Software 

4.6 Installing Software 

You install <strong>Adept</strong> DeskTop 2.1 from the <strong>Adept</strong> Software CD-ROM. You also need 

Microsoft .NET Framework 1.1. The <strong>Adept</strong> DeskTop Setup Wizard scans your PC for 

.NET, and installs it automatically if needed. 

1. Insert the CD-ROM into the CD-ROM drive of your PC. If Autoplay is enabled, 

the <strong>Adept</strong> Software CD-ROM menu is displayed - see Figure 4-2. 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. 

Figure 4-2. <strong>Adept</strong> Software CD-ROM Menu 

2. From the <strong>Adept</strong> Software CD-ROM menu, click Install <strong>Adept</strong> DeskTop version 

2.1. 

NOTE: If you do not have .NET Framework 1.1 installed on your system, 

you will be given the opportunity to install that software before the 

<strong>Adept</strong> DeskTop 2.1 Setup Wizard is displayed. 

3. The <strong>Adept</strong> DeskTop Setup wizard opens - see Figure 4-3. Follow the instructions 

as you step through the installation process. 

Figure 4-3. <strong>Adept</strong> Desktop Setup Wizard 

4. When the install is <strong>com</strong>plete, click Close. 

5. After closing the <strong>Adept</strong> DeskTop wizard, click Exit on the CD-ROM menu. 



4.7 Connecting 24 VDC Power to Robot 

NOTE: This section provides information on the 24 VDC power supply 

and making the 24 VDC power cable. If you have ordered the optional 

Starter Kit, then you can skip to “Installing 24VDC Robot Cable” on 

page 41 

Specifications for 24 VDC Power 

Table 4-2. Specifications for 24VDC User-Supplied Power Supply 

User-Supplied Power Supply 

Circuit Protection 

Power Cabling 

Shield Termination (re<strong>com</strong>mended for 

<strong>com</strong>pliance with EN Standards) 

24VDC (+/- 10%), 150W (6A) 

(21.6 V< V in < 26.4 V) 

Not more than 15A (below the amperage 

rating of the cable used) 

1.5 – 1.85mm² (16-14 AWG) 

Braided shield connected to “-“ terminal at 

both ends of cable. See Figure 4-4 on 

page 42. 

The power requirements for the user-supplied power supply will vary depending on the 

configuration of the robot and connected devices. <strong>Adept</strong> re<strong>com</strong>mends a 24V, 6A power 

supply to allow for startup current draw and load from connected user devices, such as 

solenoids and digital I/O loads. If multiple robots are to be sourced from a <strong>com</strong>mon 24 V 

power supply, increase the supply capacity by 3A for each additional robot. 

CAUTION: Make sure you select a 24 VDC power supply 

that meets the specifications in Table 4-2. Using an 

under-rated supply can cause system problems and 

prevent your equipment from operating correctly. See 

Table 4-3 for re<strong>com</strong>mended power supplies. 

Table 4-3. Re<strong>com</strong>mended 24VDC Power Supplies 

Vendor Name Model Ratings 

XPiQ JMP160PS24 24VDC, 6.7 A, 160 W 

AstroDyne SP-150-24 24VDC, 6.3 A, 150 W 

Mean Well SP-150-24 24VDC, 6.3 A, 150 W 


Connecting 24 VDC Power to Robot 

Details for 24 VDC Mating Connector 

The 24VDC mating connector and two pins are supplied with each system. They are 

typically shipped in the cable/accessories box. 

Table 4-4. 24VDC Mating Connector Specs 

Connector Details 

Ground 

24VDC 

Connector receptacle, 2 position, type: 

Molex Saber, 18A, 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 


Re<strong>com</strong>mended crimping tool, Molex Hand 

Crimper 

Molex P/N 63811-0400 


Procedure for Creating 24 VDC Cable 

1. Locate the connector and pins from Table 4-4 on page 41. 

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. 

3. Crimp the pins onto the wires using the crimping tool re<strong>com</strong>mended in Table 4-4 

on page 41. 

4. Insert the pins into the connector. Confirm that the 24 V and ground wires are in 

the correct terminals in the plug. 

5. Prepare the opposite end of the cable for connection to your user-supplied 24VDC 

power supply. 

Installing 24VDC Robot Cable 

1. Connect one end of the 24VDC cable to your user-supplied 24 VDC power supply. 

Do not turn on the 24VDC power until instructed to do so in Chapter 5. 

2. Plug the mating connector end of the 24VDC cable into the 24VDC connector on 

the interface panel on the back of the robot. 





– + 

Shield 

User-Supplied Shielded 

Power Cable 

+ 

– 

User-Supplied 

Power Supply 

24VDC 

Optional User 

Equipment 

Figure 4-4. User-Supplied 24VDC Cable 

NOTE: In order to maintain <strong>com</strong>pliance with EN standards, <strong>Adept</strong> 

re<strong>com</strong>mends that DC power be delivered over a shielded cable, with the 

shield connected to the return conductors at both ends of the cable. 


Connecting 200-240 VAC Power to Robot 

4.8 Connecting 200-240 VAC Power to Robot 

Specifications for AC Power 

Table 4-5. Specifications for 200/240VAC User-Supplied Power Supply 

Auto-Ranging 

Nominal 

Voltage 

Ranges 

Minimum 

Operating 

Voltage a 

Maximum 

Operating 

Voltage 

Frequency/ 

Phasing 

Re<strong>com</strong>mended 

External Circuit 

Breaker, 

User-Supplied 

200V to 240V 180V 264V 50/60Hz 

1-phase 

10 Amps 

a Specifications are established at nominal line voltage. Low line voltage can affect robot 

performance. 

Table 4-6. Typical Robot Power Consumption 

<strong>Cobra</strong> Robot 

Move 

Average 

Power (W) 

RMS 

Current (A) 

Peak Power 

(W) a 

No load - <strong>Adept</strong> cycle b 

344 1.56 1559 

s600/<strong>i600</strong> 

5.5 kg - <strong>Adept</strong> cycle b 494 2.25 2061 

5.5 kg - all joints move 880 4.00 2667 

No load - <strong>Adept</strong> cycle b 531 2.41 1955 

s800/i800 

5.5 kg - <strong>Adept</strong> cycle b 377 1.71 1406 

5.5 kg - all joints move 794 3.61 2110 

a For short durations (100 ms) 

b See Table 9-1 on page 119 for details on <strong>Adept</strong> cycle. 

DANGER: AC power installation must be performed by a 

skilled and instructed person - see Section 2.11 on 

page 25. During installation, unauthorized third parties 

must be prevented from turning on power through the use 

of fail-safe lockout measures. 

Facility Overvoltage Protection 

The user must protect the robot from excessive overvoltages and voltage spikes. If the 

country of installation requires a CE-certified installation, or <strong>com</strong>pliance 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 overvoltage 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 voltage 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 

3Ø 

200–240VAC 

L1 

L2 

L3 

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

F5 10A 

200–240VAC 

F4 10A 

E 

User-Supplied 

AC Power Cable 

E 

N 

L 

L = Line 1 

N = Line 2 

E = Earth Ground 


s600/s800 and 

<strong>i600</strong>/i800 Robots 

1Ø 200–240VAC 

Figure 4-5. Typical AC Power Installation with Single-Phase Supply 

3Ø 

200–240VAC 

L1 

L2 

L3 

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

F5 10A 

200–240VAC 

F4 10A 

E 

User-Supplied 

AC Power Cable 

E 

N 

L 

L = Line 1 

N = Line 2 

E = Earth Ground 


s600/s800 and 

<strong>i600</strong>/i800 Robots 

1Ø 200–240VAC 

Figure 4-6. Single-Phase AC Power Installation from a Three-Phase AC Supply 


Connecting 200-240 VAC Power to Robot 

Details for AC Mating Connector 

The AC mating connector is supplied with each system. It is typically shipped in the 

cable/accessories box. The supplied plug is internally labeled for the AC power 

connections (L, E, N). 

Table 4-7. AC Mating Connector Details 

AC Connector details 

AC in-line power plug, 

straight, female, screw 

terminal, 10 A, 250 VAC 

Qualtek P/N 709-00/00 

Digi-Key P/N Q217-ND 

Procedure for Creating 200-240 VAC Cable 

NOTE: This section provides information on making the AC power cable. 

If you have ordered the optional Starter Kit, then you can skip to 

“Installing AC Power Cable to Robot” on page 46. 

1. Locate the AC mating connector shown in Table 4-7. 

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 4-7 on page 46. 

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

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

5. Strip 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. Replace 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. 



Removable 

Bushing 

Earth 

Cable 

Clamp 

Line 

Neutral 

Figure 4-7. 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 Figure 4-6 on page 44. 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. 


Grounding the <strong>Adept</strong> Robot System 

4.9 Grounding the <strong>Adept</strong> Robot System 

Proper grounding is good practice for safe and reliable robot operation. Follow these 

re<strong>com</strong>mendations to properly ground your robot system. 

Ground Point on Robot Base 

The user can install a ground wire at the robot base to ground the robot. See Figure 4-8. 

The robot ships with an M8 x 12 stainless steel, hex-head screw, and M8 split and flat 

washers installed in the grounding hole. The user is responsible for supplying the ground 

wire to connect to earth ground. 

Ground Point on Robot 

Base, with M8 x 12 

screw and washers 

installed 

Figure 4-8. Ground Point on Robot Base 

NOTE: Early robots did not have a ground point on the robot. The 

alternative ground point is located on the AIB chassis, as described in the 

following section. 

Ground Point on AIB 

On robots without the ground point on the base, the user can install a ground wire at the 

AIB chassis. Use one of the threaded holes around the Robot Interface Panel - see Figure 

4-9. The user must provide an M4 screw, an external tooth lockwasher, and a ground wire 

to connect to earth ground. Make sure to tighten the screw on the ground wire to create a 

proper ground connection. 

Ground Point on AIB 

(1 of 4 locations) 

Figure 4-9. User Ground Location on AIB 



Robot-Mounted Equipment Grounding 

The following parts of an <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 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 equipment/tooling to the ground point on the robot base. Hazardous voltages 

can be considered anything in excess of 30 VAC (42.4 VAC peak) or 60 VDC. 

See also Figure 9-4 on page 114 for the grounding point on the tool flange. 

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 

electrical fault condition exists. 

4.10 Installing User-Supplied Safety Equipment 

The user is responsible for installing safety barriers to protect personnel from <strong>com</strong>ing in 

contact 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 Chapter 2 in this manual for a discussion of safety issues. 

Refer to the Section 5.6 on page 59 for information on connecting safety equipment into 

the system through the XUSR connector on the AIB XPANEL cable. There is a detailed 

section on Emergency Stop Circuits and diagrams on re<strong>com</strong>mended E-Stop 

configurations. 


System Operation 5 

5.1 Robot Status LED Description 

The robot Status LED Indicator is located on the top of the robot. See Figure 5-1. This is a 

bi-color, red and green LED. The color and blinking pattern indicates the status of the 

robot. See Table 5-1. 

Robot Status LED 

Indicator 

Figure 5-1. Robot Status LED Indicator Location 

Table 5-1. Robot Status LED Definition 

LED Status 

Off 

Green, Slow Blink 

Green, Fast Blink 

Green/Red Blink 

Red, Fast Blink 

Solid Green or Red 

Description 

24VDC not present 

High Power Disabled 

High Power Enabled 

Selected Configuration Node 

Fault, see Diagnostics Display 

Initialization or Robot Fault 


Chapter 5 - System Operation 

5.2 Diagnostic Panel Fault Codes 

The diagnostic panel, shown in Figure 5-2, displays alpha-numeric codes that indicate the 

operating status of the robot, including detailed fault codes. Table 5-2 gives definitions of 

the fault codes. These codes provide details for quickly isolating problems during 

troubleshooting. 

The displayed fault code will continue to be displayed even after the fault is corrected or 

additional 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. 

Diagnostics 

Panel for 

Displaying Fault 

Codes 

Z Brake Release 

Button 

Figure 5-2. Diagnostic Panel 

Table 5-2. Diagnostic Panel Fault Codes 

LED Fault Code LED Fault Code 

OK No Fault V# Hard Envelope Error 

ON High Power ON Status M# Motor Stalled 

I# Initialization Stage 24 24V Motor Fault (Award) 

I0 FPGA Initialization in Process IO 24V I/O Fault 

I1 Software Initialization Started AC AC Power Fault 

I3 1394 initialization Done bF Base Board Fault 

I4 Amp Offsets Done LV Low Voltage 

I5 Servo Initialization Done FW 1394 Fault (V+) 

I7 MicroV+ Initialization Done F# 1394 Fault 

I9 Interrupt Started ES E-Stop 

A# Amp Fault PR Processor Overloaded 

h# High Temp Amp FM Firmware Mismatch 

H# High Temp Encoder NV Non-Volatile Memory 

E# Encoder Fault RC RSC Fault 

D# Duty Cycle Exceeded SW Watchdog Timeout 

hV High Voltage Bus Fault B# IO Blox Fault 

# = Joint Number 


Using the Brake Release Button 

NOTE: Two diagnostics labels, which display the fault codes, are provided 

with each system, so that you can place these in a convenient location, for 

easier access to diagnostic information. 

5.3 Using the Brake Release Button 

Brakes 

The robot has a braking system which decelerates the robot in an emergency condition, 

such as when the emergency stop circuit is open or a robot joint passes its softstop. The 

braking system will not prevent you from moving the robot manually once the robot has 

stopped (and High Power has been removed). 

In addition, Joint 3 has an electromechanical brake. The brake is released when High 

Power is enabled. When High Power is turned off, the brake engages and holds the 

position of Joint 3. 

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 diagnostic panel (see Figure 5-2 on page 50). When system power is on, 

pressing this button releases the brake, which allows movement of Joint 3. 

If this button is pressed while High Power is on, High Power will automatically shut 

down. 

CAUTION: When the Brake Release button is pressed, Joint 

3 may drop to the bottom of its travel. To prevent possible 

damage to the equipment, make sure that Joint 3 is 

supported while releasing the brake and verify that the 

end-effector or other installed tooling is clear of all 

obstructions. 



5.4 Front Panel Description 

1 

2 

Manual 

Mode 

Auto 

Mode 

4 

STOP 

5 

3 

Figure 5-3. Front Panel 

1. XFP connector 

Connects to the XFP connector on the AIB XPANEL cable on an <strong>i600</strong>/i800 robot. 

2. System 5V Power On LED 

Indicates whether or not power is connected to the robot. 

3. Manual/Automatic Mode Switch 

Switches between Manual and Automatic mode. In Automatic mode, executing programs 

control the mechanism, and the mechanism can run at full speed. In Manual mode, the system 

limits mechanism speed and torque so that an operator can safely work in the cell. Manual 

mode initiates software restrictions on robot speed, <strong>com</strong>manding no more than 250 mm/sec as 

required by RIA and ISO standards. 

4. High Power On/Off Switch and Lamp 

Controls high power, which is the flow of current to the robot motors. Enabling high power is a 

two-step process. An “Enable Power” request must be sent from the user-supplied PC, an 

executing program, or the MCP. Once this request has been made, the operator must press this 

button and high power will be applied. 

5. 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. See “Remote Front Panel or User-Supplied 

Replacement” on page 65 for a summary of connections required to 

replace the Front Panel. 


Using Digital I/O on Robot XIO Connector 

5.5 Using Digital I/O on Robot XIO Connector 

The XIO connector on the robot interface panel supports 20 digital I/O signals - 12 inputs 

and 8 outputs. These signals can be used by MicroV+ to perform various functions in the 

workcell. See Table 5-3 for the XIO signal designations. 

• 12 Inputs, signals 1001 to 1012 

• 8 Outputs, signals 0001 to 0008 

XIO Connector Description 

Table 5-3. XIO Signal Designations 

Pin 

No. Designation 

1 GND 

Signal 

Bank 

MicroV+ 

Signal 

Number 

2 24VDC 

3 Common 1 1 

4 Input 1.1 1 1001 

5 Input 2.1 1 1002 

6 Input 3.1 1 1003 

7 Input 4.1 1 1004 

8 Input 5.1 1 1005 

9 Input 6.1 1 1006 

10 GND 

11 24VDC 

12 Common 2 2 

13 Input 1.2 2 1007 

14 Input 2.2 2 1008 

15 Input 3.2 2 1009 

16 Input 4.2 2 1010 

17 Input 5.2 2 1011 

18 Input 6.2 2 1012 

19 Output 1 0001 

20 Output 2 0002 

21 Output 3 0003 

22 Output 4 0004 

23 Output 5 0005 

24 Output 6 0006 

25 Output 7 0007 

26 Output 8 0008 

Pin Locations 

Pin 18 

Pin 26 

Pin 19 

Pin 10 

Pin 9 

Pin 1 

XIO 26-pin female 

connector on Robot 

Interface Panel 



Optional I/O Products 

These optional products are also available for use with digital I/O: 

• XIO Breakout Cable, with flying leads on user’s end. See page 57 for information. 

• 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 <strong>Adept</strong> XIO 

Termination Block Installation <strong>Guide</strong> for details. 

• <strong>Adept</strong> IO Blox Device, adds digital I/O capacity, 8 inputs and 8 outputs, to the 

system. Connects to robot at the IO Blox connector. You can <strong>com</strong>bine up to four 

IO Blox devices, to increase capacity by 32 inputs and 32 outputs. See the <strong>Adept</strong> IO 

Blox User’s <strong>Guide</strong> 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 <strong>com</strong>mon source/sink line. 

The inputs are accessed through direct connection to the XIO connector (see Table 5-3 on 

page 53), or through the optional XIO Termination Block. See the documentation supplied 

with the Termination Block for details. 

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

vision triggers. 

XIO Input Specifications 

Table 5-4. XIO Input Specifications 

Operational voltage range 

“Off” state voltage range 

“On” state voltage range 

Typical threshold voltage 

Operational current range 

“Off” state current range 

“On” state current range 

Typical threshold current 

Impedance (V in /I in ) 

Current at V in = +24VDC 

Turn on response time (hardware) 

Software scan rate/response time 

Turn off response time (hardware) 

Software scan rate/response time 

0 to 30 VDC 

0 to 3VDC 

10 to 30 VDC 

V in = 8VDC 

0 to 7.5 mA 

0 to.5 mA 

2 to 7.5 mA 

2.5 mA 

3.9 K Ω minimum 

I in ≤6 mA 

5 µsec maximum 

16 ms scan cycle/32 ms max response time 

5 µsec maximum 

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. 



Typical Input Wiring Example 

<strong>Adept</strong>-Supplied Equipment 

XIO Connector – 26-Pin Female D-Sub 

Wiring 

Terminal 

Block 

(equivalent circuit) 

Signal 1001 

4 

Signal 1002 

5 

Signal 1003 

6 

Signal 1004 

7 

Signal 1005 8 

Signal 1006 

9 

Bank 1 3 

Common 

+24V 

2 

GND 1 

Signal 1007 13 






Bank 2 12 

Common 

GND 10 

Input Bank 2 Input Bank 1 

User-Supplied Equipment 

Typical User 

Input Signals 

Part Present Sensor 

Feeder Empty Sensor 

Part Jammed Sensor 

Sealant Ready Sensor 

Note: all Input signals 

can be used for either 

sinking or sourcing 

configurations. 

Bank 1 configured for 

Sinking (NPN) Inputs 

Bank 2 configured for 

Sourcing (PNP) Inputs 

Figure 5-4. 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 outputs. 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 <strong>com</strong>mon, 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 

0.7A of current. This Driver has overtemperature protection, current limiting, and shorted 

load protection. 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 Driver draws power from the primary 24VDC input to the robot through a 

self-resetting polyfuse. 

The outputs are accessed through direct connection to the XIO connector (see Table 5-3 on 

page 53), or through the optional XIO Termination Block. See the documentation supplied 

with the XIO Termination Block for details. 

XIO Output Specifications 

Table 5-5. XIO Output Circuit Specifications 

Parameter 

Value 

Power supply voltage range See Table 4-2 on page 40. 

Operational current range, per I out ≤700 mA 

channel 

Total Current Limitation, all channels 

on. 

I total ≤ 1.0 A @ 50°C ambient 

I total ≤ 1.5A @ 25°C ambient 

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

Output leakage current I out ≤25 µA 

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 demag ≤ (+V - 45) 

turnoff (I out = 0.5A, Load = 1 mH) 

DC short circuit current limit 0.7A ≤I LIM ≤2.5 A 

Peak short circuit current 

I ovpk ≤4A 



Typical Output Wiring Example 

<strong>Adept</strong>-Supplied Equipment 

XIO Connector – 26-Pin Female D-Sub 

Outputs 1-8 

+24VDC 

(equivalent 

circuit) 

Signal 0001 

19 

Signal 0002 

20 

Signal 0003 

21 

Signal 0004 

22 

Signal 0005 

23 

Signal 0006 

24 

Signal 0007 

25 

Signal 0008 

GND 

GND 

26 

1 

10 

User-Supplied Equipment 

Wiring 

Terminal 

Block 

Load 

Load 

Typical User Loads 

Load 

M 

M 

L 

N 

Customer 

AC Power 

Supply 

XIO Breakout Cable 

Figure 5-5. Typical User Wiring for XIO Output Signals 

The XIO Breakout cable is available as an option. 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 part number for the cable is 04465-000, and the length is 5 M 

(16.4 ft). This cable is included in the Starter Kit, and it can be ordered separately. 

See Table 5-6 on page 58 for the wire chart on the cable. 

Figure 5-6. Optional XIO Breakout Cable 



Table 5-6. XIO Breakout Cable Wire Chart 

Signal 

Pin No. Designation Wire Color Pin Locations 

1 GND White 

2 24VDC 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 24VDC 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 10 

Pin 19 

Pin 26 

Pin 18 

Pin 1 

Pin 9 

26-pin male 

connector on XIO 

Breakout Cable 


Connecting Customer-Supplied Safety and Power Control Equipment 

5.6 Connecting Customer-Supplied Safety and Power Control 

Equipment 

Connecting Equipment to the System 

The connection of the customer-supplied safety and power control equipment to the 

system is done through the XUSR and XFP connectors on the AIB XPANEL cable. Refer to 

Table 5-7 for the XUSR pin-out explanations. Refer to Table 5-8 on page 60 for the XFP 

pin-out explanations. See Figure 5-7 on page 62 for the E-Stop wiring diagram. 

Table 5-7. Contacts Provided by the XUSR Connector 

Pin 

Pairs 

Description 

Comments 

Shorted if 

NOT Used 

Voltage-Free Contacts Provided by Customer 

1, 14 

User E-Stop CH 1 (mushroom PB, 

safety gates, etc.). 

N/C contacts 

Yes 

2,15 

User E-Stop CH 2 (same as pins 1 and 

14). 

N/C contacts 

Yes 

3,16 Not supported on <strong>Cobra</strong> i-series robot 


5,18 

Muted Safety Gate CH 1 (causes 

E-stop in AUTOMATIC mode only). 

N/C contacts 

Yes 

6,19 

Muted Safety Gate CH 2 (same as pins 

5 and 18). 

N/C contacts 

Yes 

Voltage-Free Contacts provided by <strong>Adept</strong> 





11,12, 

13,24,25 

No connection 

Pin 13 

XUSR 

Pin 1 

Pin 25 

Pin 14 



Table 5-8. Contacts Provided by the XFP Connector 

Pin 

Pairs 

Description 

Requirements for 

User-Supplied Front Panel 

Voltage-Free Contacts Provided by Customer 

1,9 

2,10 

3,11 

4,12 

6,14 

5,13 

Front Panel E-Stop CH 1 (N/C contacts) 

Front Panel E-Stop CH 2 (N/C contacts) 

Remote MANUAL/AUTOMATIC switch CH 1. 

MANUAL = Open AUTOMATIC = Closed 

Remote MANUAL/AUTOMATIC switch CH 2. 

MANUAL = Open AUTOMATIC = Closed 

Remote High Power On/Off momentary PB 

Nonvoltage-Free Contacts 

<strong>Adept</strong> Supplied 5 VDC and GND for High Power 

On/Off Switch Lamp 

User must supply N/C 

contacts. 

User must supply N/C 

contacts. 

Optional - jumper closed for 

Auto Mode only operation. 

Optional - jumper closed for 

Auto Mode only operation. 

User must supply 

momentary push button to 

enable High Power to 

system. 

User must supply lamp, or 

use 1/4 W, 220 ohm resistor. 

System will not operate if not 

present. 

7,15 System 5V power ON LED, 5V, 20mA Optional - indicator only 

8 No connection 

Pin 8 

XFP 

Pin 1 

Pin 15 

Pin 9 

See Figure 5-8 on page 63 for a schematic diagram of the <strong>Adept</strong> Front Panel. 



Table 5-9. Remote MCP Connections on the XMCP Connector 

Pin XMCP 

(15-Pin D-Sub) 

Pin MCP 

(16-Pin CPC) 

Description 

1,9 6,7 MCP E-stop PB CH 1 

2,10 11,12 MCP E-stop PB CH 2 

3,11 14,16 MCP Enable CH 1 (Hold-to-run) 

4,12 13,15 MCP Enable CH 2 (Hold-to-run) 

13 1,4 Serial GND/Logic GND 

7 2 MCP TXD: “V + to MCP TXD” 

8 3 MCP RXD: “V + to MCP RXD” 

14 5 No connection 


Shield 9 Shield GND 

6 24V (used by MCP Power Adapter) 




<strong>Cobra</strong> <strong>i600</strong>/i800 

Internal Circuits Front Panel and MCP Circuits User-Supplied Circuits 

ESTOPGND 

(Channel 2) 

XFP-2 (XPANEL-10) 

ESTOPSRC (Channel 1) 




Front Panel 

ESTOP 

Pushbutton 

NOTE: The “Line E-Stop” and 

“User Manual/Auto Indication” 

functions of the XUSR connector 

are not supported on the 

<strong>Cobra</strong> <strong>i600</strong>/i800 robots. 

XMCP-2 (XPANEL-15) 

XMCP-1 

(XPANEL-6) 

MCP ESTOP 

Pushbutton 

User E-Stop and Gate Interlock 

(Jumper closed when not used, 

MUST open both channels 

independently if used.) 

XUSR-2 

XUSR-1 


XUSR-14 (XPANEL-7) 


XUSR-15 (XPANEL-16) 


MCP-4 

3-Position 

Enable Switch 



Manual Mode 

Path 


Front Panel 

Manual/Auto 

Keyswitch 

XUSR-6 

Muted Safety Gate - 

Active in Auto mode only 

(Jumper closed when 

not used.) 

Auto Mode 

Path 

XUSR-5 


Front Panel 

High Power ON/OFF 

XUSR-18 

(XPANEL-4) 

Force-<strong>Guide</strong>d Relay 

Cyclic Check 

Control Circuit 



6V, 1.2 W 

bulb 

XUSR-19 

(XPANEL-13) 


Single-Phase 

AC Input 

200-240VAC 

High Power to 

Amplifiers 

Force-<strong>Guide</strong>d 

Relay 

Force-<strong>Guide</strong>d 

Relay 

Figure 5-7. <strong>Cobra</strong> <strong>i600</strong>/i800 E-Stop Circuit Connections 



<strong>Adept</strong> Front Panel Schematic 

ESTOPSRC 

XFP 

15PDSUBM 

5VD 

24VS 

1 

2 

MANUALSRC1 

3 

MANUALSRC2 

4 

HPLT5V 

5 

6 

SYSPWRLT 7 

NC 8 

16 

9 

10 

11 

12 

13 

14 

15 

ESTOPFP1 

ESTOPFP2 

MANUALRLY1 

MANUALRLY2 

HIPWRLT 

HIPWRREQ 

17 

D 

"System Power LED" 

"MANUAL/AUTO" 

"HIGH POWER ON/OFF" 

"EMERGENCY STOP" 

SYSPWRLT 

5VD 

(XFP-7) 

(XFP-4) 

MANUALSRC2 

MANUALSRC1 

(XFP-3) 

24VS 

(XFP-6) 

(XFP-5) 

HPLT5V 

ESTOPSRC (XFP-1) 

2PIN_MINI 

(XFP-15) 

D 

SWL1 

D 

(XFP-2) 

SW1 

SW2 

(XFP-12) 

MANUALRLY2 

MANUALRLY1 

(XFP-11) 

(XFP-13) 

HIPWRLT 

HIPWRREQ 

(XFP-14) 

(XFP-10) 

ESTOPFP2 

ESTOPFP1 

(XFP-9) 

Emergency Stop Circuits 

Figure 5-8. Front Panel Schematic 

The <strong>Cobra</strong> <strong>i600</strong>/i800 robot provides connections for Emergency Stop (E-Stop) circuits on 

the XUSR and XFP connectors. This gives the robot system the ability to slave E-Stop 

functionality from a remote location using voltage-free contacts. See Figure 5-7 on page 

62. 

The XUSR connector provides external two-channel E-Stop input on pins 1 to 14 and 2 to 

15. The XFP connector provides two-channel E-Stop input on pins 1 to 9 and 2 to 10. 

NOTE: These pins must be shorted if not used. Both channels must open 

independently if used. Although an Emergency Stop will occur, the robot 

will display an error if one channel is jumpered closed and the other 

channel is opened. It will also display an error if the channels are shorted 

together. 



Muted Safety Gate E-Stop Circuitry 

Two pairs of pins on the XUSR connector (pins 5, 18 and 6, 19) provide connections for a 

safety gate designed to yield an E-Stop allowing access to the workspace of the robot in 

Manual mode only, not in Automatic mode. The E-Stop is said to be “muted” in Manual 

mode (see Figure 5-7 on page 62, Table 5-7 on page 59, Table 5-8 on page 60, and 

Table 5-9 on page 61 for the customer E-Stop circuitry). 

The muted capability is useful for the situation where a shutdown must occur if the cell 

gate is opened in Automatic mode, but you need to open the gate in Manual mode. If the 

mute gate is opened in Automatic mode, the robot defaults to Manual mode operation 

when power is re-enabled. In muted mode, the gate can be left open for personnel to work 

in the robot cell. However, safety is maintained because of the speed restriction. 

CAUTION: If the cell gate must always cause a robot 

shutdown, do not wire the gate switch into the muted 

safety gate inputs. Instead, wire the gate switch contacts in 

series with the user E-Stop inputs. 

Remote Manual Mode 

If the user needs to control the Manual/Automatic mode selection from other control 

equipment, then a custom splitter cable or <strong>com</strong>plete replacement of the <strong>Adept</strong> Front Panel 

may be required. See Figure 5-8 on page 63 for the Front Panel schematic. In this situation, 

a pair of contacts should be wired in series with the <strong>Adept</strong> Front Panel Manual/Automatic 

mode contacts. Thus, both the <strong>Adept</strong> Front Panel and the customer contacts need to be 

closed to allow Automatic mode. 

WARNING: Do not wire customer-supplied 

Manual/Automatic contacts in parallel with the <strong>Adept</strong> 

Front Panel switch contact. This would violate the “Single 

Point of Control” principle and might allow Automatic 

(high-speed) mode to be selected while an operator is in 

the cell. 



Remote High Power On/Off Control 

The easiest and most effective way to provide the high power on/off control in a remote 

location is to mount the <strong>Adept</strong> Front Panel in the desired location with an extension cable. 

However, if the user needs to control high power on/off from other control equipment or 

from a location other than the <strong>Adept</strong> Front Panel, then a custom splitter cable or <strong>com</strong>plete 

replacement of the <strong>Adept</strong> Front Panel will be required. See the Front Panel schematic 

(Figure 5-8 on page 63) for details of the Front Panel’s wiring. In this situation, a second 

momentary contact for high power on/off would be placed in parallel with the <strong>Adept</strong> Front 

Panel push button contact. This second contact should be suppressed when in Manual 

mode (see the note on “Single Point of Control” below). 

This method allows relocating the push button switch to a more convenient location. 

Implementation of this method must conform to EN standard re<strong>com</strong>mendations. 

The European standard, EN 775, Ind. Robots, Part 6, Re<strong>com</strong>mendations for Safety: Item 

7.2.5 Emergency Stop, reads: “Each robot system operator station shall have a readily 

accessible emergency stop device. The manual intervention and reset procedure to restart 

the robot system after an emergency stop shall take place outside the restricted space”. 

Thus, it is important that the remote High Power push button be located outside of the 

protected space of the robot. 

Pins 6 and 14 and 5 and 13 of the XFP connector provide this remote capability. Pins 5 and 

13 provide power for the lamp, +5VDC and ground, respectively. Pins 6 and 14 are inputs 

for voltage-free N/O contacts from a customer-supplied momentary push button switch. 

WARNING: To fulfill the “Single Point of Control” 

requirement, do not place the Manual/Automatic and 

High Power On controls in multiple locations. To put the 

robot into Manual mode, the operator should remove the 

key for safety purposes. The system should not be wired 

so that a PLC or another operator can put the system back 

into Automatic mode. 

High Power On/Off Lamp 

The Front Panel High Power On/Off Lamp (P/N 27400-29006) will cause a MicroV + error 

if the lamp burns out. This error prevents High Power from being turned on. This safety 

feature prevents a user from not realizing that High Power is enabled because the High 

Power indicator is burned out. See the Maintenance chapter in the <strong>Adept</strong> SmartController 

User’s <strong>Guide</strong> for information on changing this lamp. 

Remote Front Panel or User-Supplied Replacement 

Users can mount the Front Panel remotely by using an extension cable or by wiring a 

user-supplied Front Panel (control panel) to the robot using the 15-pin XFP connector. The 

Front Panel contains no active <strong>com</strong>ponents, only switches and lights. Users should be able 

to adapt the Front Panel’s functionality into their own Front Panel design. To 

automatically control the Front Panel’s signals, use relay contacts instead of switches. See 

Figure 5-8 on page 63 for a schematic drawing of the Front Panel and Table 5-8 on page 60 

for a summary of connections and pin numbers. 



5.7 Turning On the System 

Turning on the robot system for the first time is known as “<strong>com</strong>missioning the system.” 

You must follow the steps in this section to safely bring up your robot system. The steps 

include: 

• Verifying installation, to confirm all tasks have been performed correctly. 

• Starting up the system by turning on power for the first time. 

• Verifying all E-Stops in the system function correctly. 

• Move each axis of the robot to confirm it moves in the proper directions. 

Verifying Installation 

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

correctly is an important process. Before using the robot, make the following checks to 

ensure that the robot system has 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 the robot is mounted level and that all fasteners are properly installed 

and tightened. 

• Verify that any end-of-arm tooling is properly installed. 

• Verify that all other peripheral equipment is properly installed and in a state where 

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

System Installation Checks 

Verify the installation procedures in Section 4.4 through Section 4.9 have been <strong>com</strong>pleted. 

User-Supplied Safety Equipment Checks 

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


Turning On the System 

Turning on Power and Starting <strong>Adept</strong> DeskTop 

After the system installation has been verified, you are ready to turn on AC and DC 

power to the system and start up <strong>Adept</strong> DeskTop. 

1. Manually move the robot joints away from the folded shipping position. 

2. Turn on the 200/240VAC power. See Section 4.8 on page 43 

3. Turn on the 24VDC power to the robot. See Section 4.7 on page 40. The Robot 

Status LED blinks green slowly, and the code on the Diagnostic Panel reads OK. 

4. Verify the Auto/Manual switch on the Front Panel is set to Auto Mode. See 

Figure 5-12 on page 68. 

5. Turn on the user-supplied PC and start <strong>Adept</strong> DeskTop. Double-click the <strong>Adept</strong> 

DeskTop icon on your Windows Desktop; or, from the Windows Start menu bar, 

select Start > Programs > <strong>Adept</strong> Technology > <strong>Adept</strong> DeskTop 2.1. 

6. Connect to the robot. From the <strong>Adept</strong> DeskTop menu bar, select File > Connect. 

7. The first time you connect to the controller, in the Connect to Controller dialog 

(see Figure 5-9), click Configure to establish the connection properties. In the 

Connection Properties dialog (see Figure 5-10), select Serial, Com Port number (1 

is default), Amp In Base, and then click OK. (On subsequent connections, you will 

not need this step.) 

8. In the Connect to Controller dialog, click Connect to make the connection. You 

will see the message "Connecting, Please stand by..." 

Figure 5-9. Connect to Controller 

Figure 5-10. Connection Properties 

Enabling High Power 

After you have started <strong>Adept</strong> DeskTop and connected to the internal controller, choose 

one of two options below to enable high power to the robot motors: 

• Option 1 (re<strong>com</strong>mended): use the Diagnostics Wizard, which steps you through 

the process of bringing up your system. See page 68. 

• Option 2: enable high power directly from <strong>Adept</strong> DeskTop. See page 70. 


R 


Option 1: Using the Diagnostics Wizard to Enable High Power 

NOTE: This start-up procedure using the Diagnostics Wizard utility is also 

shown in the <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot Quick Setup <strong>Guide</strong>. 

1. In <strong>Adept</strong> DeskTop, open the Diagnostics Wizard: Select Utilities>Diagnostics 

Wizard. A screen similar to Figure 5-11 opens. 

Figure 5-11. Main Screen in Diagnostics Wizard 

2. The Wizard verifies the workcell configuration, to confirm all equipment is 

installed correctly. Click Next to continue to the Enable Power sequence. 

3. The Wizard then asks you to press the blinking High Power button on the Front 

Panel. See Figure 5-12. This step turns on high power to the robot motors. The 

Robot Status LED blinks green rapidly, and the code on the Diagnostic Panel 

reads ON. 

Switch set to 

Auto Mode 

STOP 

Press High Power button 

when blinking 

Figure 5-12. High Power Button on Front Panel 

4. Follow the directions in the Diagnostics Wizard to step through these items: 

• If you have the XIO Terminal Block product installed, verify digital input 

and outputs 

• Calibrate the robot 

• Verify robot motions 


Turning On the System 

5. When you finish the Wizard, the robot is ready to use - see Figure 5-13. 

Congratulations: installation 

is <strong>com</strong>plete and your robot is 

ready to use! 

Figure 5-13. Diagnostics Wizard Complete 


R 


Option 2: Using <strong>Adept</strong> DeskTop to Enable High Power 

1. In <strong>Adept</strong> DeskTop, open the Robot Control window - see Figure 5-14A. In the 

<strong>Adept</strong> DeskTop menu bar, select Tools > Robot Control.) 

Auto Mode 

STOP 

Press High Power 

button when blinking 

A - Enable Power 

B - Press High Power 

C - Calibrate 

Figure 5-14. Steps to Enable Power and Calibrate 

2. See Figure 5-14A and Figure 5-14B. Click the Enable Power button, then press the 

blinking High Power button on the Front Panel within 10 seconds. (If the button 

stops blinking, you must click Enable Power again.) This step turns on high 

power to the robot motors. The Robot Status LED blinks green rapidly, and the 

code on the Robot Diagnostic Panel reads ON (see Figure 5-2 on page 50). 

3. Click the Calibrate button on the Robot Control window. See Figure 5-14C. The 

brakes will release, making a clicking sound. Once the calibration is <strong>com</strong>plete 

(5-10 seconds), the robot is under servo control and ready to move. The label on 

the Menu button now displays Disable Power. 

4. Use the Jog Pendant window (see Figure 5-15 on page 71) to verify that each robot 

joint moves correctly in both directions. From the <strong>Adept</strong> DeskTop menu bar, select 

Tools>Jog Pendant. Select Joint mode. Select Joint 1. Use the Jog Control arrows 

to move Joint 1 a short distance in both directions. Repeat for Joints 2, 3, and 4. 


Learning to Program the <strong>Adept</strong> <strong>Cobra</strong> I-Series Robot 

Use Jog Control arrows 

to move Joints 1 to 4 in 

each direction. 

Figure 5-15. Jog Pendant Menu 

5. The robot is now ready to use. Go to the next section to verify E-Stops and to 

Chapter 6 for details on installing optional equipment. 

Verifying E-Stop Functions 

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

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

opening the safety device. The High Power push button/light on the Front Panel must go 

out. See Section 5.6 on page 59. 

5.8 Learning to Program the <strong>Adept</strong> <strong>Cobra</strong> I-Series Robot 

To learn how to use and program the robot, go to the <strong>Adept</strong> DeskTop and MicroV+ online 

documentation in the <strong>Adept</strong> Document Library, to find information on basic operation 

and programming. 




Optional Equipment 

Installation 6 

6.1 Installing End-Effectors 

The user is responsible for providing and installing any end-effector or other end-of-arm 

tooling. End-effectors can be attached to the user flange using four M6 screws. See Figure 

9-4 on page 114 for a detailed dimension drawing of the user flange. 

A 6 mm diameter x 12 mm dowel pin (not supplied) fits in the through hole in the user 

flange and can be used as a keying or antirotation 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 “Robot-Mounted 

Equipment Grounding” on page 48. 

NOTE: A threaded hole is provided on the user flange (see Figure 9-4 on 

page 114). The user may attach a ground wire through the quill 

connecting the outer link and the user flange. 

6.2 Removing and Installing the User Flange 

The user flange can be removed and reinstalled if this is required for a specific reason. If 

the flange is removed, it must be reinstalled in exactly the same position to avoid losing 

the calibration for the system. 

There is a setscrew on the flange that holds the rotational position of the flange on the 

quill shaft. A ball bearing behind the setscrew contacts the shaft in one of the 

vertical-spline grooves in the shaft. Follow the procedures below to remove and replace 

the flange assembly. 

Removing the 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 driver to loosen the setscrew (see Figure 6-1 on page 74). Note 

the vertical-spline groove that is in line with the setscrew. You must replace the 

flange in the same position. 

4. Use a Torx 25 driver to loosen the two M4 Torx-head screws. 

5. Slide the flange down slowly until it is off the shaft. Be careful not to lose the ball 

bearing (3.5 mm) that is inside the flange behind the setscrew. 


Chapter 6 - Optional Equipment Installation 

Quill shaft 

M4 Torx-head screws 

User flange 

assembly 

Setscrew 

Installing the Flange 

Figure 6-1. User Flange Removal Details 

1. Make sure the ball bearing is in the setscrew hole inside the flange. Hold it in 

place with your finger as you get ready to install the flange. 

2. Slide the flange up on the quill shaft as far as it will go, and rotate until the 

setscrew is lined up with the original vertical groove. 

3. Support the flange while using a 2.5 mm Allen driver to tighten the setscrew to 

finger tight. Do not over-tighten the setscrew because this will cause the flange to 

be off-center from the quill shaft. 

4. Use a Torx 25 driver to tighten one of the Torx-head screws part of the way, then 

tighten the other one the same amount. Alternate between the two screws so there 

is even pressure on both once they are tight. The torque specification for each 

screw is 8 N•m (70 in-lb). 


User Connections on Robot 

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). 

• The two larger connectors are 6 mm diameter. 

• The three smaller connectors are 4 mm diameter. 

NOTE: The DeviceNet feature is not operational in the <strong>Cobra</strong> i-series 

robot. The connectors for DeviceNet are wired through the robot, and can 

be used if the user is supplying the control software for DeviceNet. 

DeviceNet 

User Electrical 

4mm Air Lines 

6mm Air Lines 

Figure 6-2. User Connectors on Joint 1 

4mm Air Lines 

6mm Air Lines 

DeviceNet 

4mm Air Line 

User Electrical 

Figure 6-3. User Connectors on Joint 2 



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 connector 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. 

Specifications: 

Wire size: 0.1 mm 2 (12 pair, Pin Numbers 1-24) 

Maximum current per line: 1 Amp 

6.4 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 9-5 on page 115 and Figure 9-6 on page 

116 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. 


Installing Robot Solenoid Kit 

6.5 Installing Robot Solenoid Kit 

Introduction 

This procedure describes how to mount the 24V solenoid option kit on an <strong>Adept</strong> <strong>Cobra</strong> 

i-series and s-series robot. The solenoid kit is available as <strong>Adept</strong> P/N 02853-000. 

The robot has been prewired to ac<strong>com</strong>modate 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 6-4 on page 78). The signals actuating the valves are directly 

switchable from MicroV + utilizing software signals 9 and 10. Each driver is designed to 

handle 24 VDC solenoids at a nominal 75 mA per valve. 

The solenoid valve assembly consists of two independent valves (Valve #1 and Valve #2) 

on a <strong>com</strong>mon manifold. The manifold supplies air at the user’s line pressure (28 psi 

minimum to 114 psi maximum). Each valve has two output ports, A and B. The output 

ports are arranged so that when Port A is pressurized, Port B is not pressurized. 

Conversely, when Port B is pressurized, Port A is not. In the <strong>Adept</strong> <strong>Cobra</strong> s- and i-series 

robots, the air lines from Port A on each valve are plugged at the factory (at the solenoid 

assembly). 

The Solenoid Kit for the <strong>Adept</strong> <strong>Cobra</strong> i-series and s-series robot is available through 

<strong>Adept</strong>. Contact your <strong>Adept</strong> Sales Representative for current price and availability. 

Tools Required 

Procedure 

• Assorted Allen drivers 

•Tie-wraps 

• Pair of diagonal wire cutters 

• Solenoid Valve upgrade Kit (<strong>Adept</strong> P/N 02853-000) 

1. Turn off all power to the robot. 

2. Remove two screws on s600/<strong>i600</strong> (three screws on s800/i800) on each side of the 

outer link cover. Remove two screws on top and remove 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. 



Spare air line 

Connector for the 

solenoid valves 

Pem nuts to mount the 

solenoid manifold 

Figure 6-4. Solenoid Mounting Bracket With Connector and Spare Air Line 

4. Cut and discard the tie-wraps 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 6-4). 

5. Mount the solenoid manifold onto the bracket using the supplied M3 x 25 mm 

screws and washers (see Figure 6-5 on page 79). 

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. Confirm by pulling the air line. 

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

bracket. 

8. Use tie-wraps to secure air line to the bracket as needed. 


Installing Robot Solenoid Kit 

Air intake coupling 

with spare air line 

installed 

Tubing connected 

to output port 

Mounting screws for 

solenoid assembly 

Figure 6-5. 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. Route the tubing up along the tower bracket next to 

the quill and down through the center of the quill. Use tie-wraps, as needed, to 

secure the tubing. 

10. 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 6-6. 

Joint 1 cover lifted to 

access spare air line 

User Air fitting for 

connecting spare line. 

Remove factory 

installed tubing first. 

Tubing bundle 

containing spare air 

line 

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

11. Disconnect the tubing from the 6mm User Air fitting shown in Figure 6-6. Fold 

the tubing out of the way and restrain using tie-wraps. 



12. 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. 

13. Insert the spare air line into the back of the empty 6mm User Air fitting. 

NOTE: This 6mm User Air connector and the 6mm User Air connector at 

the top of Figure 6-2 on page 75 are not functional for other uses after this 

modification. 

14. Replace the Joint 1 cover, taking care to insure that all tubing is inside the cover 

and nothing gets crimped or pinched while pushing the cover into position. 

Replace four screws to secure the cover. Tighten the screws to 14 in-lbs of torque. 

15. Replace the outer link cover and tighten the screws to 14 in-lbs of torque. 

16. Connect the factory air supply to the modified 6mm User Air connector. 

17. Turn on system power and boot the system. The default values for the gripper 

signals that activate the solenoids are 9 and 10. Once the system boot has 

<strong>com</strong>pleted, at the MicroV + dot prompt, type in the following <strong>com</strong>mands to 

activate the solenoids one at a time. 

.SIGNAL 9 

.SIGNAL 10 

WARNING: The robot air pressure may be disconnected 

until this test has been done to prevent unsecured 

pneumatic lines from accidentally injuring personnel. 


Installing Adjustable Hardstops 

6.6 Installing Adjustable Hardstops 

<strong>Adept</strong> offers an adjustable hardstop kit for Joint 1 and Joint 2 on the <strong>Adept</strong> <strong>Cobra</strong> 

<strong>i600</strong>/i800 robots. These are user-installed options that can be used to limit the work 

envelope of the robot. The <strong>Adept</strong> part number for the kit is 02592-000. 

Joint 1 Adjustable Hardstops 

The Joint 1 Adjustable Hardstops consist of two black rubber stop cylinders, and the 

required screws to install them. There are two locations for the hardstops on each side of 

the robot, Position 1 and Position 2. See Figure 6-7. 

Location for 

Position 1 

Joint 1 Adjustable 

Hardstop 

installed in 

Position 2 


Figure 6-7. Joint 1 Adjustable Hardstops 

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 45 ft-lbs. 

3. Repeat the process on the other side of the robot. 

Modifying Joint Limit Softstop Locations for Joint 1 

After installing the adjustable hardstops, you must modify the softstop locations using the 

Configuration Manager utility. See the online help for more details on this utility. 

1. In <strong>Adept</strong> Desktop, under the Utilities menu, select Configuration Manager. 

2. Click on Joint 1. The screen similar to Figure 6-7 on page 81 opens to allow editing 

the limits. 



Figure 6-8. Configuration Manager - Modifying Joint 1 Limits 

3. In the Lower Limit field, enter the new value for the J1 lower limit softstop. See 

Table 6-1 for re<strong>com</strong>mended softstop values for Position 1 or Position 2. Note that 

this value must be a negative number. 

Table 6-1. Joint 1 Ranges for Adjustable Hardstops 

Hardstop Value 

Re<strong>com</strong>mended Joint 

Limit Softstop 

J1 Hardstop Position 1 +/– 50° Lower limit: – 49° 

Upper limit: + 49° 

J1 Hardstop Position 2 +/– 88° Lower limit: – 87° 


4. In the Upper Limit field, enter the new value for the J1 upper limit softstop. See 

Table 6-1 for re<strong>com</strong>mended softstop values for Position 1 or Position 2. 

5. In the next screen, you must write the changes to either temporary or permanent 

memory. See Figure 6-9. 

Figure 6-9. Configuration 

Manager - Apply Changes 



Joint 2 Adjustable Hardstops 

The Joint 2 Adjustable Hardstop kit (see Figure 6-10) 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 6-10. Joint 2 Hardstop Kit 

1. Slide the two adjustable hardstop plates into the space between inner and outer 

links. See Figure 6-11. Looking up at the inner link from underneath, align the 

holes in the plates with the holes in the inner link - see Figure 6-12 on page 84. 

Joint 2 Adjustable 

Hardstop Plates Installed. 

Figure 6-11. Joint 2 Adjustable Hardstop Locations 



2. Use a 4 mm Allen wrench to install four supplied M5 x 10 screws to secure the 

plate. Tighten the screws to a torque of 40 in-lbs. Repeat the process for the second 

plate. Note that the plates can be installed in multiple positions, depending on 

how much you need to limit the range of Joint 2. See Table 6-2 on page 86. 

Joint 2 Fixed 

Hardstop Device 

Joint 2 Left Hardstop Plate, 

installed in +81 degree position 

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 

View of under side of Inner Link, looking up 

Joint 2 Right Hardstop Plate, 

installed in -81 degree position 

Figure 6-12. Screw Locations for Joint 2 Adjustable Hardstops 



3. Slide the fixed hardstop device into the slot on the underside of the outer link. See 

Figure 6-13. 

Joint 2 Fixed Hardstop 

Device installed on 

underside of Outer Link. 

Figure 6-13. Fixed Hardstop Device for Joint 2 

4. Use a 3 mm Allen wrench to install two supplied M4 x 10 screws to secure the 

hardstop device. Tighten the screws to a torque of 22 in-lbs. 

Modifying Joint Limit Softstop Locations for Joint 2 

After installing the adjustable hardstops, you must modify the softstop locations using the 

Configuration Manager utility. See the online help for more details on this utility. 

1. In <strong>Adept</strong> Desktop, under the Utilities menu, select Configuration Manager. 

2. Click on Joint 2. The screen similar to Figure 6-14 opens to allow editing the 

limits. 

Figure 6-14. Configuration Manager - Modifying Joint 2 Limits 



3. In the Lower Limit field, enter the new value for the J2 lower limit softstop. See 

Table 6-2 for re<strong>com</strong>mended softstop values. Note that this value must be a 

negative number. 

Table 6-2. Joint 2 Ranges for Adjustable Hardstops 

Hardstop Value 

Re<strong>com</strong>mended Joint 

Limit Softstop 

J2 Hardstops installed as 

shown in Figure 6-12 on 

page 84. 

+/– 81° Lower limit: – 80° 


Note: J2 Hardstops can be installed in multiple positions, depending on 

how the robot workcell needs to be configured. Each position is spaced 

30° apart. 

4. In the Upper Limit field, enter the new value for the J2 upper limit softstop. See 

Table 6-2 for re<strong>com</strong>mended softstop values. 

5. In the next screen, you must write the changes to either temporary or permanent 

memory. See Figure 6-9 on page 82. 

6. Once the joint limits have been changed and written to memory, the system is 

ready to use with the new limits in place. 

NOTE: With both adjustable hardstop plates installed, Joint 2 has a 

maximum range of motion of 160°. 


7 

Using the Manual 

Control Pendant (MCP) 

7.1 Manual Control Pendant Basics 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> and i800 systems are designed to allow control of the robot from the 

Manual Control Pendant (MCP). Figure 7-2 on page 89 shows how to hold the MCP. The 

current version of the MCP is the MCP-4. 

MCP-4 

NOTE: In <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> and i800 systems running under MicroV+, the 

MCP-4 has a reduced set of functions, <strong>com</strong>pared to systems running with 

a SmartController and the V+ operating system. Functions that are not 

available are noted in this chapter. 

The MCP-4 has a palm-activated, 3-position enable switch that is connected to the remote 

dual channel emergency stop circuitry of the robot. When the system is operating in 

Manual mode, releasing the Enable Switch turns off high power to the robot. 

When a <strong>Cobra</strong> <strong>i600</strong> or i800 system is operating in Auto Mode, the Enable Switch on the 

MCP has no effect on the operation. This means in the Auto mode, the Enable switch does 

not have to be pressed to enable High Power, and releasing the Enable switch while 

running will not turn off High Power. 

When the MCP is not being used, the operator can place it in the special cradle provided 

or remove it from the XMCP connector and install the MCP jumper plug. The cradle 

retaining clip will keep the enabling switch depressed when the pendant is not in use. 

Figure 7-3 on page 89 shows how to place the pendant in its cradle. 

To operate the MCP, put your left hand through the opening on the left-hand side of the 

pendant and use your left thumb to operate the pendant speed bars. Use your right hand 

for all the other function buttons. The various button groupings of the pendant are 

reviewed in this section. 


Chapter 7 - Using the Manual Control Pendant (MCP) 

MCP Enable Switch Function 

3-Position Enable Switch 

The 3-position enable switch on the MCP-4 works as follows (see Figure 7-1): 

Position 1 - switch is not pressed, high power cannot be enabled. (Switch is open.) 

Position 2 - switch is pressed in to the middle position, high power can be enabled. 

(Switch is closed.) 

Position 3 - switch is pressed in past the middle position, high power is removed. (Switch 

is open.) 

3-Position Enable Switch on MCP-4 

Position 1: 

switch is not 

pressed 

Position 2: 

switch is pressed in 

to the middle position 

Position 3: 

switch is pressed in 

past the middle position 

Figure 7-1. 3-Position Enable Switch on MCP-4 


Manual Control Pendant Basics 

EDIT 

DISP 

CLR 

ERR 

CMD 

PROG 

SET 

- + 

USER 

SLOW 

F 1 

J – J 7 12 

F 2 

WORLD TOOL JOINT FREE DEV 

X 

1 

Y 

2 

Z 

3 

T 1 

MAIN 

HALT 

DIS 

RUN 

COMP 

PWR 

HOLD 

PWR 

REC 

NO YES 

DONE 

7 8 9 

4 5 6 

1 2 3 

DEV 

F 3 

0 • DEL STEP 

Depress the 

palm-activated 

enable switch 

Figure 7-2. Holding the MCP 

EDIT 

DISP 

CLR 

ERR 

CMD 

PROG 

SET 

- + 

USER 

SLOW 

F 1 

J – 7 

J 12 

F 2 


RUN 

HOLD 

REC 

DONE 

DIS 

PWR 

NO 

MAIN 

HALT 

COMP 

PWR 

YES 

7 8 9 

4 5 6 

1 2 3 

X 

1 

Y 

2 

Z 

3 

RX 

4 

RY 

5 

RZ 

6 

T 1 

DEV 

F3 

0 • DEL 

STEP 

MCP cradle 

retaining clip 

Figure 7-3. Cradling the MCP 



WARNING: The cradle for the pendant MUST be mounted 

outside of the robot or motion device work envelope. 

Connecting the MCP 

In a <strong>Cobra</strong> <strong>i600</strong>/i800 system, the MCP connects to the XMCP connector on the AIB 

XPANEL cable. See the system cable diagram in Figure 4-1 on page 35 for more 

information. 

The pendant emergency stop switch and the palm-activated enabling switch are wired 

into the emergency stop circuitry. Therefore, either the pendant or the optional pendant 

jumper plug must be attached to this connector. If neither one is connected, you cannot 

enable High Power. If the pendant or jumper plug is removed, High Power is turned off. 

CAUTION: Do not modify or extend the MCP cable. Doing 

this will void the warranty on the MCP. 

WARNING: The Auto/Manual keyswitch on the <strong>Adept</strong> 

Front Panel must be set to Manual if the MCP is to be used 

inside the robot workcell. This enables important safety 

features to protect the operator by limiting the speed of the 

robot. 



MCP Layout 

The major areas of the MCP are shown in Figure 7-4. 

Liquid Crystal 

Display (LCD) 

Soft 

Buttons 

User LED 

EDIT 

DISP 

CLR 

ERR 

CMD 

PROG 

SET 

Predefined 

Function 

Buttons 

Speed 

Bars 

- 

+ 

USER 


MAN 

HALT 

Y 

2 

X 

1 

Manual State 

LEDs 

Emergency Stop 

Switch 

Enabling 

Switch 

SLOW 

F1 

J – 7 

J 12 

F 

2 

RUN 

HOLD 

REC 

DONE 

DIS 

PWR 

NO 

COMP 

PWR 

YES 

7 8 9 

4 5 6 

1 2 3 

Z 

3 

RX 

4 

RY 

5 

RZ 

6 

T 1 

Mode Control 

Buttons 

Joint/Axis 

Control Buttons 

Disable Power 

Button 

Programmable 

Function 

Buttons 

DEV 

F 3 

0 • DEL STEP 

Figure 7-4. MCP Layout 

Mode Control and Joint/Axis Control Buttons 

The mode control and joint/axis control buttons are used to control the robot from the 

pendant. The use of these buttons is covered in “Moving a Robot or Motion Device With 

the MCP” on page 95. 

Speed Bars and Slow Button 

The speed bars and slow button are used primarily to move the robot when it is in manual 

mode. These options are described in “Moving a Robot or Motion Device With the 

MCP” on page 95. 

In some cases, application programs will make special use of the speed bars. See the 

documentation for any application program for details on how it uses these buttons. 



Data Entry Buttons 

NOTE: These features are not available on <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 

systems. 

REC/DONE Button 

DEL Button 

NOTE: This feature is not available on <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 systems. 


SLOW 

REC 

DONE 

NO 

YES 

RX 

4 

F 1 

J – 7 

J 12 

F 

7 8 9 

4 5 6 

1 2 3 

RY 

5 

RZ 

6 

T 

1 

DEV 

F3 

0 • DEL 

STEP 

Figure 7-5. Data Entry Buttons 

Soft Buttons 


Function Buttons 




Emergency Stop From the MCP 

To immediately halt program execution and turn off High Power, press the emergency 

stop switch on the MCP. This switch has the same effect as pressing the emergency stop 

switch on the Front Panel. 

To re-enable High Power after pressing the MCP emergency stop switch, follow this 

process: 

1. Turn the emergency stop switch to the right (clockwise). The switch is spring 

loaded and will return to its normal position. 

2. Depress the enabling switch. High Power can now be re-enabled by pressing the 

COMP/PWR button (mode control group), or by entering the ENABLE POWER 

<strong>com</strong>mand from the keyboard. 

3. Press the blinking High Power button on the Front Panel. High Power is enabled 

and current can flow to the robot motors. 

Re-Enabling Power After Enable Switch Released 

In Automatic Mode 

When operating in Automatic Mode, the Enable Switch is ignored by the system. 

Releasing the Enable switch has no effect on operation. 

In Manual Mode 

When the system is operating in Manual Mode and you release the Enable switch (or go to 

position 3 in the 3-position switch), the system turns off in a controlled manner. This puts 

the system in a different state than when the E-Stop button is pressed. To re-enable high 

power, follow this process: 

1. Depress the enabling switch. 

2. High Power can now be re-enabled by pressing the COMP/PWR button on the 

MCP, or by clicking the Enable Power button in the Robot Control window in 

<strong>Adept</strong> Desktop. High Power is enabled and current can flow to the robot motors. 

Be aware: if a user program is continuously attempting to enable power, as soon 

as the enable switch is pressed, high power turns on and the robot can move. 

Background Mode 

The pendant is in background mode when the USER LED is not lit and none of the 

predefined functions are being used. The USER LED is lit whenever an application 

program is making use of the MCP. The MCP will not return to background mode until 

the program <strong>com</strong>pletes execution or is aborted. The LEDs above the predefined function 

buttons indicate whether the functions are being used. If one of the LEDs is lit, the MCP 

can be returned to background mode by pressing the REC/DONE key (more than one 

press may be necessary). The predefined functions are described in “MCP Predefined 

Function Buttons” on page 94. 

When the MCP is in background mode, the viewing angle of the LCD can be changed. 

There are three different angles. Press the “2”, “5”, or “8” button to select a different 

viewing angle. 



7.2 MCP Predefined Function Buttons 

EDIT 

DISP 

CLR 

ERR 

CMD 

PROG 

SET 

USER 


Figure 7-6. MCP Predefined Function Buttons 

Edit Function 


Display Function 


Clear Error Function 


CMD Function 


Prog Set Function 



Moving a Robot or Motion Device With the MCP 

7.3 Moving a Robot or Motion Device With the MCP 

Introduction 

The MCP is used with a robot or motion device primarily to teach robot locations for use 

in application programs. The MCP is also used with custom applications that employ 

teach routines that pause execution at specified points and allow an operator to teach or 

reteach the robot locations used by the program. The <strong>Adept</strong> AIM software system makes 

extensive use of the pendant for teaching robot locations. 

When you move the robot using the MCP, motion will be in world state, tool state, or joint 

state. 

When moving in World state, directions are sent from the MCP to move the robot in a 

Cartesian coordinate system centered at the base of the robot. When moving in Tool state, 

directions are sent from the MCP to move the robot in a Cartesian coordinate system 

centered at the robot’s end-of-arm tooling location. 

In Joint state, directions are sent from the MCP to move individual robot joints. 

Mode Control Buttons 

The mode control buttons, Figure 7-7, change the state being used to move the robot, 

switch control of the robot between the MCP and application programs, and enable High 

Power (when necessary). 

USER 


- 

+ 

MAN 

HALT 

Y 

2 

X 

1 

RUN 

HOLD 

DIS 

PWR 

COMP 

PWR 

Z 

3 

Emergency Stop Switch 

Figure 7-7. Mode Control Buttons 

The emergency stop switch will stop program execution and turn off High Power. If your 

robot is equipped with brakes, they will be activated. 

COMP/PWR Button 

If High Power is enabled, the COMP/PWR button selects <strong>com</strong>puter mode. If the system is 

in AUTO mode and High Power is disabled, the COMP/PWR button enables High Power 

and selects <strong>com</strong>puter mode. In <strong>com</strong>puter mode, an executing program or the system 

terminal has control of the robot. (If the robot has not been calibrated and High Power is 

turned on, the MCP emergency stop switch LED will be lit, and both the COMP/PWR 

and MAN/HALT LEDs will be off.) 



After you press the COMP/PWR button to enable High Power, the High Power lamp 

begins blinking and the LCD prompts you to press the High Power button. You must 

press this button before within the allowed time (this time is programmable) or High 

Power will not be enabled. 

If the system is in Manual mode and you press the COMP/PWR button to enable High 

Power, you need to take the following actions: 

• release the MCP enable switch 

• press and hold the MCP enable switch (position 2 in MCP-4) 

• press the High Power button within the allowed time. 

MAN/HALT Button 

When there is no program executing, or a program has paused for a pendant teach 

routine, pressing the MAN/HALT button selects manual mode. In manual mode, the 

MCP has control of the robot. If a program is executing, the MAN/HALT button will stop 

program execution (without shutting off High Power). 

Manual mode cannot be entered if High Power is off (E-Stop button LED not illuminated). 

To enable High Power, press the COMP/PWR button. The MCP is in manual mode when: 

1. The LED on the MAN/HALT button is illuminated, and 

2. One of the manual state LEDs is also illuminated (the manual state LEDs indicate 

the type of manual motion that has been selected, either World, Tool, or Joint). 

The system will remain in Manual mode until High Power is turned off or the 

COMP/PWR button is pressed. When you have finished moving the robot manually, 

press the COMP/PWR button to return control to the controller. If a program attempts to 

execute with the MCP in manual mode, the error “Comp mode disabled” will be 

generated. 

When the MAN/HALT button is pressed the first time, the MCP will be in world state. 

Pressing the MAN/HALT button again selects the next state to the right (tool, joint, free), 

eventually wrapping back to the leftmost state (world). If manual mode is terminated and 

reentered (without turning off system power) the last active state is selected. 

DIS PWR Button 

The Disable Power button will shut down High Power to the robot or motion device when 

pressed. Unlike the emergency stop switch, the Disable Power Button initiates a 

controlled stop, where the robot is decelerated under software control. After the robot has 

stopped, power is turned off. 

RUN/HOLD 




Joint/Axis Control Buttons 

The buttons on the far right side are the joint/axis control buttons. When the MCP is in 

manual mode, these buttons select which robot joint will move, or the coordinate axis 

along which the robot will move. The X/1, Y/2, Z/3, RX/4, RY/5, and RZ/6 buttons are 

covered starting on page 98. (The MCP must be in manual mode before a joint/axis 

control button can be selected.) 

STEP Button 


Speed Bars 

In World, Tool, and Joint Mode 

The speed bars are used to control the robot’s speed and direction. The joint(s) that will 

move when the speed bars are pressed depends on the “state” selected with the 

MAN/HALT button. Press the speed bars with your left thumb. Pressing the speed bars 

near the outer ends will move the robot faster; pressing the speed bar near the center will 

move the robot slower. See page 98 for details on positive and negative directions. 

Fast 

Slow 

USER 


- 

+ 

PANIC 

RUN DIS 

HOLD PWR 

MAN 

HALT 

COMP 

PWR 

Z 

3 

Y 

2 

X 

1 

Fast 

Figure 7-8. Speed Bars 

Slow Button 

The slow button selects between the two different speed ranges of the speed bars. When 

the slow button LED is lit, the slower speed range is selected. This slower speed is 25% of 

the normal MCP speed. 



Robot States 

World State 

When world state is selected, movement in the X, Y, or Z direction is parallel to an axis of 

the world coordinate system. Before the speed bars will move the robot, an axis of motion 

must be selected from the manual control buttons. The world coordinate system for a 

SCARA robot is shown in Figure 7-9. If X1 is selected, pressing the “+” speed bar will 

move the robot tool flange in the positive X direction. Pressing the “–” speed bar will 

move the flange in the negative X direction. 

+Z 

X 

1 

X direction 

+RZ (CCW) 

+Y 

Y 

2 

Z 

3 

RX 

4 

RY 

5 

RZ 

6 

T 1 

Y direction 

Z direction 

Rotation 

Gripper Activity 

STEP 

+X 

Figure 7-9. WORLD State (Four-Axis SCARA) 

The T 1 button cycles the gripper solenoids. Press anywhere on the “+” side of the speed 

bar to open the gripper, on the “–” side to close the gripper. 

NOTE: This is the most <strong>com</strong>mon gripper setup. The gripper solenoids 

may be configured so they operate differently (or they may not be 

configured at all). Place your robot in a safe location and cycle the gripper 

to verify which side of the speed bar opens the gripper. Contact <strong>Adept</strong> for 

details on a utility to configure gripper activity. 



Tool State 

When tool state is selected, movement in the X, Y, or Z direction is along an axis of the tool 

coordinate system. The tool coordinate system is centered at the robot tool flange with the 

Z axis pointing away from the flange. On most robots, the positive X axis is aligned with 

the center of the tool flange keyway. Before the speed bars will move the robot, an axis of 

motion must be selected from the manual control buttons. If X1 is selected, pressing the 

“+” speed bar will move the robot tool flange in the positive X direction. Pressing the “–” 

speed bar will move the flange in the negative X direction. 

In a four-axis robot, positive rotation of the gripper (RZ) is clockwise as viewed from 

above. Figure 7-10 shows the tool coordinate system for a four-axis SCARA robot. 

NOTE: Figure 7-10 is drawn with the assumption that the TOOL 

transformation is set to NULL (all values are 0). If a TOOL transformation 

is in effect, the tool coordinate system will be offset and rotated by the 

value of the TOOL transformation. Any motion in tool state will now be 

relative to the offset coordinate system, and not the center of the tool 

flange. 

X 

1 

Y 

2 

Z 

3 

X direction 

Y direction 

Z direction 

+Y 

RX 

4 

RY 

5 

RZ 

6 

Rotation about 

Tool Z axis 

+X 

+RZ 

T 1 

Gripper 

+Z 

STEP 

Figure 7-10. TOOL State (Four-Axis SCARA) 



Joint State 

When joint state is selected, movement is about the axis of the specified joint. Figure 7-11 

shows an <strong>Adept</strong> SCARA robot with three rotational joints (Joints 1, 2, and 4) and one 

translational joint (Joint 3). Positive rotation of joints 1 and 2 is counterclockwise as 

viewed from above. Positive rotation of Joint 4 is clockwise as viewed from above. 

Positive movement of Joint 3 is downward. Before the speed bars will move a joint, the 

correct joint must be selected from the manual control buttons. 

Joint 2 

X 

1 

Joint 1 

Joint 1 

Y 

2 

Z 

3 

RX 

4 

RY 

5 

Joint 2 

Joint 3 

Joint 4 

Joint 3 

Joint 4 

RZ 

6 

T 

1 

STEP 

Figure 7-11. JOINT State (Four-Axis SCARA) 

Free State 



Maintenance 8 

8.1 Periodic Maintenance Schedule 

Table 8-1 gives a summary of the preventive maintenance procedures and guidelines on 

frequency. 

Table 8-1. Inspection and Maintenance 

Item Period Reference 

Check E-Stop, enable and key switches, and barrier 

interlocks 

6 months See Section 8.2. 

Check robot mounting bolts 6 months See Section 8.3. 

Check for signs of oil around of harmonic drive area. 3 months See Section 8.4. 

Lubricate Joint 3 (Z-axis) ball screw 3 months See Section 8.5. 

Replace Encoder battery 

18 months 

to 3 years 

See Section 8.7 

NOTE: The frequency of these procedures will depend on the particular 

system, its operating environment, and amount of usage. Use the times in 

Table 8-1 as guidelines and modify the schedule as needed. 

WARNING: The procedures and replacement of parts 

mentioned in this section should be performed only by 

skilled or instructed persons, as defined in Chapter 2. The 

access covers on the robot are not interlocked – turn off 

and disconnect power if covers have to be removed. 


Chapter 8 - Maintenance 

8.2 Checking of Safety Systems 

It is re<strong>com</strong>mended that tests be done every six months. 

1. Test operation of: 

• E-Stop button on Front Panel 

• E-Stop button on MCP 

• Enabling switch on MCP 

• 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. 

8.3 Checking Robot Mounting Bolts 

Check the tightness of the base mounting bolts every 6 months. Tighten to 85 N•m 

(50 ft-lb). Also check the tightness of all cover plate screws. 

8.4 Check Robot for Oil Around Harmonic Drive 

The <strong>Cobra</strong> i-series and s-series robots use oil in the harmonic drive <strong>com</strong>ponents for 

lubrication. It is re<strong>com</strong>mended that you periodically inspect the robot for any signs of oil 

in areas outside of the harmonic drive. Check these locations: 

• the area around Joint 1 

• the area around Joint 2 

• inside the base of the robot, by opening the AIB chassis and inspecting internally. 

Be sure to remove all power to the robot before opening the AIB chassis. 

Contact <strong>Adept</strong> if you find any signs of oil in these areas. 


Lubricate Joint 3 Ball Screw 

8.5 Lubricate Joint 3 Ball Screw 

Required Grease for the Robot 

Ball Screw/Spline Assembly Grease 

LG-2 Lubricating Grease 

Lithium Soap, Synthetic Hydrocarbon 

<strong>Adept</strong> part number: 85139-00002 

CAUTION: Using improper lubrication products on the 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong> or i800 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 six screws located on the sides and top 

of the cover. Carefully remove the cover. 

3. Move Joint 3 to the top of its travel. Remove any existing grease with a soft cloth. 

4. Using a syringe, apply a small bead of grease to the Joint 3 ball screw grooves (see 

Figure 8-1 on page 104). 

5. Move Joint 3 to the bottom of its travel. Remove any existing grease with a clean, 

lint-free, soft cloth. 

6. Apply a thin film of grease to any grooves of the ball screw that you did not reach 

in step 4. 

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

8. Replace the outer link cover. 

WARNING: When the Outer link cover is removed, you 

see the label shown in Figure 2-3 on page 19. 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 special 

software and tools. 



Joint 3 Ball Screw 

Lubrication Points 

A 

A 

Joint 3 Ball Screw 

Lubrication Points 

A 

A 

Upper Quill Grease Locations 

Lower Quill Grease Locations 

Quill Shaft 

Vertical Groove 

Lube Point A 


Lube Point B 

Top View Looking Down 

NOTE: 

Apply grease to the 

three vertical grooves 

and the spiral groove 


Lube Point C 

Section A-A 

Figure 8-1. Lubrication of Joint 3 Quill 


Replacing the SmartAmp AIB Chassis 

8.6 Replacing the SmartAmp AIB Chassis 

This procedure provides details on how to replace the SmartAmp AIB chassis on a <strong>Cobra</strong> 

i-series robot. 

CAUTION: Follow appropriate ESD procedures during the 

removal/replacement phases. 

Removing the SmartAmp AIB Chassis 

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

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

3. Disconnect the 24VDC supply cable from the chassis +24VDC input connector. 

See Figure 3-3 on page 34 for locations of connectors. 

4. Disconnect the 200/240VAC supply cable from the chassis AC Input connector. 

5. Disconnect the AIB XPANEL cable from the XPANEL connector. 

6. Disconnect any other cables, which may be connected to the chassis, such as XIO, 

RS-232, or any others. 

7. Using a 5 mm Allen key, carefully unscrew the chassis securing screw. See Figure 

8-2. Note that the screw does not need to be <strong>com</strong>pletely removed in order to 

remove the chassis, as this screw is captured on the chassis heat sink. 

Securing Screw on 

SmartAmp AIB 

Figure 8-2. Securing Screw on SmartAmp AIB Chassis 

8. While holding the chassis heat sink, carefully and slowly lower the chassis down 

(see Figure 8-3 on page 106), so that enough access is available to remove the 

internal cables. The chassis can be laid flat or placed to the right side of the robot 

for better access. 



Figure 8-3. Opening and Removing AIB Chassis 

9. Disconnect the “white” amplifier cable from the amplifier connector located on 

the chassis bracket. See Figure 8-4. 

Amplifier Connector 

J1 

PMAI Board 

J11 

J27 

Figure 8-4. Connectors on AIB Chassis 

10. Carefully disconnect the J1 cable from the J1 connector on the PMAI, by 

disengaging the securing latches. 





13. Using a 5MM Allen key, disconnect and remove the ground wire from the chassis. 

Keep the screw for reassembly later. See Figure 8-5 on page 107. 


Replacing the SmartAmp AIB Chassis 

Figure 8-5. Ground Screw on AIB Chassis 

14. Carefully remove the chassis from the robot, and place it aside. Tag it with the 

appropriate fault diagnosis faults/errors and robot serial number information. 

Installing a New SmartAmp AIB Chassis 

1. Carefully remove the new chassis from its packaging, check it for any signs for 

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 5mm Allen key, carefully connect the ground wire to the chassis. 

4. Carefully connect the J27 cable to the J27 connector on the PMAI, and engage the 

securing latches. 





7. Carefully connect the “white” amplifier cable to the amplifier connector located 

on the chassis bracket. 



Groove in robot base 

for AIB chassis 

placement. 

Figure 8-6. Installing AIB Chassis in Robot Base 

8. Carefully insert the chassis into the robot base in the groove at the bottom of the 

base - see Figure 8-6. 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. 

9. Once the chassis is in place, use a 5 mm Allen key to tighten the chassis securing 

screw. See Figure 8-2 on page 105 for details. 

10. Connect the 200/240VAC supply cable to the chassis AC Input connector. 

11. Connect the AIB XPANEL cable to the XPANEL connector. 

12. Connect any other cables, which may be connected to the chassis, such as XIO, 

RS-232, or any others. 

13. Connect the 24VDC supply cable to the chassis +24VDC input connector. 

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

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

16. Once the system has <strong>com</strong>pleted booting, test the system for proper operation. 


Replacing Encoder Battery 

8.7 Replacing Encoder Battery 

The data stored by the encoders is protected by a 3.6 V lithium backup battery located in 

the base of the robot. 

Battery Replacement Time Periods 

If the robot is kept in storage and not in production, or the robot is turned off (no 24VDC 

supply) most of the time, then the battery should be replaced every 18 months. 

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 three years. If, for example, a robot is 

typically turned off only on weekends, the battery would need to be replaced every four 

years. 

Battery Replacement Procedure 

1. Obtain the replacement battery. <strong>Adept</strong> part number: 02704-000. 

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

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

4. Disconnect the 24VDC supply cable from the robot +24VDC input connector. See 

Figure 3-3 on page 34 for locations of connectors. 

5. Disconnect the 200/240VAC supply cable from the robot AC Input connector. 

6. Using a 5 mm Allen key, carefully unscrew the chassis securing screw. See Figure 

8-2 on page 105. Note that the screw does not need to be <strong>com</strong>pletely removed in 

order to remove the chassis, as this screw is captured on the chassis heat sink. 

7. While holding the chassis heat sink, carefully and slowly lower the chassis down 

(see Figure 8-3 on page 106), so there is access to the battery. See Figure 8-7. 

Encoder Battery 

Figure 8-7. Location of Encoder Battery 



8. The battery cable assembly has two sets of connectors. Locate the secondary 

battery cable in the wire bundle in the base area. 

9. Place the new battery next to the original one, but do not disconnect the original 

one. 

10. Connect the new battery to the connectors on the secondary battery cable. Make 

sure to verify the positive and negative connections are correct. 

11. Once the new battery is connected, you can disconnect and remove the original 

battery. 

12. Place the new battery in the original location on the base of the robot. 

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


Technical Specifications 9 

9.1 Dimension Drawings 

183 

417 

200 

Required 

clearance 

to open 

AIB Chassis 

934 

888 

46 

37 

387 

342 

177 

31 

Required 

cable 

clearance 

0 

234 

0 

325 

600 

Figure 9-1. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/s600 Top and Side Dimensions 


Chapter 9 - Technical Specifications 

183 

417 

200 

Required 

clearance 

to open 

AIB Chassis 

918 

894 

46 

37 

398 

342 

31 

Required 

cable 

clearance 

188 

0 

234 

0 

425 

800 

Figure 9-2. <strong>Adept</strong> <strong>Cobra</strong> i800/s800 Top and Side Dimensions 


Dimension Drawings 

<strong>Cobra</strong> s/<strong>i600</strong> 2X 

<strong>Cobra</strong> s/i800 2X 

+.10 

∅3.0 

-.03 

+.10 

∅3.0 

-.03 

6 

7 

54 

45 

<strong>Cobra</strong> s/<strong>i600</strong> 4X M4x0.7-6H 

<strong>Cobra</strong> s/i800 4X M4x0.7-6H 

8 

10 

10 

Figure 9-3. Dimensions of the Camera Bracket Mounting Pattern 



3.0 mm 

(0.12 in.) 

12.0 mm 

(0.47 in.) 

20.0 mm 

(0.79 in.) 

See Detail A 

43 mm 

(1.69 in.) 

Dowel Pin Hole 

∅ 6.0 mm 

+.01 mm 

– 0 mm 

(0.2362 in.) 

(+.0005 in.) 

(– 0 in.) 

45˚ 

30˚ 

∅ 41.15 mm 

(∅ 1.620 in.) 

+.03 mm 

–.00 mm 

(+.001 in.) 

(–.000 in.) 

∅ 63.0 mm (2.48 in.) 

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 

4.14 mm 

(0.163 in.) 

1.5 mm 

(0.059 in.) 

6.80 mm 

(0.268 in.) 

Detail A 

25˚ 

-C- 

-A- 

-B- 

Figure 9-4. Tool Flange Dimensions for <strong>Adept</strong> <strong>Cobra</strong> Robots 



25 

4X M4x0.7 - 6H 6 

105 

Inner Link 

External Mounting 

Locations 

60 

4X M4x0.7 - 6H 8 

Outer Link 

External Mounting 

Locations 

105 

Figure 9-5. External Tooling on Top of Robot Arm 



34 

76 - <strong>Cobra</strong> s/<strong>i600</strong> 

135 - <strong>Cobra</strong> s/i800 

90 

Outer Link - Bottom View 

4X M4x0.7-6H 

8 

Figure 9-6. External Tooling on Underside of Outer Link 



Maximum Radial Reach 

Functional Area 

Maximum Intrusion 

600 mm (23.62 in.) 

Contact Radius 

647 mm (25.50 in.) Minimum 

Radial 

Reach 

162.6 mm 

(6.40 in.) 

105˚ 

105˚ 

150˚ 

150˚ 

Cartesian Limits 

300 mm (11.8 in.) 

Figure 9-7. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/s600 Robot Working Envelope 



Maximum Intrusion 

Contact Radius 

847.3 mm (33.36 in.) 

105˚ 

Maximum Radial Reach 

Functional Area 

800 mm (31.50 in.) 

Minimum 

Radial 

Reach 

163.6 mm 

(6.44 in.) 

105˚ 

157.5˚ 157.5˚ 

Cartesian Limits 

300 mm (11.8 in.) 

Figure 9-8. <strong>Adept</strong> <strong>Cobra</strong> i800/s800 Robot Working Envelope 


Robot Specifications 

9.2 Robot Specifications 

Table 9-1. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot Specifications a 

Description <strong>i600</strong> Robot i800 Robot 

Reach 600 mm (23.6 in) 800 mm (31.5 in) 

Payload - rated 2.0 kg (4.4 lb) 2.0 kg (4.4 lb) 

Payload - maximum 5.5 kg (12.1 lb) 5.5 kg (12.1 lb) 

Moment of Inertia 

Joint 4 - 450 kg-cm² 

(150 lb-in²) - max 

Joint 4 - 450 kg-cm² 

(150 lb-in²) - max 

Downward Push Force - Burst 343 N (77 lb) - maximum 298 N (67 lb) - maximum 

(no load) 

Lateral/Side Push Force - 178 N (40 lb) - maximum 133 N (30 lb) - maximum 

Burst 

<strong>Adept</strong> Cycle - Burst (no J4 rotation) b 

0 kg 0.42 sec 0.48 

2 kg 0.42 sec 0.54 

5.5 kg 0.53 sec 0.64 

<strong>Adept</strong> Cycle - Burst (180° J4 rotation) 

0 kg 0.42 sec 0.48 

2 kg 0.42 sec 0.54 

5.5 kg 0.59 sec 0.76 

<strong>Adept</strong> Cycle - Sustained (no J4 rotation) b 

0 kg 0.42 sec at 20°C 

0.48 sec at 40°C 

2 kg 0.45 sec at 20°C 

0.51 sec at 40°C 

5.5 kg 0.58 sec at 20°C 

0.64 sec at 40°C 

<strong>Adept</strong> Cycle - Sustained (180° J4 rotation) 

0 kg 0.42 sec at 20°C 

0.48 sec at 40°C 

2 kg 0.45 sec at 20°C 

0.51 sec at 40°C 

5.5 kg 0.80 sec at 20°C 

0.86 sec at 40°C 

Repeatability 

0.48 sec at 20°C 

0.51 sec at 40°C 

0.54 sec at 20°C 

0.54 sec at 40°C 

0.70 sec at 20°C 

0.70 sec at 40°C 

0.48 sec at 20°C 

0.48 sec at 40°C 

0.54 sec at 20°C 

0.61 sec at 40°C 

0.77 sec at 20°C 

0.91 sec at 40°C 

x, y ±0.017 mm (±0.00067") ±0.017 mm (±0.00067") 

z ±0.003 mm (±0.00012") ±0.003 mm (±0.00012") 

Theta ±0.019° ±0.019° 



Table 9-1. <strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot Specifications a (Continued) 

Description <strong>i600</strong> Robot i800 Robot 

Joint Range 

Joint 1 ±105° ±105° 

Joint 2 ±150° ±157.5° 

Joint 3 210 mm (8.3") 210 mm (8.3") 

Joint 4 ±360° ±360° 

Joint Speed (maximum) 

Joint 1 386°/sec 386°/sec 

Joint 2 720°/sec 720°/sec 

Joint 3 1,100mm/sec (43 in/sec) 1,100mm/sec (43 in/sec) 

Joint 4 1200°/sec 1200°/sec 

Encoder type 

Absolute 

Robot Brakes 

Joints 1, 2, and 3: Dynamic 

Joint 4: Electric 

Airline pass-through 

6 mm diameter (2), 4 mm diameter (3) 

(quantity) 

Electrical pass-through 

24 conductors (12 twisted pair) 

DeviceNet pass-through 

One available 

Weight (without options) 41 kg (90 lb) 43 kg (95 lb) 

a Specifications subject to change without notice. 

b The robot tool performs continuous path, straight-line motions 25 mm (1 in.) up, 305 mm (12-in.) over, 

25 mm (1 in.) down, and back along the same path. COARSE is enabled and BREAKs are used at each 

end location. Not achievable over all paths. 

Table 9-2. Softstop and Hardstop Specifications 

<strong>Cobra</strong> <strong>i600</strong>/s600 

<strong>Cobra</strong> i800/s800 

Joint 

Softstop 

Hardstop – 

Approximate 

Softstop 

Hardstop – 

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 


Index 

Symbols 

.NET Framework, installation 39 

Numerics 

200/240VAC connector 34 

24VDC connector 34 

24VDC power 

connecting to robot 40 

making cable 41 

mating connector 41 

specifications 40 

A 

AC power 

connecting to robot 43 

diagrams 44 

making cable 45 

mating connector 45 

robot power consumption, typical 43 


turning on 67 

<strong>Adept</strong> DeskTop 

installing 39 

jog pendant menu 71 

Setup Wizard 39 

starting up 67 

<strong>Adept</strong> Document Library 16 

adjustable hardstops 

installation 81 

air lines 

user, in robot 75 

B 

Background mode 

on MCP 93 

Brake Release button 51 

brakes 

description 51 

releasing J3 for manual movement 51 

Breakout Cable, XIO 57 

C 

cable and parts list 36 

cable diagram for system 35 

camera bracket mounting pattern 

dimensions 113 

Comp/Pwr button 

on MCP 96 

Configuration Manager utility 

for modifying Joint 1 limits 81 

for modifying Joint 2 limits 85 

connectors on robot, description 34 

Customer Service assistance 16 

D 

DC power, see 24VDC power 

diagnostic panel, fault codes 50 

Diagnostics Wizard 

to enable power 68 

Digital I/O 

input specifications 54 

on robot XIO connector 53 

output specifications 56 

signal designations 53, 58 

dimensions 

camera bracket mounting pattern 113 

<strong>Cobra</strong> <strong>i600</strong>/s600 robot 111 

<strong>Cobra</strong> i800/s800 robot 112 

external equipment mounting 115 

robot mounting holes 32 

user flange 114 

Document Library CD-ROM 16 

dowel pin, for keying on end-effectors 73 

E 

electrical lines, user, in robot 76 

emergency situation, what to do 27 

emergency stop 

from MCP 93 

Emergency Stop circuit 


diagram 62 

Emergency Stop switch 

on Front Panel 52 

on MCP 95 

enable power 

using <strong>Adept</strong> DeskTop 70 

using Diagnostics Wizard 68 

encoder battery, replacing 109 

end-effector 

dowel pin 73 

grounding 73 


Index 


environmental requirements 31 

external equipment 

mounting locations on robot 76, 115 

F 

facility overvoltage protection 43 

fault codes, on diagnostic panel 50 

Front Panel 

connectors and indicators 52 

G 

grounding 

at AIB 47 

at robot base 47 

robot-mounted equipment 48 

H 

hardstops 


hardstops, adjustable, for J1, J2 81 

High Power On/Off Switch, on Front 

Panel 52 

How Can I Get Help? 16 

I 

impact and trapping points 20 

installation 

.NET Framework 39 

24VDC power to robot 40 

AC power to robot 46 

<strong>Adept</strong> DeskTop 39 

adjustable hardstops 81 

end-effectors 73 

overview 15 

robot 32 

solenoid kit 77 

user-supplied safety equipment 48 

verifying 66 

intended use of the robots 22 

interface panel on robot 34 

IO Blox device, description 54 

J 

jog pendant menu, in <strong>Adept</strong> DeskTop 71 

Joint 1 adjustable hardstops 81 

Joint 2 adjustable hardstops 83 

joint state 100 

with SCARA robot 100 

L 

lubrication 

Joint 3 103 

type of grease for robot 103 

M 

maintenance 

lubricating Joint 3 103 

Man/Halt button 

on MCP 96 

Manual Control Pendant, see MCP 

manual states 

joint 100 

tool 99 

world 98 

Manual/Automatic Mode switch, on Front 

Panel 52 

MCP 

mode control buttons 95 

slow button 91 

speed bar 91 

viewing angle, on MCP 93 

mechanical specifications 119 

modifications 

acceptable 23 

unacceptable 23 

mounting hole pattern, for robot 32 

mounting locations for external 

equipment 76 

muted safety gate E-Stop circuitry 64 

O 

overvoltage protection 

facility 43 

P 

parts list 36 

performance specifications, robot 119 

Power On LED, on Front Panel 52 

precautions and required safeguards 20 

protection 

against unauthorized operation 26 

facility overvoltage 43 

Q 

qualification of personnel 25 

R 

remote Manual Mode control 64 

remote MCP connections on XMCP 

connector 61 


Index 

repacking for relocation 30 

requirements 

environmental 31 

facility 31 

robot system operating environment 31 

robot 

AC power consumption, typical 43 


diagnostic panel fault codes 50 


grounding on AIB 47 

grounding on robot base 47 

intended uses 22 

interface panel 34 

joint motions 14 

modifications 23 

mounting bolt specifications 33 

mounting hole pattern 32 

mounting procedure 32 

programming 71 

solenoid kit 77 


status LED 49 

transport and storage 29 

transportation pallet 29 

unpacking and inspection 30 

user connections 75 

work envelope 117, 118 

working area 25 

robot states in manual mode 

joint 100 

tool 99 

world 98 

robot system operating environment 

requirements 31 

RS-232 connector 34 

S 

safety 

aspects while performing 

maintenance 26 

during maintenance 26 

equipment for operators 26 

impact and trapping points 20 

required safeguards 20 

sources for information 21 

safety barriers 20 

safety equipment for operators 26 

safety requirements for additional 

equipment 24 

shipping and storage 29 

shipping information 29 

slow button, on MCP 91, 97 

SmartAmp AIB 

chassis replacement 105 


internal connectors 106 

SmartServo connector 34 

softstops 


modifying for Joint 1 81 

modifying for Joint 2 85 

solenoid kit 


sound emissions 24 

sources for international standards and 

directives 21 

speed bar 

on MCP 91, 97 

Starter Kit, description 36 

status LED, description 49 

storage information 29 

system 

cable diagram 35 

operating environment requirements, 

robot 31 

startup using Diagnostics Wizard 68 

turning on 66 

System 5V Power On LED, on Front Panel 52 

T 

thermal hazard 25 

tool flange dimensions 114 

tool state 

and tool transformation 99 

on MCP 99 

transport and storage 29 

transporting the robot 24 

U 

unpacking 

and inspecting <strong>Adept</strong> equipment 30 

information 30 

user 

air lines, in robot 75 

electrical lines, in robot 76 

user flange 



V 

viewing angle 

LCD panel, on MCP 93 


Index 

W 

warning labels, location 18 

work envelope 

<strong>Cobra</strong> <strong>i600</strong>/s600 117 

<strong>Cobra</strong> i800/s800 118 

working areas 25 

X 

XFP connector on Front Panel, description 52 

XFP connector on robot, contacts 60 

XIO Breakout Cable 


wire chart 58 

XIO connector 

description and location 34 

digital input circuit specifications 54 

digital output circuit specifications 56 

signal designations 53 

XIO Termination Block, description 54 

XMCP connector 

remote MCP connections 61 

XPANEL connector 34 

XSLV connector 34 

XUSR connector, contacts 59 


Revision History 

<strong>Adept</strong> <strong>Cobra</strong> <strong>i600</strong>/i800 Robot User’s <strong>Guide</strong>, part number 03589-000 

First release, Rev A, March 2004 

Second release, Rev B, July 2004 

Changes from Rev A: 

•In Figure 1-2 on page 14, added revised drawing of <strong>Cobra</strong> s600 robot. 

• Added Figure 2-3 on page 19 showing Encoder Cable Warning Label. 

•In Figure 4-1 on page 35, deleted parts list and moved to following page. 

•In Section 4.2 on page 36, moved parts list from previous page, expanded 

contents. Deleted section on First Time Buyer’s Kit. 

•In Section 4.6 on page 39, revised software installation for <strong>Adept</strong> Desktop 2.1 

• Added Table 4-3 on page 40 with information on 24VDC power supplies. Also 

added Caution on selecting correctly rated supply. 

• Added Figure 4-4 on page 42 with details on using shielded 24VDC cable. 

•In Section 4.9 on page 47, added information on new ground point on robot base. 

•On page 54, added section on optional DIO products, including XIO Breakout 

Cable, XIO Termination Block, and IO Blox device. 

•In Table 5-4 on page 54, revised specs for operational voltage range, “On” state 

voltage range, operational current range, and “On” state current range. 

•On page 57, added section on the XIO Breakout Cable. 

•On page 68, added section about enabling power using the Diagnostics Wizard. 

•In Section 6.6 on page 81, added details on Installing Adjustable Hardstops. 

•On page 80, revised step 17 to include default gripper signals, and added a second 

SIGNAL <strong>com</strong>mand. 

•On page 97, removed section on STEP button function. 


P/N: 03589-000, Rev B 

3011 Triad Drive 

Livermore, CA 94551 

925•245•3400

Download Adept Cobra i600 User's Guide - pulsar.com.tr

Create successful ePaper yourself

Delete template?

Save as template?