User Manuals: CRS A255 Robot Arm

Manuals and User Guides for CRS A255 Robot Arm. We have 2 CRS A255 Robot Arm manuals available for free PDF download: Service Manual, User Manual

CRS A255 Service Manual (272 pages)

Brand: CRS | Category: Robotics | Size: 6 MB

Table of Contents
6
Introduction
17
Robot Arm Schematic
17
Figure 1-1 Profile of the Robot in the "READY" Position Viewed from the
17
Figure 1-2 C500 Controller
17
Figure 1-3 Serial Teach pendant
17
Safety Summary
18
General Safety Rules
18
Safety and Operation Checks
19
Safety Checks for Working Within the Robot's Workspace
20
Serial Number Location
21
Service Tools Required
22
Controller Operation
23
Introduction
23
Power-Up Sequence
23
Figure 2-1 Initialization Sequence
23
Default Power-Up Parameters
25
Table 2-1 Serial Default Values
25
Initialization Logic Sequence
26
User Memory Allocation
28
Figure 2-3 Auto Execute Sequence
28
Command Processing Loop
29
Figure 2-4 Command Processing Loop
29
Immediate Mode
30
Figure 2-5 Immediate Mode
30
Auto Execute Sequence
31
Requirements for Arm Power
31
Arm Power Checks
32
Requirements for Interactive Communication
32
Interactive I/O
33
Important Codes
34
Host Interface Communication (ACI Operation)
35
Communication Errors Reported at the Host
35
Table 2-2 ACI Communication Error Source Codes
35
Communication Errors Reported at the Controller
36
Table 2-3 ACI Communication Error Source Codes (RAPL-II End)
36
Digital I/O Operation
37
Servo Operation
38
Command Interpreter
38
Figure 2-6 Servo Block Diagram
38
Command Generator
39
Position Command
39
Position Error
39
Positional Gain
40
Command Signal
40
D/A Converter
41
Power Amplifier
41
Motor
41
Encoder
42
Discriminator/ Hardware Counter
42
Figure 2-7 Optical Encoder Schematic
42
Integrator
43
Actual Position
43
Example of Servo Operation
43
Homing Procedure
45
Home Command
45
Table 2-4 RAPL-II Software HOME and CALIBRATION Commands
45
Zero Position
46
Zero-Cross Pulse
46
Calibration Position
46
Calibration Array
46
Home Range
47
Figure 2-8 Alignment Test Strip
47
Homing Errors
48
HOME Sequence Errors
48
Gripper Operation
50
Air Gripper
50
Servo Gripper
50
Software Diagnostics
51
RAPL-II Memory Organization
51
Memory Checksums
53
RAPL-II Error Messages
55
The @@DIAG Command
55
WHERE" Commands
55
Electronics Description
57
A255 Controller Electronics
57
Figure 3-12 PWM Amplifier
57
Table 3-1 A255 Controller Electronic Modules
57
Controller Board
58
Controller Board Components
59
Socketed Components
60
Table 3-2 C500 Controller Board Socketed Components
60
Table 3-3 JP25 Test Strip (Condition Signals)
61
Controller Board Connectors
62
Figure 3-2 Controller Board Connector Locations
62
Table 3-4 Controller Board Connectors Legend
63
Table 3-5 AB-2 I/O Board Interconnect
64
Table 3-6 Communications Port Connector
66
Table 3-7 Teach pendant Connector
67
Table 3-8 Transputer up Connector
68
Table 3-9 Transputer down Connector
69
Table 3-10 AB -1 Connector
70
Table 3-11 Encoder Connector
72
Table 3-12 Encoder Power Connector
74
Table 3-13 Amp Expansion Connector
75
Table 3-14 Power Supply Connector
76
Table 3-15 Auxiliary Board Logic Power Input Connector
77
Auxiliary Board
78
Auxiliary Board DIP Switch
78
Diagnostic Led's
78
Figure 3-3 DIP Switches 2 and 3 on
78
Table 3-16 Dip Switch Settings for the A255
78
Table 3-17 Auxiliary Board Diagnostic Led's
78
Auxiliary Board Connectors
79
Table 3-19 CB-1 I/O Board Interconnect
81
Table 3-20 CB-2 I/O Board Interconnect
83
Table 3-21 Display/Control Connector
85
Table 3-22 Linear Amp Vcom Connector
86
Table 3-23 Home Switch/Brake Connector
87
Table 3-24 Relay/Power Fuse Connector
88
Table 3-25 Air Gripper/Brake Power Connector
89
Table 3-26 VO3PWM
90
Table 3-27 General Purpose I/O Connector
91
Table 3-28 SYSIO Connector
93
Table 3-29 Ax1-3 Circuit Breaker Connector
94
Table 3-30 AX4-6 Circuit Breaker Connector
95
Table 3-31 Linear Amp Power Supply out Connector
96
Table 3-32 PWM Amp Power Supply out Connector
97
Table 3-33 High Voltage Power Supply in Connector
98
Table 3-34 Power Supply Connector
99
Controller AC Power System
100
Soft Start Board
100
Table 3-35 Soft Start Board J2
100
Table 3-36 Soft Start Board J1
100
Table 3-37 Soft Start Board J4
100
Table 3-38 Soft Start Board J3
100
Figure 3-5 Primary Power Circuit A255
101
Figure 3-6 Primary Power Circuit T265/A465/T475
102
Figure 3-7 A255 Motor Power
103
Figure 3-8 A255 Position Feedback from Encoders
104
Figure 3-9 A255 Connections to the Auxiliary Board (AB)
105
Figure 3-10 A255 Connections to the Controller Board (CB)
106
Computer Power Supply and Amplifier Power
107
Power Supply
107
Table 3-39 Power Supply J1
107
Table 3-40 Power Supply J2
107
Power Filter Board
108
Table 3-41 Power Filter Board J1
108
Table 3-42 Power Filter Board J2
108
Table 3-43 Power Filter Board J3
108
Table 3-44 Power Filter Board J4
108
Table 3-45 Power Filter Board J5
108
Linear Amp/Brake/Gripper Power
109
Power Supply Function of Auxiliary Board
109
Amplifier Electronics
110
Linear Amplifier Module
110
Linear Amplifier Connectors
111
Table 3-46 Amplifier Input Connector Pin-Out
111
Table 3-47 Amplifier Power Supply Connector Pin-Out
111
Table 3-48 Motor Output Connector Pin-Out
111
PWM Amplifiers
112
Table 3-49 T265 Track System Configuration
112
PWM Amplifier Connectors
113
Table 3-50 PWM - 4 Pin Molex Connector
113
Table 3-51 PWM - 22 Pin Signal Connector
113
T265 Track Connectors
114
Table 3-52 T265 Track Connectors
114
Front Panel Display Board
115
Figure 3-13 Front Panel Function Buttons
115
Table 3-53 E-Stop Connector
115
Front Panel Display Board Connectors
116
Table 3-54 Front Panel Display Board Connector J1
116
Table 3-55 Front Panel Display Board Connector J2
116
Encoder Connector Board
117
Table 3-56 Encoder Connector Board J1
117
Table 3-57 Encoder Connector Board J2
118
Table 3-58 Encoder Connector Board J3
118
Wiring and Connectors
119
Introduction
119
Front Panel Connectors
119
Figure 4-1 A255 Controller Front Panel Connectors with Access Door
119
Teach pendant Connector
120
Table 4-1 Teach pendant Connector Pin-Out
120
Communication Serial Connector
121
Table 4-2 Communication Serial Connector Pin Functions
121
Controller Rear Panel Connectors
122
Figure 4-2 C500 Controller Rear Panel Connectors
122
System I/O (SYSIO)
123
Table 4-3 System I/O (SYSIO) Pin Descriptions
123
Figure 4-3 C500 SYSIO Connector Description
124
General Purpose I/O (GPIO)
125
Table 4-4 General Purpose I/O (DD5OS Connector)
125
Figure 4-4 C500 GPIO Connector Description
127
Robot Feedback Connector
128
Motor Power Connector
130
Table 4-7 Expansion Amplifier Connector Pin Signal Descriptions
131
Arm Wiring Harnesses
132
Encoder Connectors
133
External Connectors
134
Arm Signal Connector Schematic
136
Figure 4-6 Arm Signal Connector Schematic
136
Diagnostics and Troubleshooting
137
How to Use this Chapter
137
Arm Power Problems
138
Arm Power Cannot be Turned on
138
Arm Power Turns off with Error "40" Display
139
Arm Power Indicator on Front Panel Comes on but All Joints of the Arm Stay Limp
140
ARM POWER" Error Message Seen but Arm Power Indicator Still on
141
Arm Power Indicator Comes On, One Axis Stays Limp, no "AXIS OUT" Error
141
Arm Power Indicator Comes On, One Axis Stays Limp
142
AXIS OUT" Error When the Axis in Question Is Moved
142
Servo Problems
143
One Axis Runs Away as Soon as Power Is Applied
143
One Axis Limp until Command Given, then Runs Away
144
All Axes Run Away Simultaneously
145
Robot Position Changes in "Jumps" of One Axis
145
Robot Position Changes Slowly in One Axis (Drift)
146
Homing Problems
147
056 Checksum Errors
147
101 Sequence Error
147
034-39 Home Fail Error
147
Digital I/O Problems
148
Input from External Device Errors
148
Output to an External Device
149
Serial Communication Problems
150
Recurring Memory "Failures
151
Servo Gripper Problems
152
Diagnostic for Gripper Recently Installed
152
Standard Diagnostic
152
Connector Visual Inspection
153
Servo Gripper Fuse Test
153
Motor Driver Output Test
154
Finger Position Feedback Test
155
Finger Position Feedback Continuity Test
156
Servo Gripper Motor Test
157
Servo Potentiometer Check
157
Set Servo Potentiometer Position
158
Air Gripper Problems
159
Controller Boot-Up Problems
160
Serial Teach pendant Problems
161
Serial Teach pendant Parameters
162
Table 5- 1 Serial Teach pendant Parameter Settings
162
Function Key Settings
163
Table 5- 2 Serial Teach pendant Function Key Settings
163
AC Power Problems
164
Service Repair Checks
165
Figure 3-1 Controller Board
166
Figure 3-11 Linear Amplifier Module
169
6-1 Controller External Checks
170
Table 6-1 Front Panel Fuses
174
6-2 Controller Internal Visual Checks
175
Table 6-2 Socketed Components on the Controller Board
175
Table 6-3 Socketed Components on the Auxiliary Board
175
Table 6-4 Internal Fuse Location
177
6-3 Controller Internal Function Checks
183
Table 6-5 LED Locations
183
Table 6-6 Input Signals
197
Wiring Diagnostic Checks for the Controller, Arm, and Umbilical Cables
205
Table 6-7 Signal Feedback Signals Directly from Encoders
206
Table 6-8 Breaker Circuit Pin Measurements
210
Table 6-9 Proximity Sensor Wiring on Auxiliary Board
212
Table 6-10 Proximity Sensor Location on Controller Board
212
6-5 Controller Board Servo Loop Signal Checks
215
Table 6-11 Chip Pins
215
Table 6-12 JP25 Test Strip (Condition Signals)
217
Table 6-13 Feedback Signals Directly from Encoders (Unconditioned Signals)
218
6-6 Controller Module Replacement Procedures
220
6-7 Software Checks
227
Reload Firmware
228
Table 6-14 Serial Command Display
231
Table 6-15 Displayed Value Definitions
231
6-8 Amplifier Servo Signal Level Checks
233
Table 6-16 Amplifiers Settings for the A255
237
6-9 Arm Electronic Checks
240
Mechanical Checks and Adjustments
241
A255 Robot Arm General Schematic
241
Figure 7-1 A255 Robot Arm General Schematic
241
Mechanical Maintenance Schedule
242
A255 Robot Arm and Controller
242
Table 7-1 Scheduled Mechanical Maintenance
242
A265 Track Maintenance
243
Table 7-2 T265 Track Scheduled Mechanical Maintenance
243
Chain Tension Adjustment
244
Important Note
244
Wrist Gears
245
Wrist Gear Mesh Adjustment
245
Wrist Gear Lubrication
247
Wrist Drive Gears Mesh Adjustment
248
Check Motor Brush Wear
250
Encoder Alignment
251
Introduction
251
Square Wave
251
Axial Adjustment of the Disk Relative to the Stator
252
Calibrating the Arm
253
Restoring Factory Calibration Values
253
Recalibrating the Robot Arm
254
Calibrating an Extra Axis
259
Cleaning
260
Cleaning the Controller's Fan Filter
260
Mechanical System Drawings
261
Mechanical Drawings
261

CRS A255 User Manual (80 pages)

Robot Arm

Brand: CRS | Category: Robotics | Size: 2 MB

Table of Contents
5
Chapter 1 Introduction

7
- Optional Equipment
  8
Chapter 2 Specifications

9
- Range of Motion, Dimensions, and Weight
  10
- Reach
  12
- Torque Ratings
  14
- Joint Speeds and Acceleration Rates
  14
- Payload
  15
- Resolution
  17
- Brakes
  18
- Gripper
  19
Chapter 3 Safety Precautions

21
- Physical Barriers
  21
- Emergency Stops (E-Stops)
  23
- Presence Sensors
  24
- Other Safeguards
  25
- Power
  26
- Environment
  27
- Robot Handling
  27
- Operator Safety
  28
- Safety and Operation Checks
  29
- Working Within the Robot's Workspace
  30
Chapter 4 Installation

31
- Required Tools and Supplies
  32
- Component Parts
  32
- Designing a Work Cell
  33
- Unpacking the Arm
  34
- Preparing the Mounting Platform
  37
- Mounting the Arm on the Platform
  40
- Grounding the Arm
  40
- Connecting the Umbilical Cables
  41
- Next Steps
  42
Chapter 5 Commissioning

43
Chapter 6 Basic Operation

51
- Homing the Arm
  52
- Moving with the Teach Pendant
  57
- Moving with Terminal Commands
  58
- Moving by Limping One Joint at a Time
  60
- Gripper Installation
  62
- Installing the Gripper
  63
- Connecting the Cable or Hose
  64
Chapter 8 Calibration

67
- Restoring Factory Calibration Values
  68
- Recalibrating the Robot Arm
  69
- Calibrating an Extra Axis
  73
- Glossary
  75
- Index
  79

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More CRS Manuals

User Manuals: CRS A255 Robot Arm

CRS A255 Service Manual (272 pages)

Table of Contents

CRS A255 User Manual (80 pages)

Table of Contents

Chapter 1 Introduction

Chapter 2 Specifications

Chapter 3 Safety Precautions

Chapter 4 Installation

Chapter 5 Commissioning

Chapter 6 Basic Operation

Chapter 8 Calibration

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