INSTRUCTIONS MODEL 9OOO MASTERLAB SYSTEM

Transcription

0993-8'r54
INSTRUCTIONS
MASTERLABSYSTEM
MODEL9OOO
illlt
April 1986
PE|E|KIN-ELMER
N . R W A L cKo, N N E C ' c u ru, s A
C o p y r i g ho
t 1 9 8 6T h e P e r k i n - E l m eCro r p o r a t i o nA. l l r i g h t sr e s e r v e d .
without
i n a n y f o r m o r f o r m a tp r o h i b i t e d
R e p r o d u c t i oonr p u b l i c a t i o n
w r i l t e np e r m i s s j o on f T h e P e r k i n - E l m eCro r p o r a t i o o
nr a n yo f
i t s s u b s i di a r i e s .
TABLEOF CONTENTS
Page
Section
1
SYSTEMDESCRIPTION
1-1
INTRODUCTION
1-1
H A R D W A R EO F THE MASTERLABSYSTEM
1-3
Robot and Robot Drive Unit ..
7-4
SystemController(IBM PC) ...
1-5
Model 9010 NlasterDeviceInterf8ce
L_O
MasterLab Worksurface
1-8
AccessoryModules
1-8
P E R LS O F T W A R E. . . ,
PERL, a Roboties Language
The PERL ProgrammingEnvironment
l-l.t
Creating a PERL Applications Procedure
USINGTHIS MANUAL
7-74
Organizationof this Manual
1-14
Conventions
1-15
Rulesfor Names .
1-15
M A S T E R L A BS Y S T E MS P E C I F I C A T I O N .S. . .
1-16
Robot Specifications.,
1-16
SystemControllerSpecifications ....
1-16
Printer Speeifications .
l-17
TABLEOF CONTENTS(cont.)
Page
Section
2
INSTALLATION ..
2-7
SITE REQUIREIvIENTS.
2-J.
Electrical Requirements
2-1
Sn.oop R anrrinomants
2-2
..
Ventilation and Cleanliness
P A R T SP R O V I D E D
U N P A C K I N GA N D S E T U P
Initial lnspection
2-6
2-6
Placementof SystemComponents
INSTALLATIONOF SYSTENICOMPONENTS
2-9
Installing the System Controller
2-9
InstallingCircuit Boards
2-9
Installing the NtasterLabWorksurface
Installing the Robot
Attaching the Robot to the l!'orksurface...
Attaching the Hand to the Robot
Attaching the Grippers to the Robot
2-74
z-ro
2-77
Installing the Robot Drive Unit
2-I8
Setting the DIP Switcheson the Robot Drive Unit
2-2t
Conneetingthe Teach Pendant
2-22
Installingthe OptionalPrinter .
2-22
I n t e r c o n n e c t i o n s. . . , ,
Printer Controlsand Indicators .. ...
DIP Switeheson the Printer
Connectingto Line Power
ADDING NIODULESTO YOUR SYSTE}i
2-22
2-26
2-26
Page
Section
3
STARTUP
3-1
PRELIMINARYPROCEDURBS
3-1
Turning ON the Masterlab System
3-1
Backing up DOS and PERL Disks
3-1
Loading the PERL/DOS Work Disk
3-2
Creating a Data Disk
3-3
CONFIGURINGTHE SOFTWAREFOR YOUR SYSTEM
Th fF^.1,
'^ t;^h
3-4
3-4
LoadingCONFIG
Adding a Nlodule ,
Adding a Robot to Your Masterlab System
3-6
.t_1 I
Changinga l\iodule
3-72
Deleting a Nlodule
,-1 i
DisplayingModuleInformation .,.
', _1 A
L O A D I N GP E R L S O F T W A R E . . .
.t-to
TEACHINGAND PROGRAMMINGTHE ROBOT
3-18
Infr^.1'r^1i^.
3-18
Accessingthe Teach Programs
a-1 0
Defining a Rack .
3-20
Moving the Robot .
Naminga Position
Moving to a Position
Positioningthe Gripper
3-26
Page
Section
3- 2 9
CREATINGA PROCEDUREWITH THE PERL EDITOR
PlanningYour Procedure
3-30
Writing a Procedure
3-30
CombiningProcedures
3-33
DEBUGGINGA PROCEDURE
3-36
RUNNINGA PROCEDURE
3-36
LEAVINGPERL .
3-36
MAINTENANCE PROCEDURESAND TROUBLESHOOTING .,..
4-1
I N T R O D U C T I O N. . . . .
4-L
D A I L YC H E C K S . . . . .
4-L
PERIODICI\,iAINTENANCE.....
4-2
TROUBLESHOOTING.
4-2
R E P L A C I N G F U S E S,
.
4-4
Fuse on the Robot Drive Unit
4-4
Fuseson the Rear Panelof the DevieeInterface Unit . ,...
4-5
Fuseson the Device Interface P.C.B. .
4-6
HOW TO RESTARTYOUR ROBOTFOLLOWINGDEPRESSION
OF
THE REMOTESHUTDOWNSWITCH
REPLACINGTHE ROBOTHAND .
4-7
4-8
REPLACINGTHE ROBOTGRIPPERS
4_10
S E C U R I N GT H E R O B O TB A S ET O T H E I T O R K S U R F A C E. . . . . .
4-11
CONSUNlABLE
PARTS
4-72
Page
Section
PREVENTIVENIAINTENANCE
4-73
Preventive NlaintenanceSchedulefor the Robot
4-13
Parts and Tools You Need
4-14
Adjustingthe Wrist Gear ..
4-15
Adjusting the Elbow TensionChain .,
4-17
Removingand Replacing the Drive Belts ..
.
4-27
Drive Belt Tension
Drive Belt in Base .
Drive Belts in Shoulderand Elbow
.
4-2I
4-27
4-24
Replaeingthe Motor Brushes
Replacingthe NfotorBrusheson the Basel\'lotor ....,.
Replacing the fillotorBrusheson the ShoulderMotor . ,.
Replacingthe Motor Brusheson the Elbow Nlotor ,. ...
5
PRECAUTIONS ..
GLOSSARY
4-26
4-26
4-3 0
4-3 3
5-1
L I S TO F I L L U S T R A T I O N S
Page
Figure
1-1
l\{odel9000 Masterlab Systemwith Typical
AceessoryNlodules
1-3
Robot ShownDeliveringSamplein Test Tube to Eleetronic
1-A
Balance
L-.1
SystemController(IBNIPC) ...
1-4
Interfaee
Nlodule9010 NlasterDevice
1-5
Nlodel9020 N{asterNlixer
1-8
l-o
l\{ndal
1-9
afl40
MqsfarSvnino'p
Nlodel9050 l\lasterCrimper
t-D
1-q
1-8
Balance
Kit .,..
1-10
1-9
Fncnn
lyovrr
1-10
1 - 1 0a
16-mm Test Tube Rack
1-11
1 - 1 0 b 12- or 13- mm Test Tube Rack
1-11
1-11
Vial Rack
1-11
1-13
Dnin
r r
fan
2-8
2-1
Typical Plaeementof SystemComponents
2-2
Jumper Configuredto Utilize Ports 3-6
2-L0
t-1
Jumper Configuredto Utilize Ports 7-10
2-10
Configuringthe Asynchronous
Communications
Adapter ....
2-7L
ExpansionSiot Cover Removal
2-72
2-5
(cont.)
LISTOF ILLUSTRATIONS
Figure
2-6
Page
Installing Circuit Boards
Robot MountingTemplate
2-74
2-8
Attaching the Robot to the Worksurface.. .
2-75
2-9
2-77
2-70
Attaching the Grippersto the Robot Iland ..
2-17
NlasterLabSystemElectrical Connections .. .,.
2-79
2-12
DIP Switch Settingsfor the Robot Drive L,nit
2-2L
Printer Cable Connection
2-22
2-74
J -,t
DIP Switch AccessCover Removaland
Switch Location on the EpsonPrinter
2-24
PERL FunctionKey I(eyboardOverlay
3-18
The TeaehPendant
'lacf
Tr rha
P onL'
3-4
Robot Motion in X. Y. and Z Planes
.J -D
Edit Commands[lenu Screen
4-7
Locationof Fuseon Rear Panelof
Locationof Fuseson Rear Panelof
DevieeInterface Unit
4-4
4-6
4-5
Locationof Fuseson DeviceInterface P.C.B.
A-R
FlandReplacement
4-8
Gripper Replacement
4-70
Securingthe Baseof t h e R o b o tt o t h e l V o r k s u r f a c e
,.. ..,. .,
4-71
(cont.)
LISTOF ILLUSTRATIONS
Page
Figure
4-7
Detaching the Hand Assemblyfrom the Wrist Assembly
4-15
4-8
Adjustingthe Wrist Gear ..
4-16
4-9
Drive Belt Covers on the Robot
4-I7
4-70
Robot Upper Arm Front Cover .
4-18
4-77
ElbowTensionChain Adjustment ..,.
4-79
4-72
Removing the Base Cover .
4-27
4-13
Looseningthe Bolts Securingthe BaseDrive fiIotor
.
4-22
4-14
Drive Belt on Base liotor
.
4-23
4-15
ScrewsSecuringthe ShoulderDrive &lotor
4-24
4-16
SerewsSecuringthe Elbow Drive i\{otor
4-25
4-1-7
Removingthe PlastieCap that Serewsthe NiotorBrush
.
on the Side of the Base Motor
,
4-18
Inserting a l\lotor Brush in the Base NIotor
4-19
Locationof Screwsthat Securethe CableBracket
to Robot Base ..
4-20
4-2?
4-27
4-28
Locationof Plastic Cap that Secureliotor Brushon
Rear of Base jotor
4-29
4-21
Locationof SerewsSecuringCover of Shoulder
4-30
4-22
Removingthe Top Cover of the Robot Shoulder
A_11
4-23
Locationof Motor Brusheson Shoulderllotor
4-32
4-24
Location of i\{otor Brusheson Elbow Nlotor
A-ea
G-1
rrwuw( ru
rrSurcrLrurrr,
G-5
S Y S T E MD E S C R I P T I O N
Section
Page
SYIYIEM DESCRIPTION
1-l
I N T R O D U C T I O N. . . . .
HARDWARE OF THE MASTERLABSYSTEM
Robot and Robot Drive Unit ..
System Controller (IBM PC)
Model 9010 MasterDeviceInterfaee
MasterLab Worksurface
Accessory Modules
P E R LS O F T W A R E. . . .
PERL, a Robotics Language
Creating a PERL Applications Procedure
USINGTHIS MANUAL
Organization of this Manual
Conventions
Rules for Names .
MASTERLABSYSTEMSPECIFICATIONS....
Robot Specifications ..
System Controller Specifieations ....
Printer Specifications .
l-1
1-3
1-4
t-b
t-o
1-8
1-8
t-12
L-t
z
t-L4
l-14
1-15
l-r5
l-16
1-16
1-16
t-17
S Y S T E MD E S C R I P T I O N
INTRODUCTION
The I\IodeI9000 Masterlab* AutomatedSamp1ePreparationSystem
provides,as its name indieates,a systemfor automatinglaboratorysample
preparationprocedureswhich you would otherwiseperform manually. Such
stepsas pipetting, mixing, and weighingare carried out by a robot
interactingwith variousaccessorymodulessuchas a syringe,a mixer, and a
balance.
As is the casein any automatedoperation,the most appropriateapplications
are thoseprocedureswhich must be repeatedmany tintes. Theseare
monotonous
and time-consumingfor a humantechnician,and manual
techniquesinevitablyintroducenonsystematicerrors. A softwarecontrolledrobot can perform suchprocedureswith precision,freeing
laboratory personnelto do one-of-a-kind proceduresor work on methods
developmentand other more challenging tasks,
Robots are also valuable for procedureswhiclr involve hazardousmaterials.
They can reducehumanexposureto carcinogens,radioactivesubstances,
or
strong acids and bases. On the other hand, you ean also use the robot in
experimentsin which contaet with a humanoperator might contaminate
sensitivebiologicalmaterials.
The MasterLabSystemcomprises:
-
Robot and Robot Drive Electronics: The robot is an articulated arm
with removableand interchangeable
gripperswhich can graspobjectsof
different shapes. It is fully programmable,and the programsare
portablefrom one Perkin-Elmerrobot to another.
-
SystemController: This is an IBNIPC**, which ean be equippedwith
up to ten RS232communications
ports for interfacingwith the various
modulesof the llasterlab System. (The IBili pC is the System
Controller on the l\lodel 9000 Stasterlab System shippedin the United
States.)
x-Masterl,ab is a trademark of the perkin-Elmer CorDoration.
* {' IB IV.lPC is a trademark of International BusinessNiaehines.
PERL* Applicatio4sSoftryqre: A softwarelanguagedevisedfor use in
the Masterlab automatedSamplePreparationSystem, It is designedto
facilitate communicationin a robotiessystem.
The robot, robot drive electronics,and SystemControllerare described
in this manual. PERL software is describedin this manualand in the
PERL Instructions.The aecessorymodulesare eachdescribedin a
separateaeeompanying
manual.
Accessory[iodules: Somemodulesare deviceswhich are capableof
RS232communicationrvith the systemcontroller. Examplesare the
syringe, balance,or bar code reader. Other modules,such as the mixer,
the erimperand the gas controllerare connectedto the Device
Interface;commandsto the DeviceInterface control them. Finally,
there are moduleswhich are simply locationswith which the robot
interacts; for example, the test tube racks, The partieular modules
which make up your systemwill be tailored to your particular
application.
Worksurface:The optionalPerkin-ElmerWorksurfaceis a formicacovered woodenbench/table top which is pre-drilled at the factory for
mountingyour particular configuration of l\{asterlab System modules.
*
PERL is an acronymfor Perkin-EtmerRobot Language.
1-3
HARDWAREOF THE MASTERLABSYSTEM
The basic \iasterlab systemcomprisesa Robot,a Robot Drive Unit,_a
SystemController(IBM PC) and d Communications
Interface whiclris
installedon the IBNIPC. Your specificapplicationor samplepreparation
systemwill requireparticular accessorymodules,suchas mixers,dispensers,
balances,a printer, and a DeviceInterfaee. A typical MasterLabSystemfor
automatedsamplepreparationis shownin Figure 1-1.
The followingsectionsgive detaileddescriptionsof the basic componentsof
the l{asterlab System and the optional accessories.
1 Model 9010 MasterDeviceInterface
2 Robot
3 Model 8320 Cas ChromaLograph
(nith AS-1 Autosampler)
SystemController (IBlu)pC)
,5 Crimp Stotion
ll orkstrf ace
7 ViaL Rack
8 16-mm Test Tube Rack
9 12-mm Test Tube Rack
10 T op-LoadingBalance
11 Nrodel9020 MasterNli.xer
12a lllodel 9040 lvasLerSyrtnge
(dual- syringe)
12b DtspenserAssembly
(included in 12a)
13 Robot Dri\)e Untt (not shown)
14 Printer (not shown)
Ftgure 1-1- Modet 9000 lviaster
Lab System with Typical Accessory Mo|.l,jites
r-4
Robotand RobotDriveUnit
Robot
The Robot in your Masterlab Systemis a revoluterobot, that is, a robot
which has an arm on a rotating base, The articulatedarm has five degrees
of freedom:baserotation; shoulderjoint; elbowjointi wrist pitch; and wrist
rotation, With its five degreesof freedom,the robot can move to objects
and reach over them, giving it considerablefreedomof movementin
aceessingaccessorymodulesand analyticalinstruments.
Figure 1-2 - Robot ShownDetivering Sample in
Test Tube to Electronic Batance
The drive systemof the Robot utilizes DC servo motorswith limit switches
for home detection;the homepositionis usedfor calibration. ODticat
encodersare incorporatedinto the fobot to monitor its positioning.The
encodersare non-contactdevicesand will not wear with time. EJch joint
has its own motor encoder. Positioningrepeatabilityof the robot is +0,5
mm.
The travelingspeedof the robot is programmable,you can programthe
robot to move very slowly whenperformingdelicateoperationssuchas
pouringa powdersample,or very rapidly when movingbetweenmodules.
1-a
NOTE: The speedis programmedusinga PERL system
command, Refer to Section2 of the PERL manualfor
additionalinformation.
Robot Drive Unit (not shown)
The Robot Drive Unit eontainsthe }lasterlab robot electronicsand
interfaces the robot with the System Controller (IBl\l PC). It is usually
located on a shelf under the niorksurface,but you must place it so that the
robot power switch on its front panel is accessible.
SystemGontroller(lBM PC)
The SystemControlierfor the Masterlab Systemis the IBM pC Computer.
The IBM PC is comprisedof three modules: an electron ics/disk module, a
display module and a keyboard.
Figure 1-3 - System C ontroller (IBM pC)
Eleetronies/Disk Module
The elbetronics/disk moduleemploysthe high-speedIntel 808g micro_
processorand has 256 kilobytesof randoma-cesi memory. It
includestwo
floppy disk drives, each oapubl" of storing 320
g"uble-density
9:l?l-O-*l
Klrooytes ot lnlormation.
l_o
Display Module
The displaymoduleis a 12-ineh,high-resolutionCRT with an anti€Iare
phosphorscreen. You use the display module to view the menusand options
providedwith the PERL applicationsoftware.
Keyboard
The keyboard,which you use to enter commandsand data to the system,
attaehes to the electron ics/disk module unit with a z-meter (6-foot) coiied
cable, The keyboard includes83 keys for data and text entry. In addition,
ten programmablefunction keys whosefunetions are set by the applications
software are available,
The System Controller standardly includes four RS-232Cports for
communicationwith RS-232C-compatibledevices. If additionalports are
necessaryfor your MasterLabSystem in order to include more modules
(syringe,analyticalbalance,ete.),you ean add up to six additionalRS-232C
Dorts.
Model9010MasterDevice
Interface
The Nlodel9010NlasterDeviee
Interfaeeprovidesthe systemwith prograntmablecontrol of two A.C, devices.For example,if the systemincludesa
vortex mixer, the Device Interface unit can be programmedto turn the
mixer on and off at the proper time in the samplepreparation procedure.
Commandsto the Deviee Interface can also control up to twelve external
switch closuresand monitor up to twelve externalinputs. The Device
Interface has a built-in alarm, which you can program to alert you to any
problemsencounteredby the system.
The Deviee Interface also contains two RS-232Cports as well as terminals
for connectingexternaldevicesthat require5V o. +tZV lC.
t\
--v!!rtt
- - -!rtrtl
\
A. Front View
B. Back Panel
Figure 1-4 - Model 9010 MasterDevicehlterface
1-8
Masterlab Worksurlace (seeFigure1-1)
The Nlasterlab Worksurfaceis a table top constructed of quality wood and
Iaminatedwith FormieaTl\{ 1e p.o1""1 its surface. The componentsof the
NlasterlabSystemas well as all modulesservicedby the robot are mounted
on the works-urface.Holes are drilled in the worksurfaceat the factory for
mounting the modulesyou require in your robotics application'
The worksurfacemeasures48 inches(123cm) deepby 72 inches(185em)
wide, large enoughto accommodatea variety of moduleswhich the robot
can service.
Normally, the robot is positionedat the center of the back edgeof the
worksurface(seeFigure 1-1), From this positionit can serviceboth an
instrumentand moduleslocatedon the worksurface.
AccessoryModules
Some of the many available Xiasterlab System accessorymodulesare shown
in Figures1-5 through1-11. lvith the exeeptionof the printer, theseare all
moduleswith which the robot interacts directly.
Figure 1-5
Model 9020 MlasterMixer
A singletest tube vortex mixer
which thoroughly mixes the
contents of the test tube, It is
controlledby the DeviceInterface.
1-O
Figure 1-6
Model 9040 Master Syringe
Dual-syringeassemblyrvith two
valves for automatic liquid
handling operations.
The lllodel 9030 [{asterSyringe
(not shown)is a single-syringe
assemblywith a singlevalve.
Figure 1-7
Model 9 050 MasterCrimper
A crimping station that both holds
caps (usinga vacuum) and seals
vials with the caps.
1-10
Figure 1-8
Balance Kit
Allows the use in the System of
any I\lettler SeriesPE electronic
balance using the 016 Data
Interface. A kit is also avaiiable
for Mettler Series AE analytieal
balances.
Figure 1-9
EpsonPrinter
Optional printer for hardcopy
printout of sample
documentationfor the
MasterLabSystem Controller.
1-11
Figure 1-10a
76-mm Test Tube kack
Holds forty 16-mm test tubes
a4x10matrix.
Figure 1- 10b
12- or 13-mm Test Tube Rack
Holdsforty 12- or 13-mrntest
tubesina4xl0matrix.
Figure 1-11
Vial Rack
Holdsforty 1.8 mL microvialsin
a4x10matrix.
t-tz
PERLSOFTWARE
PERLas a RoboticsLanguage
PERL (Perkin-ElmerRobot Language)is a new softwarelanguagedevised
for use in the Masterlab Automated SamplePreparation System' It is
specificallyintendedto facilitate communicationin a roboticssystem.
Becausethe h{asterLabSystemis modular,PERL must accommodatethe
is
additionof new modulesto the system. This aceommodation
by the interactiveprogramnamed"CONFIG." This program
accomplished
createsa systemconfigurationfile (PERL.SCF)which containsthe name,
initializationsequence,
and communicationsparametersfor each module.
The system reads this file each time PERL is loaded, Whenyou add or
delete a module,you need only run I'CONFIG to change the system
configurationfile; you do not have to rewrite existingapplications
procedures.
The TeachProgramsare a uniquePERL feature which allowsyou to create
new commandsin your laboratory,and store them for use in procedures.
Whenyou add a new moduleor programa new application,you can easily
add the appropriatecommandsto PERL.
The NlasterLabSystem ean potentially carry out many different sample
preparation proceduresin your laboratory. The programming language
provided for your use is powerful, yet simple to use, so that you can program
the proceduresas readily as you devisethem, PERL appearssimilar to
BASIC, a languagewhich is easy to learn and with which you may already be
fam iliar, I\'lanyof the statements are the same as BASIC statements.
However,PERL also containsseveraluniquestatementsto make robotics
applicationsrun smoothly and effieiently. For example, the "parallel"
statement allows two operationsto proceed simultaneously,and the I'speedrl
statement allows you to choosethe most appropriate speedfor the robot at
eaehstageof a procedure.
You will aecumulatea certain amountof data (weights,volumes,numbers
of samples)during samplepreparations. PERL is capable of processingthis
data. In fact, PERL can be usedfor any usual programmingneedsi the
difference from other languageslies mainly in its additional ability to
communieatewith robotsand other devieeseasilv.
1-13
The PERLProgramming
Environment
The PERL programmingenvironment(seeFigure 1-12)consistsof a set of
programming tools to help you develop PERL applicationsprocedures.Some
of these tools you will never use directly. Those with which you do interact
are constructed with clear menusand prompts to guide you.
,4_\6,
TecU4
SFten
CoofiAur.tlo
flffi
([,
Udrlty
F
&^
@f,
Figure 1-12 - The PERL programming En\)ironment
Ascan be seenin Figure 1-12, you wiil use the pERL Editor to create pro_
cedures,which are compiled by the Compiler and stored on disk. Vou witt
Programsto create new stored commandsto. "onirotting
?1.:
^:.r^:
^,I".|":c,h
tne system
modules,and the fiCONPIG" program to store the configuration"
of the system in the system eonfiguration file.
When the stored proeedureis run, the Interpreter usesboth the stored com_
mandsand the system configuration file to interpret the procedure state_
ments. It then communicates,via the Serial CommunicaiionsFacility, with
the deviceswhich are to carry out the eommands.
Creatinga PERLApplicationsProgram
Whenyou wish to program a new application using PERL, first analyze the
procedureyou are programming,to determineexactly what stepsare
involvedand what commandsyou will need to create to carry it out. The
programmingprocedureis then as follows:
-
Use the Teach Programsto create the uniquestatementswhich will be
neededin the procedure. Examplesmight be I'fi11_syr_2.5
m1'ror
"m ove_to_crimper".
-
Accessthe PERL Editor to create and edit the procedure. It is a full
screeneditor which takesadvantageof the functionkeys and other
special keyboardkeys available on the System Controller (IBUIPC).
-
Using the BASIC-Iike PERL statements to provide overall program
structure,and the statementsyou created with the Teachprogramsto
give eommandsfor specifieactions,enter your procedureand eclit it.
-
Save the procedure. It is automatically compiled when you save it. The
system then savesboth an ASCII and a compiled version of the
procedure.
The PERL InstruetionManualwhich came vrith your NlasterlabSystem
containscompleteinformationabout all the TeachProgramsand the statements available to you in PERL, as well as instructions on using the pERL
Editor to ereate and saveapplieationsprocedures.Consultit whenyou wish
to program a new application for your Masterlab System.
U S I N GT H I SM A N U A L
Organization
of This Manual
The l\Iodel9000 NlasterLabSysteminstruetionmanualhas six sections:
Section1, SystemDescription,providesa descriptionof the hardwareand
software that comprisethe systemas well as a listing of the systen
specifieations,
Section 2, Installation, contains instruetions for installing the system in your
fa c ili ty.
t-lD
Section 3, Startup, introducesyou to preliminary operating procedures. It
describesthe steps to follow to rrteachrrthe robot to move to accessory
positions. It also outlines the steps to follow in creating a program. Finally,
it tells you how to run your program.
Section 4, MaintenanceProceduresand Troubleshooting,includes
maintenanceprocedureswhich you ean perform and a troubleshootingguide'
In this section you will also find a list of consumableparts and the
correspondingpart numbers. This is provided for your conveniencein
ordering parts.
Section 5, Precautions,describesprecautionsyou should take when
operating the robot,
A glossary of robotics terms completes the manual.
Protruding tabs help you find the seetion you are looking for, Each section
has a contents page listing the subjeetscovered in the section.
Conventions
Specific words and characters that you must type are in boldfaee. For
example,whenyou are starting to write a procedurewhere the first line
must be
procedure prep_uv
you will type the words exactly as they appear.
Rulesfor Names
Whenselecting names for use in PEIiL and tlle System Configuration Utiiity,
observethe rules listed below.
*
Use an alpha character as the first character.
*
Usea maximumof 16 alphanumericcharacters(8 for proeedureor
other file names).
*
Useno spaces.Spacescan be indicatedusing the underlinecharcter
or the period.
*
Do not use any of the following eharacters:
| - + * / $ % ^ & ( ) \ < > ' ,? ' @= I
t-ro
MASTERLABSYSTEMSPECIFICATIONS
RobotSpecifications
Type:
Perpendiculararticulated arm
Degreesof freedom:
Five, plus openingand closing of fingers
Total arm reaeh:
25.7inches(660mm)
Operation range (in degrees):
Waist
Shoulder
Eibow
I! rist pitch
Wrist roll
300
130
90
+/- 90
+90 / -27tJ
Travel Speeo:
Programmableat 9 levels, 400 mm/sec (15,?
inches/sec)maximum
Lilting capacity:
L.2 ke Q.7 lb)
Control:
5 axes driven simultaneously with I_;Cservo
motors
Position detection:
Optical encodersand limit switches
Position repeatability:
+ 0.5 mm (0.112
inches)
Power:
120/220VAC, single phase,50/6u hz
Weight:
59.?lb (2? kg)
SystemControllerSpecifications
Computer type:
IBM PersonalComputer (pC)
Processor:
Intel 8088 mieroprocessor
&iemory:
256 kilobytes RANr
Visual display:
High-resolution,monochrome,l2-inch
oisplay unit with anti-glare phosphorscreen
Visual attributes:
Blinking, underlining,reverse vioeo
Disk storage:
Two double-sided,double-densityfloppy disk
drives, each capable of storing 320
kilobytes; total storage: 640 kilobytes
Keyboard:
83 keys for data and text entry with tactiie
and audio feedback, adjustable typing angle,
detached and connectedby 6-foot coil cable
Options (available from
third parties):
* Memory expansionto 640 kilobytes
* Hard disk storage
+ Additional programs available for nonrobotic applications
Communications:
4 kS-232C interfaee ports are standardi
expandableto a maximum of 10 Dorts.
I parallel printer port stanoaro.
PrinterSpecifications
Print rate:
160 characters per secondper line in pica
Character sets:
Roman; Italic; Special international
character sets; N LQ charaeters (roman);
IBM standard and alternate
Columnwidth:
80 (pica); 40 (Pica expanded)r96 (Etite); 48
(Elite expanded);132 (Compressed);
I60
(CompressedElite); 68 (Compresseo
expanded)
Print controls:
Character:
6 pitches, 5-20 CPI; emphasizedano
doublestrike weights; italie style: super ano
subscript heights; uncerline moce
Formatting:
Programmablehorizontal ano vertical tabs:
lelt anc right n,argins;Iine spacingi skip
over.perforation; page iength; proportionat
spactng
Bit images
60-240DPI, mixablewith text
Paper feed mechanism:
Friction/pin feed
Media handling:
9,5 to lO-inch tractor feed stockt 8.s-inch
roll paper;7,25 to 8.5-inchsinglesheets;
original plus 2 carbons
INSTALLATION
Page
Section
2
INSTALLAIIoN
2-7
..
SITE REQUIREMENTS .
Electrical Requirements
SpaceRequirements ..
Ventilation and Cleanliness
PARTSPROVIDED ...
UNPACKING AND SETUP
Initial Inspection .....
Plaeementof System Components
INSTALLATION OF SYSTEMCOMPONENTS
Installing the System Controller
Installing Circuit Boards
Installing the Masterlab Worksurfaee
Installing the Robot
Attaching the Bobot to the Worksurface ....
Attaehing t}te Hand to the Robot
Installing the Robot Drive Unit
Setting the DIP Switcheson the Robot Drive Unit
Connecting the Teach Pendant
Installing the Optional Printer .
Intereonnections.....
Printer Controls and Indicators
DIP Switehes on the Printer
Connecting to Line Power
ADDING MODULESTO YOUR SYSTEM
.
.
2-L
2-l
2-2
2-2
2-4
24
24
2-7
2-9
2-9
2-9
2-13
2-t4
2-74
2-76
2-17
2-18
2-21
2-22
2-22
2-22
t -t.t
2-24
2-26
2-26
INSTALLATION
SITEREQUIREMENTS
Your Nlasterlab Systemshouldbe installed by a perkin-Elmer service
representative. You are responsiblefor providing a stable supply of power
and an adequatespace in a clean location. If your system is to include a
modulewhich requiresan air supply,suchas the MasterCrimper,you rnust
providea sourceof clean air at a maximumpressureof ?0 psi.
Locate the table or bench that supportsthe Masterlab System in an area
free of vibration, corrosive fumes, and magnetic fields. The temperature of
the area shouldremain between15 and 40 degreesCelsius(59 to 104 degrees
Fahrenheit),at a relative humidity of between20 and 80 pereent.
ElectricalRequirements
The Robot and the Robot Drive Unit require 120 or 230 volts AC, 50 or 60
Hz. Their power consumptionis 400 watts, If possible,the Robot and the
Robot Drive Unit shouldutilize separategrounds,to minimize electrical
noise. The groundingresistanceshouldbe 100 ohms or less. The grounding
point shouldbe as near as possibleto the Robot and Robot Drive Unit to
keep the groundingleads as short as possible.
The System Controller (IBM PC ) requires 120 volts AC, 60 Hz. The typical
power consumptionof the SystemControlleris 200 watts. To prevent
voltage spikes,do not connect the Masterlab System to circuits serving
Lprgeor heavy duty equipment. If the power available is unstable,
fluctuates in frequency, or is subject to surges,additional control of
incoming power may be required. In that case, regulating transformers and
uninterrupted power suppliesmay be purchasedfrom the following firms:
Curtin l\IathesonScientific
P.O. Box 1456
Houston,"lX 77251
( 7 1 3 )280 - 1 66 1
Rapid Electfic Co., Inc.
CraysbridgeRoad
Brookfield,CT 06804
(203)775-0477
Topaz Division SquareD Co.
9192 Topaz Way
SanDiego, CA 92723
( 6 1 9 ) 297- 0 83 1
SpaceRequirements
Perkin-Elmer manufacturesa Worksurface(Part Number N090-0029)on
which the Nlasterlab Systemand its modulescan be conveniently mounted.
It is a table top constructed of quality wood and laminated with Formica
(TNI)to protect the surface. Holes are drilled in the Worksurfaceat the
factory for mounting the modulesneededin your particular robotics application,
The robot and the moduleswhich it is to service rest on the Worksurface.or
on a table or bench top. The Robot Drive Unit may be placed on a shelf
under the Worksurface,where its cable connectionsand power switch are
accessible. The System Controller shouldbe placed on a nearby table or
bench.
The spacerequirementsfor eachcomponentof the systemare given in
Table 2-1.
Ventilation
and Cleanliness
Protect the componentsof your [lasterlab System from spills and fumes.
Clean spills from the Worksurfaceand the robot promptly, to avoid possible
damageto the systemor contaminationof samples.
2-3
Exhaustcorrosive, flammable or toxic fumes away from the system components. If your sample preparation proceduresgenerate fumes, use a table
top hood to remove them. AIso useful to remove fumes is a down-draft slot
type hood. Locate hoodsat the perimeter of the Worksurface,to draw
fumes away from the Masterlab System. Suitable hoods are available from
the following firms:
Hemco Corporation
111 N. Powell
Independence,Missouri 64050
(816)796-2900
St. Charles Manufacturing Co,
St. Charles, trlinois 60174
(312)584-3800
TABLE2-1
MASTERLAB
SYSTEMDIMENSIONS
Height
Width
inches (em) inches (em)
Depth
inches (cm)
Weight
Ib (ke)
Robot:
35.8(91.0)
Total arm reaeh 25.?in
(66.0em)
6 0( 2 7 )
Robot Electronics
Module:
5.5(14.1)
20.0(51.3)
16.0(41.0)
28.0(12.?)
System Controller
(IBM PC):
Display:
Keyboard:
Electronics
Module:
1 1 . 0( 2 8 . 2 ) 1 5 . 0( 3 8 . 2 )
2 . 0( 5 . 1 )
8 . 0( 2 0 . 5 )
14.0(35.9)
8.0(20.5)
1 7 . 3( 7 . 8 )
6 . 0( 2 . ? )
5 . 5( 1 4 . 1 )
2 0 . 0( 5 1 . 3 )
1 6 . 0( 4 1 . 0 )
2 8 . 0( 1 2 . 7 )
Printer: *
3.s (e.91)
r7.4(44.2)
13.?(34.8)
1 7 . 2( 3 7 . 9 )
Worksurface:*
r.25 (3.2)
71.5(181.6) 4 8 . 0( 1 2 1 . 9 ) 1,24(272.8)
E dtiionai-
z-4
PARTSPROVIDED
The Masterlab Automated Sample Preparation System (ASPS)may be
ordered in one of three configurations:
Automated SamplePreparationSystem (120V),with System Controller
Automated SamplePreparationSystem (120V)'without System
Controller
Automated SamplePreparation System (230V),witnout System
Controller
The parts suppliedwith each configuration are listed below.
ASPS(120V), with Slptem Controller (P/N N09(F0100):
P-E Part No-
Description
0993-8154
0993-8155
N 0 90 - 0 0 1 1
N090-0020
N090-0028
N 090-0041
N090-1003
N090-1153
N090-1154
N090-1000
N 0 90 -1 0 0 1
N090-10?5
N090-1076
N 0 90 - 1 1 1 2
N090-9014
N090-0105
N090-.0026
N090-1r55
N0 I 0 - 9 0 0 4
0993-8180
N090-1115
N0 9 0 - 1 1 5 7
N 090-0007
Manual - Masterlab System
Manual - PERL Software
Robot Assembly(120V),includes
Cable - Robot to Comm Interface
Cable - Hand SensePCB
Robot Hand Assembly,includes
Hand
Bracket
Shroud
Robot
Robot Drive Unit (120V)
Bracket, Hand SensePCB
Plate, Hand SenseConnector
Teach Pendant
PCB Assembly,Hand Sense
Gripper Assembly
IBM CommunicationKit, includes
Label-CommunicationsRS232
PCB Assembly.RS232Interface
Manual - ASPSCommunications
Software Kit
Keyboard Overlay
System Controlter (IBM PC)
Quantity
I
I
1
I
1
I
1
2
I
I
I
1
I
I
I
2
1
I
I
I
I
t-(
ASPS(120V), without System Controller (P/N N090-.0102):
P-E Part No.
Description
0993-81s4
09I3-815
N090-0011
N090-0020
N090-0028
N090-0041
N090-1003
N090-1153
N090-1154
N090-1000
N090-1001
N090-10?5
N090-1076
N 0 90 - 1 1 1 2
N090-9014
N090-0105
N090-0026
N 0 9 0 - 1 155
N090-9004
0 9 I 3 - 8 10
8
N 0 90 - 1 1 1 5
N 0 90 - 1 1 5 7
Manual- Masterlab System
Manual- PERL Software
Robot Hand Assembly,ineludes
Hand
Bracket
Shroud
Robot
Plate, Hand SenseConnector
Teach Pendant
Gripper Assembly
IBM CommunieationKit, includes
LabeI-CommunicationRS232
PCB Assembly,RS232Interface
Manual- ASPSCommunieations
Software Kit
Keyboard Overlay
Quantity
ASPS(230v),without SystemControuer (p/N N090-0103):
P-E Part No.
Description
0993-815
4
09 9 3 - 8 155
N 090-0011
N090-0020
N090-0028
N090-0041
N090-1003
N 0 90 - 1 1 53
N 090-1154
N090-1000
N090-1002
N090-107
5
N090-1076
N0 9 0 - 1 1 1 2
N090-9014
N090-0105
Manual- Masterlab Systen
Manual- PERL Software
Robot Hand Assembly,includes
Hand
Bracket
Shroud
Robot
Plate, Hand SenseConneetor
Teach Pendant
Gripper Assembly
Quantity
2-6
N090-0026
N090-1155
N090-9004
0993-8180
N 0 90 - 1 1 1 5
N090-115?
IBM CommunicationKit, ineludes
Label - Communication RS232
PCB Assembly, RS232Interface
Manual- ASPSCommunications
Software Kit
Keyboard Overlay
I
1
1
1
1
Optional Printer:
P-E Part No.
Description
N500-2187
or
N500-2186
EpsonPrinter, 120V
1
EpsonPrinter, 230V
1
N500-2031
Requires:
Connecting Cable
N500-1409
N500-2189
N500-2148
AIso available:
Paper
Ribbon Cartridge
Paperholder
Quantity
1
I
1
Additional modulesfor your Masterlab Systemare available to meet the
needsof your laboratory. Such modulesmight include a syringe, a mixer, a
crimper, a device interface, and various racks and stands. Parts lists for
these rnodulesare in their resDectivemanuals.
U NPACK I NGA ND S E TU P
InitialInspection
Your Masterlab System will arrive in cartons containing the fotlowing
components:
Robot
Robot Drive Unit
System Controller (IBM PC)
After the system componentshave been removed from their cartons,
perform a visual inspection. If any of the componentswere damagedin
transit, eontact the carrier and request instructions for filing a damage
claim. Cheek the contents against the appropriate parts list on the
precedingpages. If any parts are missing,notify Perkin-Elmer immediately.
Placementof SystemComponents
IMPORTANT: Do not eonnect the comoonentsof the Masterlab
System to line power until told to do so later in this procedure.
Carefully plan the location and arrangementof your Masterlab System
before it is installed, as the robot and all aecessorieswiII be securely
fastened to fixed locations at installation. This prevents them from moving
in relation to each other during use, which would disturb the ability of the
robot to service the other modules.
The placement of the Worksurfacein your laboratory is the first consideration. If the robot is to service an analytical instrument, you will, of course,
have to place the Worksurfacenext to the instrument. You will then need
to determine the exact locations of the robot, the instrument, and the
various MasterLab modulesas follows:
a)
Place the robot on the IVorksurfacein a position where it will be
able to reach the instrument which it is to service. Place the
instrument in its location,
b)
Use the Teach Pendantto move the robot to the various positions
it will have to assumewith respect to the instrument. (SeeSection
3 for information on using the Teach Pendant.) If there are any
that are not within reach, move the robot or the instrument
aecordingly.
e)
Whenyou are sure that the robot will be able to service the instrument, determine the appropriate locations for the other modules
basedon the eonsiderationsdescribedbelow.
d)
FinaIIy, permanently install the robot and the modulesas described
in "Installation of System Componentsrr,which follows in this
manual and in the respective module manuals.
The arrangementof the componentsof your system will dependon the
location of the Worksurfaeeand the partieular applications to be performed
in your laboratory. A typical placement is shown in Figure 2-1. Generally,
you shouldplace the robot in the eenter of the Worksurface,but it may
need to be eloser to one side if it is to service an instrument. Loeate the
system controlier (IBM PC) to one side of the Worksurfaceor on an adjacent
table or desk. Place the Robot Drive Unit on a shelf under the Worksurface,
Iocated so as to permit aecessto the controls on the front panel.
The three-dimensionalspace which is aecessibleto the robot is called the
"work envelope'r. Moduleswith which the robot is to interaet must be
located within the work envelope. The manual for each module contains the
2-8
Figure 2-1 - Typical Placement ofSystem Components
distance from the robot pivot point to the mounting holes for that module.
Locating the module at this distance from the robot places it within the
work envelope,
If locations for your moduleswere not pre-drilled for you on a Perkin-Elmer
Worksurfaee,place the modulesin their proposedlocation at the suggested
distance from the robot, and use the Teach Pendantto verify that the robot
can reach them before fastening them down.
A final considerationin the placement of modulesis the order in which the
robot will usually be using them in your application. If the robot will be
frequently taking test tubes from the syringe dispensingstand to the mixer,
for examole. these two modulesshouldbe elose to each other.
2-9
INSTALLATION
OF SYSTEMCOMPONENTS
Installingthe SystemController
If you did not purchaseyour System Controller from Perkin-Elmer, be sure
that it is equippedwith 256 kilobytes of memory, 2 double-sided,doubledensity, 5-1l4r'floppy disk drives, and a HereulesGraphicsCard (available
from Perkin-Elmer, P/N N500-2150)or IBM GraphicsCard (or an
equivalent).
This manual assumesthat an IBM PC is usedas the System Controller. It
presentsonly the information that is required to interface the computer
with the Robot. To install the System Controller, follow the installation
information given in the computer manufacturerrsmanual, Iocating it as
describedearlier in "Placement of System Components.rl
InstallingCircuitBoards
You can use the procedurein this section to install circuit boardsin the
System Controller at any unusedslot. There are special considerations
which pertain to particular boards,however:
es board (P/N N500-2r50): Install the
cs board in slot L.
Perkin-Elmer communicationsboard (P/N N090-9004): lf vou are
to
COM6:; if you install a secondboard, its ports are COi\4?:to COtVtl0:.
The jumper plug on the board as shippedwill be in the position shown in
Figure 2-2. This is the correct configuration for ports J through ti. If
the board is to be used for ports 7 through 10, remove the plug, rotate
it 180 degrees,and replace it as shownin Figure 2-3.
IBM esynchronouscommunicStionsadapter: To obtain RS23Zports
asynchronous
communicationsadapter for each port. Place its pluggabiemodule in
position for an RS232interface as shown in Figure 2-4. The
asynchronouscommunicationsadapter wiII be configured for COMl: as
shipped. If you install a secondadapter, configure it for COMZ: by
removing the pluggableaddressmodule (see Figure 2-4l, rotating the
module 180 degrees,and replacing it.
NOTE: The pluggablemodule may have a dust cover. Simply lilt
to remove it.
2-10
:^
r, F*
lqr
Y
E.
ql!
a'<cl
/_Y-\'
JumFr
Plw
Figure2-2 - JumperConfiguredto Utilize Ports3-6
q.!? t--.1
6i.
{t
ftrE
I
i
I
))
c'
!:F t--.1.
'1
pll
Fi
efl
[ror+
Jump€a
Prla
F igure 2-3 - Jumper C onfigured to U tilize Ports 7-70
2.LL
--,__-t
r ---,
I
I
!
l
I
I
D o q
D o q
p o q
b'o d
D o q
Po . t
B 3 t
Paitid
fo" coml:
Pcitio
I
I
I
i
ta cotnz:
i
:11':1_J
PLUGGAXLE
PLUGGAXLE
ADDBESS
n
0
0
Il 0
ul0CI
m00
l- __',
Ii l's
d
B 3 t
I
I
I
D o d
D o d
D o (
Ir6iticn I
83232-C
Intedace
.
L-7":"*
UODULB
II
l
I
I
Figure 2-4 - C onfiguring the AsynchronousC ommunications Adopter
To install either the Perkin-Elmer Communicationsinterface board or anv
optional boards proceed as follows:
1)
Remove aII cables from the rear of the IBM PC.
2)
Unplug the power cords from the wall outlets, and remove the monitor
from the top of the electronics module (systemunit,,.
3)
Locate the five cover mounting screws on the rear of the electronics
module. Remove them with a flat biade screw driver or l./4r'nut driver.
2-t2
4)
Slide the cover back toward the front of the electronics module until it
will go no farther. Tilt it up to remove it from the base' and set it
aside.
5)
Remove the cover from the expansionslot which correspondsto the
desired location of the eircuit board to be installed.
NOTE: The circuit board may be installed in any unused slot. Use
aTlat-uuaeo screw driver or 3/16" nut driver to remove the screw
which holds the expansionslot eover (Figure 2-5).
?
Rear Panel
Support
Bracket
Figure 2-5 - ErponsionSlot Cover Removal
6)
Locate the black circuit board support bracket (packedwith the eircuit
board), and press it into the small mounting holes at the front of the
electronics module. Be certain the board support is located direetly
opposite the slot in which the boardis to be mounted; install it with the
open end up.
crasp the circuit board to be installed firmly at the top edge and press
it into the connector behind the new open expansionslot (Figure 2-6).
Securethe circuit board by tightening the retaining screw removed in
steD 5.
2-L3
NOTE: To instali the graphiesboard (N500-2150),place the board
in the rear board support, then align the connectorsand press
down firmly to seat the cireuit board.
e
I
lz
J
,Wffi
L)
a /
Figure 2-6 - Irutolling Circuit Boords
8)
Replace the electronics module cover, and secure it with the cover
serewsremoved in step 3.
9)
Select the appropriate section of the label suppliedwith the IBM
CommunicationKit. (That is, if this is your fiist RS-232
eommunicationinterface board, use the upper portion of the label,
COM3 through COM6; if this is your secondboard, use the lower
portion, COMT through COM10.) Peel off the backing from the label,
and affix the label to the rear of the electronies module just to the left
of the board you have installed. This label identifies the individual
ports of the board, Refer to Figure 2-11.
Installingthe MasterLabWorksurface
Place the Worksurface(P/N N090-0029)on top of a sturdy beneh or
table. You may bolt it into position, if you wish,
Slide the Worksurfaceover to one side of the bench when installinE the
robot, which is bolted to the Worksurfacefrom the underside,
Installingthe Robot
Attaching the Robot to the Worksurfaee
The robot must be rigidly bolted to the Worksurfaceor the table top on
which it rests. It is extremely important to be sure that the robot will
not move once it is mounted. Small movementsat the robot mount will
translate into large errors in position during applicationsprocedures.
1)
If mounting holes were not drilled at the factory, or if you are installing
the robot on a table top, drill holes in the Worksurfaee,using the
templateprovidedin Figure 2-7:
a)
Place the template in the approximate center of the Ivorksurface.
b)
Nleasurethe distancesthe robot can reach in all directions.
e)
Center the template in the area the robot ean reach, and scribe the
mounting bolt hole loeation marks. Also scribe the pivot center,
for future use in mounting other modules.
d)
Drill exactly perpendicularto the Worksurfaceand exac y on the
scribe marks, using an 77/32 inch bit. The drill shouldpass
completely through the Worksurface,
2)
Remove the screws in the sidesof the cover of the base of the robot,
two in the front and two in the rear (see Figure 2-8).
3)
Remove the base cover by pulling the cover to the side, Use care to
avoid damagingthe cabled wiring which runs through the base.
4l
Attaeh the robot to the Worksurfacefrom below, using the M8 screws
provided (seeFigure 2-8). Plaee a split lock washerand a flat washer
(also provided)on eaeh screw to lock the robot in place.
o.,
Replace the basecover on the robot, and screw it in place with the
serewswhich were removedat step 2.
6)
Ground the robot separately from the other liasterlab System componentsr-to minimize possibleelectrieal noise. Run a ground lead from
one of the mounting bolts on the robot to a ground hlving less than 100
ohms groundingresistanee.
2-t5
holes for front side of robot
x_
holes for rear side of robot
Figure 2-7 ' Robot Motnting T emplate
2-16
ll orksur fa ce
Cable
Strain
Relief
Base Cover
Screr (,t)
!9!e,
Cqtue
cable s''g.in
relief ll€,rc-
Bobot
Bqse Cover (2)
Figure 2-8 - Attaching the Robot to the Workstrf ace
To attach the hand:
1)
Position the holes in the hand module over the holes on the robot wrist
and attach the hand with the four Allen head screws provided.
2)
Slide the connectoron the end of cable N090-0028throughthe hole in
the bracket on the toD of the forearm.
.r\
Attach the cable to the forearm using the strain relief clip (seeFigure
t-o )
4)
Connectthe cable to the connectoron the forearm.
Bl.d(et
(Porearm)
Straio netef
1u'
I
Plate
(Wrist)
Allen Hedd
Screr (4)
Robot Eaid
Figure 2-9 - Attaching the Hand to the Robot
Attach eachgripper to the robot hand. To attach a gripper,insert two
screwsin the recessedholesin the gripper (seeFigure 2-10),and serew them
to the handassemblyas shown,
Robot Hand
Figure 2-10 - Attaching the Gripperc to the Robot Hand
2-78
Installingthe RobotDriveUnit
If possible,locate the Robot Drive Unit on a shelf under the Worksurface.
Cable conneetionsand the power switch shouldbe aecessible. Refer to
Figure 2-11 as you make the eleetrieal conneetionsdescribedbelow.
1)
Connect one of the 20-foot cabtessuppliedwith the robot to the terminal labeled 'TMOTORPOWER'Ion the rear of the Drive Unit and to the
terminal on the robot.
Connect the other 20-foot cable to the terminal labeled T'MOTOR
SIGNALTT
on the rear of the Drive Unit and to the terminal on the robot
(Figure 2-11), (The 2O-foot cables are not interchangeable;however,
their differing connectorsmake it impossibleto confuse them.)
2)
Tighten the screws on the sidesof the conneetorsalternately until the
eonneetorsare fastened tightly to their sockets.
3)
To connect the optional remote emergencyshutoff, attaeh its wire
Ieads to the lower screw terminals in the terminal strip on the rear of
the Robot Drive Unit. (The remote shutoff terminals are marked
IEMERGENCYTI.)
Place the remote shutoff box in a convenient spot on
the Worksurface,within reach of the robot operator,
4)
Connect eable N090-0020to the connector on the lower left corner of
the Robot Drive Unit. This conneetor is Iabeled nRS-z32C'r.Tighten
the connector screws alternately until the cable is securedto the
connector. Conneet the other end of the cable to any communications
port (com 3:, com4:, ete.) on the Perkin-Elmer communicationsinterfaee card installed in the IBM-PC: insert the connector until it elicks
into plaee.
5)
Connect the line power cord to the rear of the Robot Drive Unit.
Do not connect power at this time.
REMOTE
SHUT.OFF
TEACHING
PENDANT
il!l|i
N09tF0020
Emergency
A/C POr{ER
2-19
COMSo. ? 0
CO {or80
l|[nril[[[[[l[[0[
OPTIONAL
SYSTEM CONTROLLER
(COMPAQ)
To Robot
D.ive Unit
Figwe 2-11- MasterLab SystemElectrical C onnectiotrs
Settingthe DIP Switcheson the RobotDriveUnit
Open the right side door on the Robot Drive Unit. You wiII find 3 sets of
DIP switches at the bottom of the eireuit board. Check the switch settinEs
against the illustration in Figure 2-L2 and the chart below it.
Switeh 1 -
Has eight positions which select the clock divisor to match the
selected baud rate.
Switeh 2 -
Has eight positionswhieh set the communieationsspeedto
9600 baud with 1 stop bit, ? data bits at an even parity.
Switch 3 -
Has four oositionswhieh seleet the control mode:
position 1
ON
OFF
XYZ mode
Joint Mode
position 2
not used; set to OFF
position 3
not used; set to OFF
position 4
Ioads robot
position data from
ROM to RAM
no effect
0
\
sw2
L
Figure 2-72 - DIP Suitch Settings for the Robot D ri\te Unit
2-22
Connectingthe TeachPendant
The Teach Pendant is a hand-heldDortablecontroller which oermits remote
operationof the robot. To conneetthe Teach Pendantto th; Drive Lnit,
insert the cable conneetor from the Teach Pendant into the connector
BOXfi on the left rear of the Drive Unit.
Iabeled TTTEACHING
Installingthe OptionalPrinter
Interconnections
Connect the optional Epsonprinter to the system as follows:
1)
Connectthe printer end of cable N500-2031to the rear of the pr inter
as shownin Figure 2-13. Snapthe holding clips into place.
2)
Connect the other end of the cable to the parallel port on the Hercules
graphiescard installed in the System Controller.
3)
Connectthe printer line power cord to line power.
Figure 2-13 - Printer Cable Connection
Printer Controls and Indicators
Except for the POWERswitch, all eontrols and indicators are on the control
panel on the right side of the top of the printer, Each of the three buttons
on the control panel has two functions. The functions marked on the blue
panels(ON LINE, NLQ, AND DRAFT) are active when the printer is on-line;
the functionsmarkedon the gray panels(OFF LINE, FF, AND LF) are active
when the printer is off-line.
POWERON/OFF switch - Locatedon the left side of the printer.
POWERindicator- Lights when the power is on.
READY indieator - Lights when the printer is ready for use. If it is off,
press the ON LINE button to turn it on.
PAPER OUT indicator- Lights when there is no paperor the paper is
incorrectly loaded.
OFF LINE - If you press the ON LINE button when the green iight beside it
is on, the ON LINE and READY lights go off and the printer is set off line;
that is, the power is still on but the printer won't print. The FormFeed (FF)
and Line Feed (LF) functions work only when the printer is off line.
ON LINE - The green ON LINE light indicates that the printer is on line and
ready to receive data. If the READY light is also on, the printer-s ready to
print (if it is conneetedto the computer). You may notiee that the READY
light flickers when the printer is printing, but this is normal. I!hen the
printer is on line, you can select either NLQ (Near Letter Quality)or draft
modes.
FF (Form leed) - Pressingthe FF button advancesthe paper to the top of
the next page if you are using continuous-feedpaper. If you are using
single-sheetpaper, it fully ejects one sheet, The FF function works only
when the printer is off line.
NLQ (Near Letter Quality) - Pressingthe NLQ button selects the Near
Letter Quality typestyle. The printer beepstwice to aeknowledgethe NLQ
seleetion, You can select the NLQ typestylewith the NLQ button only when
the printer is on line.
LF (Line Feed) - Pressingthe LF button advancesthe paper one line at a
time, either while you are loading paper, or when you are adjusting where
you want printing to begin. If you hold the LF button down, the paper
advancescontinuously. The LF function works only when the printer is off
llne.
DRAFT - Pressingthe DRAFT button selects the draft typestyle. The
printer beepsonce to acknowledgethe draft selection. The draft mode is
also the default setting for the printer, so every time you turn the printer
on, it is set to print in the draft mode. The IIRAFT button works onlv when
the Drinter is on line.
2-24
DIP Switches on the Printer
Two sets of DIP (Dual In-line Package)switehes control a number of
important printer functions. They are located under an accesscover on the
back right corner of the printer, as shown in Figure 2-14.
Factorysetlings
i
l
iggBBBH
DIPswllch panel2
Figure 2-14 - DIP Switch AccessCover Remolat and Switch Locations
To remove the cover, use a Phillip's head screwdriver to remove the top
screw, Then take the cover off by pressingdown and sidewayswith the
palm of your hand as shown.
Locate the two DIP switch assemblies
shownin Figure 2-14, They have been
set at the factory as shown. The meaningsof the settings are given in Table
You will probably never need to touch most of the DIp switches. There are
two, however,which you may want to change:
-
Switch 4 on assembly2: If your first printing occurs either all on one
line or with lines twice as far apart as you intended, changethis switch.
-
Switch 2 on assembly1: Changingthis switeh will add a slash to the
zero character, which makesprogram listings easier to read.
WA_RNIIIG:If you find you need to ehangea switch setting, be sure
to turn the power OFF before touching the internal switches. Use a
non-metallie object, such as the top of a pen, to changethe DIp
switches.
z-25
TABLE2.2
DIPSWITCHFUNCTIONS
S$,itch1
No. O N
Function
1-1 Compressed
1-2 0 (slashed)
Printmode
Zerocharacter
Paper-enddetector
Printermode
Printmode
Inacltve
t-3
Enrphasized
OFF
lB[/
International
characlerset
SeeTableA-2.
1.7
Standard
OFF
OFF
OFF
Switch 2
No. ON
21
2 2 Actrve
2-3 ON
Funclion
Printer
seiect
OFF
Inactve
Cutsheet feeder
Skipover pertoration
CR+LF
Automaticline feed
The shadedboxesshow the factorysettings.
TABLE2.3
INTERNATIONAL
DIPSWITCHSETTINGS
Country
USA
France
Germany
UnitedKingdom
Denmark
Sweden
Italy
Spain
SrYlich1€
On
On
On
On
off
off
oil
oft
Swltch1.7
On
On
off
ofr
On
On
off
ofl
Switch l{
On
off
On
off
On
ofr
On
oll
2-26
Conneciingto Line Power
When you have installed all the components of the system (System Controller, robot and Robot Drive Unit, and optional printer), and their respective
Iine power cords are properly connected to them, plug eaeh line eord into a
wall outlet.
TO YOURSYSTEM
ADDINGMODULES
If you decide to add a module to an existing Masterlab System, you wiII
need to place it within the work envelope of the robot, and near any other
module with which it is to interact. Once you have determined an
approximatelocation, proceed as follows:
1)
Place the module in its tentative location, without drilling the mounting
holes.
2)
Use the Teaeh Pendantto move the robot to the various positions it wiII
have to assumein order to service the new module.
3)
Adjust the location of the module, if necessary.
4\
Finally, drill the mounting holes and mount the module in its permanent
location. It is recommendedthat you have this done by a Perkin-Elmer
service representative. Should it be necessary for you to do it yourself,
you will need a module mounting kit (P/N N090-0057).
Drill exactly perpendicular to the Worksurface. (A drill bushing,
available from maehinetool suppliers,is helpful.) Use a 5/16 inch drill
bit, and drill to a depth of at least 1/4 inch. Following the instructions
in the mounting kit, insert the mounting knobs in the holes.
NOTE: If you are mounting the module in a slate bench top, use
a carbide drill bit. Replace the Dodge wedge in the mounting
kit with a lead anchor. available from hardware stores.
STARTUP
Section
3
PaEe
STARTUP
PRELIMINARY PROCEDURES
Turning ON the Masterlab System
Backing up DOS and PERL Disks
Loading the PERL/DOS Work Disk
Creating a Data Disk
CONFIGURINGTHE SOFTWAREFOR YOUR SYSTEM
Introduction
Loading CONFIG
Adding a Module ,
Changing a Module
Deleting a Module
Displaying Module Information . .
LOADINGPERL SOFTWARE ...
TEACHING AND PROGRAIIIMINGTHE ROBOT
Introduction
Accessingthe Teach Programs
Defining a Rack ..
Moving the Robot .
Naming a Position
Moving to a Position
Positioning the Gripper
CREATING A PROCEDUREWITH THE PERL EDITOR
Planning Your Procedure
Writing a Procedure
Combining Procedures
DEBUGGING
A P R O C E D U R E. . . . .
R U N N I N GA P R O C E D U R E. . . . .
LEAVING PERL .
3-1
3-1
3-1
.t -9
3-3
3-4
3-4
3-6
3-11
3-12
3-14
3-14
3-16
3-18
3-18
3-19
3-20
3-24
3-24
3-25
3-26
3-29
3-30
3-30
3-33
3-36
3-36
3-36
a
!o
STARTUP
This section providesan overview of the operation of the Masterlab System.
It contains the information necessaryto quickly familiarize you with the
robottsoperation and allow you to write simple application procedures.
PROCE
DURES
PRELIMINARY
TurningON the MasterlabSystem
1)
Check all modulesand accessoriesthat you will use in the sample
preparation procedure to ensurethat they are connected to the Robot
Drive Unit, the System Controller or the Device Interface Unit, as
appropriate. Refer to Figure 2-11 and the appropriate accessory
manualsfor electrical connections.
2)
Turn all modulesexcept the System Controller (IBl\I PC) to ON.
The llasterlab System is now ready for the loading of software.
BackingUp DOSand PERLDiskettes
(OneTimeOnty)
You should make a back-up copy of your PERL diskette for everyday use, so
that your master copy can be stored. You will find it a convenienceto have
a copy of the most frequently used DOScommandson the same diskette
that containsPERL. The followingprocedurecopiesboth DOSand PERL
onto a single disk. After you have made this disk, use it with the procedure
underI'Loadingthe PERL Work Disk" wheneveryou wish to load PERL.
1)
With power to the SystemController(IBM PC) turnedoff, insert the
DOS diskette into drive A, Turn the Controller on. (If your System
Controlleris alreadyon, insert the DOSdisketteand then reset the
Controller by pressingCTRL, ALT, and DEL si multaneously.)
3-2
2)
Whenthe date is displayed,enter the correct date and pressEnter.
Whenthe time is displayed,enter the correct time and n,'acaFnrar
again.
3)
lvhen the DOSprompt (A>)appears,put a new, unformatteddiskette in
drive B,
Issuethe followingseriesof commands,PressEnter after each one,
and wait fof the DOSprompt to reappearbefore typing the next
command,
4)
format b:/s (Whenthe system asksyou "format another", type n.)
copy format.eom b:
Removethe DOSdisl<ettefrom drive A, and insert the PERL diskette,
Type
copy *.* b:
and pressEnter. The entire PEIiL diskette will be copiedonto the
<iiskettein drive B.
6)
Removethe PERL diskette from drive A. Store it where it will be safe
from heat, magneticfields, dirt, or mechanicalinjury,
7)
Removethe diskette from drive B, and label it rrDOS/pERLv.2.0 work
disk"..To load PERL into your SystemController(IBNIpC), proceedas
describedin the following section.
Loadingthe PERL/DOS
Work Disk
For this procedure,use the DOS/PERLwork disk which vou created in the
precedingseet ion.
1)
First load DOS, To do this, with power to the SystemController turned
off, insert your DOS/PERLdiskette into drive A. Turn on all external.
devic-e-s
connected to your System Controller, then turn the Controller
on. (If your SystemControlleris alreadyon, insert the disketteand
then reset the Controlierby pressingCTRL, ALT, and DEL simultane_
ously.)
2)
After a pause,the date will be displayed.If it is not correct, enter the
correct date in either of theseformats:
8-1-85
8/7 /85
PressEnter.
3)
The present time will then be displayed(hours,minutes, seconds,
hundredthsof a second). If it is not correct, enter the correet hours
and minutes in the format
9:05
PressEnter. The DOSprompt (A>)will appear.
Creatinga DataDisk
In general, you will load the PEIiL/DOS work disk into drive A, and use a
data disk in drive B for savingyour created procedures,directory of
eommands.and data files.
To create your first data disk, use the following procedure to place the
necessaryfiles on a disk in drive B:
a)
With the PERL/DOSwork disk in drive A. place a formatted disk in
drive B,
b)
Type
eopy *.999 b:
and press Enter. The system wiII copy the initialization procedure(s)
for your robot(s)onto the disk in drive B,
e)
To make drive B the default drive, type b:, and press Enter. The
p r o m p tw i l l b e e o m eb .
d)
Create your system configuration file (perl.SCF),using the
file on your DOS/PERLwork disk. To do this, type
a:config
and press Enter. Follow the proceduregiven in "Creating the System
Configuration Filer', below. The system will place the file PERL.SCF
on the disk in drive B.
e)
Load PERL as describedin "LoadingpERLr',below. Commandsyou
create with PERL will be filed on disk B in pERL.DIR.
3-4
THESOFTWARE
FORYOURSYSTEM
CONFIGURING
lntroduction
Before you can operatethe NlasterLabSystem,you must configurethe
is an interactiveprogramwhich allows
software for the system. nCONFIGTi
the analystto create a file that identifiesthe communicationrequirements
of the different modulesincludedin the system, You can identify the
following:
*
Aecessorymoduleson the system
t
Port locationof eachaccessory
*
Initializationparametersfor each module
+
Communicationprotocol for each module
The systemconfigurationfile is read each time PERL is loade<linto
memory.This resultsin the initiaiizationof the communicationports on the
IBM PC and the communicationof the appropriate initializationcommands
to the moduleson the system.
Once the Masterlab Systemhasbeen installed,CONFIGneednot be used
again unlessa module is added,removed or ehanged. In that case, the user
changesthe system eonfiguration file to reflect the changesto the system.
For example,if you addeda bar codestation to the system,you would run
CONFIGin order to make the neeessaryaddition to the system
confiEuration file.
LoadingCONFlc.
For_thisprocedure,use the DOS/PERLworkingdiskette which you created
earuer.
1)
First load DOS. 0f DOSis alreadyloaded,proceedto step 3.)
lVith power to the SystemControllerturnedoff, insert your DOS/pERL
diskette in drive A. Turn on all externaldevicesconnectedto vour
System Controller, then turn the Controller on.
NOTE: If your System Controller is already on, insert the
diskette in drive A, and then reset the Controllerby pressing
CTRL, ALT and DEL simultaneouslv.
2)
Whenthe date is displayed,pressEnter. (You can reset the date, if
necessary,whenyou load your PERL software.)
Whenthe time is displayed,pressEnter again.
3)
Whenthe DOSprompt (A>) appears,type:
b:
and press the Enter key.
4)
Type in;
a:config
The display showsthe main menu of CONFIG. Four options are available:
*
Add a Module
*
Changea Module
*
Delete a Nlodule
*
Display ModuleInformation
The bottom of the displayidentifiesthe tasksassignedto eaehof the five
Iunctionkeys active in CONFIC.The key assignm6nts
are as follows:
4_9I
Label
Funetion
F6
Help
Displaysinformation on the operation of
various parts of the program,
F7
Quit
Stopsprogram and returns to the DOS
environment.
F8
Bkup
Returns to the menu displayedprior to the
selectionof the current menu.
F9
Up
Highlights the menu item on the tine above the
item curren y highlighted.
F10
Dn
Highlightsthe menuitem on the tine below the
item eurren y hightighted.
3-6
You will use thesekeys to:
*
move from one item to anotherin a menu;
*
return to a menu that was previously displayed;
*
display descriptive information about the current task;
*
exit from CONFIGand return to the DOSenvironment.
Adding a Module
Any module that is installed with your Masterlab System or added to the
system must be added to the configuration file to identify its
eommunicationrequirements.This enablesthe N{asterLab's
eomputerto
control the module.
CONFIGallowsyou to convenientlyadd a module,e.g., a printer or a
syringe,to the NlasterlabSystem. The variouscommunicationsoptions
associatedwith the added moduleare either selected bv default or are
seleetedby you.
The following is a general procedure for adding a module to the system, The
procedure for adding a robot to your Masterlab System is describedat the
end of this general procedure. The procedure for adding each accessory
module to the system is included in the manualprovided with the accessory.
To add a module to the system, proceed as foilows:
1)
Use the Up (F9) and Dn (F10)function keys (or the up and down arrow
keys) to highlight the option labeled:
Add a Nlodule
The display now lists categories of moduleswhich can be added to the
system. The choicesare:
Robot
Printer
Syringe
Mettler Balance
Bar Code Reader
DevieeInterface
AII Other Modules
2)
Ilighlight the type of moduleyou are adding to the Masterlab System
and pressthe Enter key.
The systemnow promptsyou to enter the communieations
requirements
for the new module. Onlv if vou chose"Printer" or "All Other Modules"
in the followingsteps. For
will you have to make alf the-responses
standard modules,for example the Syringe or Mettler Balance, the
systemmakesdefault entriesof most parameters. CONFIGTs
queries
for each standard module are describedin the appropriate Per*in-Elmer
module manual.
a l
If the Printer was seleetedas the moduleto be added,the system
prompts:
Port Type
and two options, RS-232and Centronics,are available,
Highlight the option which correspondsto the interface on the printer
that is being added to the system and press Enter.
{OTE: For devices other than printers, the system assumes
that an RS-z32serial interface is beinE used.
4a) For RS-232devices
Whenthe display pro mpts:
Port llnemonic
highlight the name of the communications
port on the System
Controller to which the module is connectedand press the Enter key.
For example, highlighting
COM3:
and pressing:
Enter
identifiescommunications
port 3 as the port to which the modulebeing
addedis connected.
NOTE: COll3: throughCOt\r6:are availableon the standard
S y s t e mC o n t r o l l e r ,C O M I : , C O I \ r 2a: n d C O M Z :throughCONl10:
are optional ports.
e-a
4b) For Centronics interface printers only
When the display prompts:
Port [Inemonic
highlight the name of the Centronics printer port to which the
printer is connected. For example, if the printer is eonnectedto the
primary parallel interfaceport, highlight:
PRN:
NOTES:
5)
1.
Steps 5 through 10, beiow, are only necessaryfor RS232
devices. Also, if you are adding a standard Masterlab
device,theseparametersare defaulted;proceedto step 11,
2.
The correct responsesto the prompts in steps 5 through 10
dependon the specific moduleyou are adding, Refer to
the manualprovidedwith the moduleto determinethe
module'scommunicationsrequirements.
The next prompt displayedis:
Handshaking
and two options, Yes and No, are available.
Ilighlight YES option if the module supportshardware handshaking
through the Clear to Send(CTS)and Data Terminal Ready (DTR) iines.
Ilighlight NO if the handshakeis not supported.
PressEnter to completethis selection.
6)
The systemnext requestsyou to select the baudrate at whieh flle
modulereceivesand transmitsdata. The choicesrange from 50 to 9600
baud.
Highlight the value at which the modulereceivesand transmitsdata
and press Enter.
7)
The systempromptsfor a parity seleetion,The three optionsare:
No Parity
Odd Parity
Even Parity
Ilighlight the option usedby the moduleand pressthe Enter key.
3-9
8)
The systenrprompts for the number of stop bits, i.e., the number of bits
terminating each character sent. The options are:
One Stop Bit
Two Stop Bits
Highlight the option required by the moduleand press the Enter key.
9)
The system prompts for the number of data bits transmitted by the
module. The options available are:
Five Data Bits
Six Data Bits
SevenData Bits
Eight Data Bits
Highlight the option required by the moduleand press the Enter key.
10)
The system next prompts for the timeout value, i.e., the time (in sec.)
that the computer waits for the module to respondto a commandsent
to the module. After the seleeted time has elapsedand no responsehas
been received, the computer displaysan appropriate error message.
When the system prompts:
Timeout
enter a value up to 99 and press Enter.
11)
The systemthen prompts:
ModuleName
Enter a name having up to sixteen characters (but no spaces)and press
the Enter key. The name entered is used to identify the module in the
PERL environment.
NOTE: The following charaetersshouldnot be usedin names in
eTtfrerCONPTCor pdRL.
! - + * / $ % ^& ( ) \ < > u ? ' @= |
Names must begin with an alpha character, may inelude up to
sixteen characters and may not include spaces, To indicaie a
space,use the underscoreor a period,
72)
The system prompts for the Initialization Sequence, The
initializationsequenceis that action or seriesof aetionsthat occurs
when the module is initialized or set to its starting position. An
3-10
It can
Initialization Sequencec^aninclude more than one com.mand'
initialization
before
module
the
-tf a responsefrom
aiio request
u."ipon." is requiredfrom the module,the following
pr""""dt,
commandis included:
,?xxx, (wherexxx is the requiredresponse)
If an ASCII commandis used,the commandis enclosedwith angle
brackets,< >.
for variousmodulesare shown
Typical InitializationSequences
below.
Nrodule
Initialization
Sequence
Explanation
Printer
<FF> <CR>
Form feed followedby a
carriagereturn'
Device Interface
Cr?*
Clear moduleand wait
for asterisk to be
returned,
Robot
NT,?$,NIO999,?$,PR999Nes! wait for a dollar
sign to be returnedl
litiiiill";"','m
Enter the combinationof ASCII and modulecommandsthat definesthe
sequenceand press Enter.
13)
The systempromptsfor the Input Terminator' the ASCIi character
or sequenceof characters used to terminate the responsecom ing
from the module to the System Controller 0BNI PC). For example, a
typical input terminator is a carriagereturn, <CR>, or a carriage
return. Iine feed. <CR> <LF>.
Enter the ASCII character,sequenceof charactersor trexadecimal
value for the ASCII character(s)for the desired input terrrrinator in
angle brackets < > and press the Enter key.
14)
The system prompts for the Output Terminator, the ASCII
character,sequenceof charactersor hexadecimalvalue for the
ASCIIcharacter(s)usedto terminate a commandsent to the module
from the System Controller (IBNIPC). For example, a typical
output terminator for a printer is a carriage return, <CB>, followed by
a linefeed,<LF>, i.e., <CR><LF>.
Enter the ASCII character or hexadecimalvalue for the ASCII
character(s)for the desired terminator in < > and press the Enter key.
15)
To store the information just entered for the module on the PERL
diskette end return to the DOS environlnent,press the Quit function
key (F7).
The systemqueries:
Save the current modifications? (y/n)
Press:
y - to save the communieationsoptions for the module
n - to abort the storage operation
parametersselectedfor the moduleare
The communications
automatically stored on the PERL disk (loeated in drive A) in the
systemconfigurationfile namedPERL.SCF.
This proceduredescribesthe steps to follow to add a robot to your
MasterLab System.
1)
Use the Up (F9) and Dn (F10) function keys (or the up and down arrow
keys) to highlight the option Iabeled:
Add a IIoduIe
2)
Ilighlight the modulelabeled:
Robot
3)
Whenthe display prompts:
Port Mnemonic
highlightthe name of the communieations
port on the System
Controller to which the robot is connectedand press the Enter key.
4)
The systemthen prompts:
NloduleName
3-r2
Enter a name that beginswith an alpha eharacterand has up to sixteen
characters (no spaces).
Press the Enter key.
5)
To store the informationjust enteredon the PERL diskette and return
to the DOSenvironment,pressthe Quit functionkey (FZ).
The systemq ucries:
Savethe current modifications?(y/n)
Press:
y - to save the communications
optionsfor the robot
n - to abort the storage operation
Changinga Module
With CONFIGyou can changethe communications
optionsassignedto a
moduleon the system.
To changea module,proceed as foliows:
1)
Use the-Up-and Dn keys (F9 and F10) to highlight the option on the main
menuof CONFIGlabeled:
Changea Module
The screen displaysa list of the modulesfor which the system is
presently configured (that is, those listed in the system configuration
fite).
2)
Highlight the name of the modulewhosecommunications
optionsyou
wish to changeand press the Enter key.
Ttre options presen y selected for the device are displayedon the
screen(seeexamplebelow).
J-1.)
Port TvDe
Port Mriemonic
Flandshaking
Baud Rate
Paritv
StopBits
Data B its
Port Timeout
RS-232
CONIT:
Yes
9600
Even
1
7
10 seconds
NloduleName
NloduleType
Initialized
Init. Sequence
lnputTerminator
Output Terminator
Instrument
Other Device
On Start-up
<CR><LF>
<CR>
3)
Use the Dn function key (F10) to move the cursor to the first option
that you wish to change.
4)
Pressthe Enter key to edit the current entry for the option.
5a) If the option requires a typed entry, type the desired entry and press
the Enter key.
5b) If the optionrequiresa selectionfrom items in a menu,use tlre Up and
Dn keys (F9 and F10) to highlightthe desireditem and pressthe Enter
key to completethe seleetion.
6)
lvhen the options for the moduleare modified as you wish, press the Dn
functionkey (F10)until you reach the bottom of the option list. You
will see the following messagel
PleasePressthe <ENTER>Key to Continue
7)
To continueoperationin CONFIG, pressthe Enter key,
8)
To store the informationjust enteredfor the module(s)on the PIRL
disketteand return to the DOSenvironment,pressthe Quit function
key (F7).
The systemqueries:
Savethe current modifications?(y/n):
Press:
y - to savethe modifiedcommunications
optionsfor the module(s)
optionsfor the
n - to retain the previousset of communications
module
3-14
Deletinga Module
CONFIG enablesthe user to delete any module from the hiesterlab
System.
To delete a module from the system, proceed as follows:
1)
Use the Up and Dn keys (F9 and F10) to highlightthe option on the
main menuof CONFIGlabele<i:
Delete a Module
A list of the modulesthat the system is configured for is displayed
on the screen.
2)
Highlight the modulethat you wish to delete and pressthe Enter
key.
The module is deleted from the system configuration file,
PERL.SCF.
IMPORTANT: Be certain that vou wish to delete the modulefrom
tIe fiIe-6eToreyou press the Enter key. Deletion follows
immediatelyafter depression
of the Enter key.
3)
To store the modified file on tire PEF,Ldiskette and return to the DOS
environment,pressthe euit function key (FZ).
The systemqueries:
Savethe current modifieations?(y/n):
Press:
y - to save the modified file
n - to retain the previousset of communications
ontions
DisplayingModuleInformation
To displaythe communieations
informationenteredfor anv modulethat is
already present on the system, proceed as follows:
3-15
1)
Highlight the option labeleo:
Display NloduleInformation
A list of the moduleswhich are configured for use with the Masterlab
System appearson the screen.
2)
To disptay information stored for any of the moduleslisted, hightight
the module name and press the Enter key.
A dispiay similar to that shownbelow appearson the screen.
NIoduIeInformation
PERL ConfigurationUtility V1.0
Port Type
Port Nlnemonic
ilandshaking
BaudRate
Parity
Stop Bits
Data Bits
Port Timeout
RS-232
COI\I1:
Yes
9600
Even
I
7
10 seconds
[ioduie Name
Module Type
Initialized
Init. Sequence
Input Terminator
Output Te minator
ROBOTl
Robot
On Start-up
NT,?$,1Vi
O9I 9,?$,PR9I 9
<CR>
<cR><LF>
PleasePressthe <ENTER>Key to Continue
F6=Help F?=HaIt F8=Bkup F9=Up F10=Dn
Refer to "Adding a Modulefiin this manual for information about the
individualitems in this list.
3)
4)
To display information for the other moduleson the system:
a)
Press the Enter key to redisplay the Iist of available modules.
b)
Highlight the name of the desired moduleand press the Enter key.
If any changesare requiredfor the modules,use the'rChangea l\iodule'i
option to make those changes.
J -.LO
LOADING PERLSOFTWARE
Loadingthe PERL softwareis the processwherebya copy of the PERL
program is read from the PERL disketteand placedin the System
Controller'smemory,
For this procedure,use the DOS/PERLwork disk whichyou created with the
procedurerrBacking
up DOSand PERL Disks.r'
1)
First load DOS. To do this, with power to the SystemController turned
off, insert your DOS/PERLdiskette into drive A. Turn on aII external
devices connected to your System Controiler, then turn the Controller
on. (If your System Controller is already on, insert the diskette and
then reset the Controllerby pressingCTRL, ALT, and DEL
cimrlfonanrrclrr'l
2)
After a pause,the date will be displayed. If it is not correct, enter the
correct date in either of theseformats:
8-1-85
8/7 /85
PressEnter.
3)
The presenttime will then be displayed(hours,minutes,seconds,
hundredthsof a seeond).If it is not correct, enter the correct ltours
and minutesin the format
9:05
PressEnter. The DOSprompt (A>) will appear.
4)
Plaeeyour data disk in drive B.
Type
b:
PressEnter.
This makesdrive B the default destinationfor the files you create with
PERL.
5)
Type:
Perl
The PERL logo appearsfollowed by the copyright nlessage3
Copyright(c)1985 Perkin-EImer Corporation
and the revision level of the software:
PERL SystemVX.XX
where X.XX is the revisionlevel,
The Masterlab moduleswhieh initiaiize at Start-Up wiII initialize as
direeted by the System Configuration File. For example, when the
robot initializes,it first movesto its NESTposition,the position
reachedwhen all the joints have actuatedtheir limit switches. It then
proceedsto its reference (or 999) position, the fully extendedposition
where the hand of the robot is parallel to the ground. This routine gives
it points of referenee from whieh it can now accurately move to
modulesincluded in the system,
The PERL main screen is now displayed. When this screen is displayed,
the PERL Direct CommandProcessoris in control and any PERL
command that you type in will be exeeuted. (Refer to Section 2 of the
PERL manual.)
The bottom of the display identifies the tasks assignedto the active
function keys. The key assignmentsare as follows:
Key
Label
Function
F1
Run
Runsa PERL procedure. Whenyou pressF1,
you will receive the message"Pleaseenter
procedurename." Type the name and press
Enter,
F2
Edit
Entersthe PERL editor wherePERL
proceduresare created.
F3
Teach
Entersthe PERL TeachProgramswherenew
commandsthat control the robot and its
accessorymodules are created.
E4
Dir
Lists the PERL files and programsas well as
user€eneratedcommandswhich are stored in
the PERL Directory.
F6
Help
Displaysinformation on the operation of the
current portion of the program.
F7
Quit
StopsPERL and returnsto the DOS
environment.
3-18
You will use these keys to accessthe various tasks that are performed
from the PERL environment. Figure 3-1 showsthe PERL keyboard
overlay whieh identifiesthe function keys.
FEFr(I|a-A_lEt
PEit
Figure 3-1 - PERL Function Key Keyboard Uverloy
TEACHING
AND PROGRAMMING
THE ROBOT
Introduction
The operationswhich the robot performscomprisea seriesof commands.
These commandsspecify:
*
robot arm position
*
gripper position
x
Iocation in a test tube rack or vial rack which the robot is to
service
You create the commandsneededfor your applicationby meansof the
PERL robot Teach Program. While running ihe Teach program, you use the
Teach Pendant to move the robot to a position that it wili-need io "know',,
and assigna commandname to that position. Onceyou have taught the
robot the commandswhich specify certain locations-orpositionsfyou can
program.it to transfer samplesfrom module to module during sam-pte
preparation.
3-19
NOTE: The positionsthe robot I'learnsrrinthe followingseetions
Ei-estored in the PERL Directory, Pleaserefer to the PERL
manual for information neededto use the PERL Directorv.
Accessingthe TeachModules
To teach the robot a seriesof commandsthat wi
speeific operation, proceed as follows:
1)
enableit to perform a
With the PERL software loaded,press the Teach function key (FB) to
aceessthe Teach Programs.
NOTE: Teach Programsexist for all the RS-232Cmodules
available as standardaccessoriesfor the Model g000
Masterlab System. Refer to the appropriate accessory
manualsfor information about Teach programs other [han the
robot's.
The Teaeh Program selection menu appearson the screen. It Iists the
modulesfor which your system is configured.
2)
Use the Up and Dn function keys to highlight ',Robot." press the Enter
key.
If only one robot is present on your system, the options shownbelow are
presentedautomatically. If more than one robot is present on your
scre.endisplay^.liststhem by the names they are asjigned in
:I:t_eTl
Jlleconliguration
tne system
file.
3)
Choosethe desiredrobot by highlighting its name and pressingthe
Enter key.
The screen display which now appearsoffers you five options.
Option
Function
Def ine a Raek
Defines the location of a test tube rack or a
vial rack so that the robot will be able to
move to every position in the rack.
Move the Robot
Moves the robot to a Iocation under the
control of the Teach Pendant.
Move to a Position
l\lovesthe robot to a previously-named
position,
3-20
4)
Name a Position
Assignsa name to the robot'spresentposition'
Positionthe Gripper
Opensor closesthe gripper,namesthe gripper
positionand adjuststhe force the gripper
applies to the objeet.
Highlight the option that identifiesthe task you wish to perform and
pressthe Enter key.
Defininga Rack
Each of the test tube or vial racks usedwith the Masterlab Systemcontains
many locations. Onceyou have usedthe TeachProgramto define three
corner positionson a rack, the robot will be able to go to each location in
the rack and pick up or replace a test tube or vial.
NOTE: Before defining the rack position:
1. Be certain that the rack is fastenedsecurely to the
worksurface.
2, Be certain that the TeachPendantis connectedto the
Robot Drive Unit.
Be
certain that the grippersare insertedsecurelyin the
3.
robot hand.
1)
Ilighlight the option in the Robot Teach hlodule labeled:
Define a Rack
Pressthe Enter key.
2)
llrhenthe programpromptsyou for the rack name, type in a name which
begins with an alphabetic character and has up to sixteen characters,
noneof which are spaces.For example,type:
raek_4
Pressthe Enter key.
3)
The next screen contains the following instructions:
Positionthe Robot to Tube PositionA
Pressthe <ENTER>Key to ComputeX, Y, Z Coordinates
NOTE: Be certain that the DIP switch SIV3-1on the }iobot Drive
lillTs in the ON position. Iiefer to "Installing the Robot Drive
Lnit" in Section2 of this manualfor additionalinfornation.
3-27
To accomplish this;
a)
Turn on the Teach Pendant,using the ON/OFF switch on the top of
the pendant. (SeeIigure 3-2,)
ON/OFF Switch
tic
0tc
t.s t c
isI
0tc
Til
tv
l0i
C16e
Grippel!
ttT EV
Op€a
Gripp€rs
Figure 3-2 - The Teach p endant
b)
PressrrOr'(Open)
on the Teachpendantto open the grippers.
c)
Use the six X, Y, and Z touch pad keys in the top three rows of the
right column to move the robot's grifpers above the first test tube
positionJi.e., the tube in the first column of the first row. Refer
to A in Figure 3-3.
NOTE: You will need to experimentwith the movement
6T-IEErobor causedby X, y and Z ["v d;p;;;ri;n. Note
that the first five steps taken are short and subsecuent
ones are longer. Figure 3-4 illustrates the robot's
movementsin the X, y and Z planes when you depress
these keys.
d) Lower the robot grippers until they are in the position they will
be
in when they are gripping the test tube or vial.
e) To-test the position, insert a test tube in position A and press ,rCr
(Close)on the Teach pendant to close thjgrippers,
Robot Location
L--------
- --
---
J
oooooooooooc
o o o o o o o o o o
o o o o o o o o o o
4 6 0 0 0 0 0 0 0 0 0
Figure 3-3 - Test Tube Rack
+z
-x
I
8Y
OY
U +x
I
-z
Figure 3'4 - Robot Motion in X, Y and Z Plqnes
a-te
NOTE: If the grippers are not positionedproperly at this
point, repeat step 3b through 3d to position the grippers
rnore accurately.
f)
Switch the ON/OFF switch on the TeachPendantto OFF.
C)
PressEnter.
After a short delay, while the system ealculates the X' Y and Z
coordinatesof the position, the coordinatesappear at the upper
right eornerof the screen.
A typical display shows:
X = 4 3 2
Y = 3 6 2
Z = 7 9 2
IMPORTANT: Do not changethe Z (height) coordinate from
this Dointon.
4)
The screen messagethen changesto request the first tube position in
the last row.
Repeat step 3, above, positioning the robot at the first tube position in
the last row (B in Figure 3-3).
5)
The screen messagethen changesto request the third tube position (C
in Figure 3-3).
Repeat step 3, positioning the robot at the last tube position in the first
row.
6)
You will then be asked for three pieces of information, as shown in the
examplebelow.
Type in the responseswhich are correct for youi rack and test tubes or
vials, pressingEnter after each response.
For example,
Numberof rows: 4
Numberof columns:10
Lengthof tube (mm)r 150
The information about the rack named rBck 4 wiII be stored in the
PERL D irectory.
The options menu of the Robot Teach Program then returns. you can
proceed to name and define another raek, or you can select another
option from the Robot Teach Program options menu.
3-24
Movingthe Robot
T h e ' ' M o v e t h e R o b o t ' ' o p t i o n a l l o w s y o u t o u s e t h"Name.a.Posi.tion"
eTeachPendanttomove
the robot. You can then name the p5sition,using.the
option. (However,iI namingis your lnlenllon, lt ls more el Ilclent lo move
the robot from within the "Name a Position"option')
1)
Highlight the option in the Robot Teach Program labeled:
Nlovethe Robot
Pressthe Enter keY.
The following messageswill appear on the screen.
Positionthe Robot with the TeachingPendant
Pressthe <ENTER>Key to ComputeX, Y, Z Coordinates
2)
Turn on the Teach Pendant,usingthe ON/OFn switch on the top of the
pendant. (SeeF igure 3-2')
3)
Use the six X, Y, and Z touch pad keys in the top three rows of the
right column to move the robot into the desiredposition.
4)
Switch the ON/OFF switeh on the TeachPendantto OFF.
5)
PressEnter.
The X, Y, and Z coordinates(in mm) of the positionare caleulated
automatically and appear in the upper right corner of the sereen.
6)
To return to the Robot TeachProgramoptionsmenu,from which you
can accessthe "Name a Position"option (to name the positionof the
robot), press F8 (Bkup). If you want to move to another position
without renamingthe presentposition,repeat steps2 through5,
Naminga Position
The "Name a Position"option is usedto name the presentpositionof the
robot. The name assignedto the positioncan be enteredlater in PERL
programsto direct the robot to this position.
NOTE: Be certain that the ON/OFF switch on the Teach
Pendantis in the OFF oosition.
a-t<
1)
Highlight the option in the Robot Teach Module labeled:
Name a Position
Press the Enter key.
2)
nhen you see the prompt:
PositionName
type in a name containing up to 16 characters (noneof which are
spaces).
NOTE: Choosea meaningfulname that elearly describesthe
!6iillon, e.g., above_mixer.
Do not press the Enter key unlessyou want to assignthis name to
the presentpositionof the robot.
3)
lf you want to move the robot before assigningthe name, turn on
the Teach Pendant. Xlove the robot as describedin fil{oving the
Robotrr,above.
4)
Whenthe robot is in the position you wish to name, turn off the
TeachPendant. PressEnter.
The system.will identify .thepresentrobot positionwith the name
you entered and store flris
inlormation in the pERL Directory.
Movingto a Position
Once you have assigneda name to a position, you can move the robot to it
by:
*
typing the position name and pressingEnter while in the Direct
CommandProcessorof pERL.
*
highlighting the position name in the pERL Directory and pressing
Enter. Refer to Section2 in the PERL manual.
*
selecting the "I ove to a position" option in the Robot Teach
Program.
To use the Teach Program to go to a position, proceedas follows:
3-26
1)
the
From the main menuof the Robot l\IoduleTeachProgram,highlight
optionnamed:
Move to a Position
2)
and pressthe Enter keY.
The screenPromPts:
PositionName
above-mixer,and
\pe in the name that identifiesthe position,e'g',
press the Enter keY.
IIViPORTANT: If the robot is about to collide with an object,
Dressi6e rea Remote Robot ShutdownSwitch immediately.
3)
After the robot completesthe move' you can move it to another
position by entering another position name.
Alternatively,you can pressthe Bkup key (F8) to return to the robot
TeachProgrammain menu.
the GriPPer
Positioning
Whenyou assigna name to a robot position, the stored position includesall
parameters exeept the position and pressureof the grippers. These are
entered separately.
1)
Highlight the option in the Robot Teach Nlodulelabeled:
Positionthe Gripper
Pressthe Enter key.
2)
The following menu appearson the screen:
I\'nrra
tha
/l ninnan
Name a GripperPosition
Name the Grip Pressure
Set the GriD Pressure
Before you name the grip pressureyou first need to set the grip
pressure(if the position is a closed one, and if it has not previously been
set for the vesselsto be gripped),
.t -,
t7
Highlight the option labeled:
Set the Grip Pressure
and press the Enter key,
The system uses three parameters to set the grip pressure. They are:
Force to Close(0-7)
Force to Hold (0-7)
Force Duration(0-99)
Default settings for the parameters are 4, 4 and 50, respectively.
You will enter the values which are suitable for the vessel that the
robot is gripping.
Initiaiiy, set the "Force to Hold'r and t'Force to Close currents low and
the I'Force Durationl time long. For example, use a rrForceto Close" of
3, a "Force to Holdrrofl and a rrlorce Duration" of 50. You may need
to experimentwith varioussettingsuntil you find the oneswhich grip
and hold your vesseisfirmly, but without excessiveforce.
3 ) The "Force to Close'rentry sets a target current. lVhenthe robot
operates,the grippers continue to close until the current value selected
is reaehedor untii the duration time has elapsed. The greater the
closing current, the greater the elosing force.
Enter a value from 0 to ?.
Pressthe Enter key.
4)
The I'Foreeto Holdrlentry sets the current that is applied to the
grippers to hold the vessel. The greater the current, the greater the
holding force.
If the grippers are holding a vessel that will be cappedin the following
steps of your procedure,select a rrForceto Hold" entry of 6 or ? to hoid
the vesselseeurely. If the grippers are holding a vial that will be
crimpedin the procedure,select arrForceto Hold" entry that holdsthe
vial loosely (1 or 2) so that the vial ean be slid higher in the grippers.
Enter a value from 0 to ?.
Pressthe Enter key.
J,,
TheriForceDurationtrentrycontrolsthe length of time (in increments
of 0.01see.)that the current rampsbefore it dropsto the holding
current.
3-28
Enter a value between0 and 99.
Pressthe Enter key.
The previousthree entriesset the grip pressurefor your vessels. Unless
iine'poiitioning is required in your-prdgram,once th-egrip pressureis
set for your vessels,you will not need to changeit until you replace the
vesselswith onesof a different size or shape.
6)
The main menu of gripper options is automatically displayedon the
screen for the selection of other gripper controls.
To name the grip pressureyou just seleeted' highlight the option
Name the Grip Pressure
and press the Enter key,
7)
The screenprompts:
Grip PressureName:
Type in the desiredname (up to 16 characters, but no spaces).
For example, type:
lightpressure
Pressthe Enter key.
The name entered identifies the grip pressureand is stored in the PI,IiL
directory. You will use the name in PERL Programsto select this grip
pressurefor a partieular objeet.
8)
The main menu of gripper options is automatically displayedon the
screen for the selection of other gripper controls.
Highiight the option named:
lllove the Gripper
o\
The screenprompts:
Use Left Arrow Key to Open Grippers
Use Right Arrow Key to Close Grippers
a-to
Use the left and right amow keys on the computer keyboard to open or
close the grippers as required for this step of your robotic operation.
The direction in which the grippers are moving (openor close) is
displayedbelow the prompts.
10)
To return to the gripper menu,pressthe Bkup key, F8,
11)
Highlightthe option labeied:
Name a GripperPosition
72)
Tlre screen prompts:
GripperPositionName
Type in the desiredname (up to t6 characters,but no spaces).
F.'r
avq
mnla
t\rna
'
large_tesr,_tube
Pressthe Enter key.
The name entered identifies the position of the gripper and is stored in
tie PERL Directory. You will use this name in pERL programsto
direct the robot to this position.
13)
To return to the main menuof the Robot Teachprogram,pressthe
Bkupkey (F8).
CREATING
A P R O C E D U RW
E I T HT H E P E R LE D I T O R
Onceyou have "taugltt" the [Iasterlab Systemthe commandsneededin a
particular samplepreparation operation, you can ereate a procedure which
performssimpleroutinesor comptetesamplepreparationoperations.These
proceduresare created in the pERL Editor environment.
Pr_ocedures
perform simpie routines such as moving a sample tube to a
mixer, turning the mixer on and off and getting th; tube from the mixer.
Several simple proceduresare usually wrltten inC run individually to be
certain that they function properly. Theseproceduresare then combined to
create a complete procedure for samplepreparation.
3-30
In the following sections, methodsfor ereating both simple proceduresand
proceduresfor samplepreparationare given.
NOTE: Before attempting to create a procedureusing the
p-E-RIEditor. vou should familiarize vourself with the PERL
anciits editor - by
lanruare - it3'architecture,its comm-ands
(P-E
part
PERL
manual
no. 0993-8155)
reading
the
cari fully
provided with your Nlasterlab Systeni.
PlanningYourProcedure
Before you begin to write your procedures,you wiU want to carefully
consider the steps which comprise the operation you wish the robot to
perform. By spendingtime planning ahead,you will improve the quality of
your procedureand reduce the debuggingtime required if it doesnot
function properly.
Considerthe following:
r
The task you want to accomplish,
t
The steps which make up each task,
*
The sequencein which you perform thesesteps,
*
The commandswhiehyou require for the robot, syringe,Device
Interface, balance and other modulesto perform the necessary
steDs.
Writinga Procedure
To create a new procedure,proceed as follows:
1)
W'iththe PERL softwareloadedand the Perl> prompt displayed,press
the Edit functionkey (F2) to enter the PERL Editor.
2)
From the PERL Editor initial screen,pressF7 (Edit Commands),The
Edit Commandsl\{enuappearson the screen(seeFigure 3-5).
NOTE: If there is no programin memory whenyou enter the
EEitor, tire Edit Comman-dsMenu will ap-pearat-once, without
your having to press F7.
J_J 1
3)
Check the compilerstatusat the bottom of the screen. If it is off, use
the Pg Up and Pg Dn keys on the IBM PC keyboard to highlight "Turn
compilerON."
Pressthe Enter key.
You may now begin to enter statements. Use any of the four types of
statements that are available in PERL. (They are describedin the
PERL languagemanual.)
CoDrriaht
(c)
1965
P.ltln-AlD€r
CorDolltioD
TurD
rqrD
Cob91l.!
oD
tr6:ltelp
F6=Stat
cobDlle!
colplr€r
F8:Bkup
ON
u!r
F9=Ins
FlO:Del
Figure 3-5 - Edit C ommandsMerur Screen
4)
The first line of your procedure must be:
procedure name
wheretrnamefi
is the nameyou are giving to the procedure. Procedure
namesin PERL may haveno more than eight characters.
Type this line and press the Enter key.
NOTE: Choosethe name for eachprocedurewith care. The name
usedshouldallow you to easily recognize the operation performed
by the procedure. For example, enter I'mix_samp"to identify a
procedurethat mixesyour sample,
o)
Type in the rest of the procedurepressingEnter after each line.
Continueto enter statementsuntil the procedureis complete.
6)
The last line of the proceduremust be:
end procedure
Type this line and press the Enter key.
7)
Store your procedure:
a)
PressF7.
b)
Highlight "Saveon disk.rr
c)
PressEnter.
The systemwill compileyour proeedureinto an intermediateform,
ready to be interpretedwhen it is run. This permits more rapid
execution.
8)
PressF8 (Bkup)to leave the Editor and return to the ptRL Direct
CommandProcessor.
NOTE: Test each simple procedureby running it before
combiningit with other proceduresto create a complete
procedure.
A sampleprocedurenamedI'to mixer" is shownbelow.This procedure
performsthe followingoperat ion:
*
movesthe sampletube into the mixer
+
turns on the mixer for 15 seconds
t
turns off the mixer
gets the samplctube from the mixer
SAMPLE PROCEDURE-TO MIXER,
procedure to_mixer
rem
rem positionthe sampletube above re mixer and then put it into the mixer
rem
above mixer
d o w n3 c m
open_grlpper
up_2c m
a_Qa
rem
rem commandto deviceinterface turns mixer on
rem
turn_on_mlxer
rem
rem set the timer and wait for the mixing to be done
rem
set timer 1 for 15 seconds
wait for timer 1
rem
rem commandto device interface turns mixer off
rem
turn_off_mixer
rem
rem now that the mixing is done,get the sampletube from the mixer
rem
down 2cm
nln<e-orinnor
above_mixer
rem
rem end the procedure
rem
and
nnnaaril
ra
CombiningProcedures
In the previoussection,you learnedto create proeedureswhich perform
simpleoperations.In this section,the proeedures
are combinedto create a
procedurewhiehperformsan entire samplepreparation.
NOTE: Whencombiningprocedures,program the robot
carefutty so that you avoid collisions rvith test tube racks,
modules,etc. as the robot movesfrom moduleto module.
To create a new procedurefrom existing procedures,proeeedas follows:
3-34
1)
to plan the
Fotlow the stepsoutlinedin "PlanningYour Procedurerr
procedure.
2)
Enter the PERL Editor by pressing:
Edit (F2)
3)
If the Edit CommandsNlenuis not displayed,pressF7 to bring it up.
Check that the compiler is on. If it is not' select the "Turn Compiler
ONrroption.
Pressthe Enter key.
4)
Type in the new procedure for the sample preparation operation as
follows:
a)
Type the first line, which must be a "procedure"statement which
namesyour procedure;for example,
procedure prep_uv
Pressthe Enter key.
b)
Type in each line of the procedurepressingEnter after each line.
T'heselines will be either the naniesof existingproceduresto be
used,or PERL statements(suchas "for.,,next"or "if,..then"
statements) which providethe logie and architectureof the
procedure.
e)
Type the last line of the procedure whieh must be end procedure.
Pressthe Enter key.
d)
To save the program, press F7 and highlight "Save on disk."
Pressthe Enter key. The systemwill compileyour procedureand
save it on disk.
e)
To leave the Editor and return to the Direct CommandProcessor,
press:
F8
The sample procedurelisted below performs the following operations:
-
adds reagent and sample to a test tube
movesthe test tube to the mixer
mixes
movesthe tube to the LV instrument
dispensesthe solution to the LrV
removesthe tube from the UV and disposesof the tube
repeats the operation for subsequentsamples
3-35
All lines, except those precededby an explanatory "rem" statement' are
assumedto be the namesof the proceduresto be executed.
SAMPLE PROCEDURE - PREPARE SAIVIPLES
AND INTRODUCE TO UV
dd,,F6
'
^
pr ussuur
Y |u' rv_pfep
^F^^
rem
begins program loop
for i = 1 to num_of_samples
rem
command to fill syringe
fill 8 ml
rem
rack commandto get tube i
sample_tube i
dispensr
disp_2ml
rem
extract 2mI sample
from_dsp
discd_tb
rem
rack command
empty_tube i
dispensr
d isp_sam
add_reag
from_dsp
tnixer
mix
to_UV
sip_UV
from_UV
discd_tb
rem
end of program loop
next i
end procedure
3-36
(not yet available)
A PROCEDURE
DEBUGGING
An optionai software packagewhich providesyou with tools, such as Trace'
for debuggingyour procedureswill be available from Perkin-Elmer. This
software is accessed,when installed, by the F5 (Debug)function key.
Runninga Procedure
Once you have written a procedure is written and saved it on disk, you can
run it immediately.
To run a procedures
1)
Return to the PERL Direct CommandProcessor(DCP).
2)
Press:
Run (F1)
You will receive the messagerrPlease
enter procedurename." Type in
the name and pressEnter.
LEAVINGPERL
lvhenyou wish to use DOScommandsor load other software,you must leave
the PERL environment. There are two ways to accornplishthis:
1.
To return to the DOSOperatingSystemwhile keepingPERL in memory,
tYPe:
dos
and pressEnter,
You can then issueDOSeommands.(For somecommands,you may
need to insert the DOS disk in drive A.)
Whenyou are ready to return to PERL, type perl and press Enter. The
PERL screenwili reappearwithout the moduleshavingto re-initialize.
3-37
NOTE: To use DOScommands.vou must have at least 18
Eil66ltes of system memory available. The PERL program
requires 235 kilobytes, and your PERL procedures,directory,
and stack spacerequire additionai memory. This meansthat if
your System Controller is equippedwith only 256 kilobytes of
memory, you may need additional memory to run DOS
commandswith PERL in memory.
2.
To abort PERL and return to DOS,type:
system
a n/i nracc
Fn far
or press:
F7 (Quit).
You will then be able to issueDOS commandsor load other software.
MAINTENANCE
PROCEDURES
AND TROUBLESHOOTING
Section
Page
MAINTENANCE PBOCEDURES AND TRO{'BLESEOOTING
4-l
INTRODUCTION
DAILY CHECKS
PERIODIC MAINTENANCE
TROUBLESHOOTING
REPLACING FUSES
Fuse on the Robot Drive Unit
Fuseson the Rear Panel of the Device l n t e r f a c eU n i t . . . . .
Fuseson the Device Interface P.C.B.
HOW TO RESTART YOUR ROBOT FOLLOWING DEPRESSIONOF
THE REMOTESHUTDOWNSWITCH
REPLACINGTHE ROBOTHAND
REPLACING THE ROBOT GRIPPERS
S E C U R I N GT H E R O B O TB A S E? O T H E W O R K S U R F A C E. . . . . .
CONSUMABLEPARTS
PREVENTIVEMAINTENANCE
Preventive MaintenaneeSchedulefor the Robot
Parts and Tools You Need
Adjusting the Wrist Gear
Adjusting t}re Elbow Tension Chain
Removing and Replacing t}re Drive Belts
Drive Belt Tension
Drive Belt in Base
Drive Belts in Shoulder and Elbow
4-l
4-l
4-2
4-2
4-4
4-4
4-5
Replacingthe Motor Brushes
Replacing the Motor Brushes on t h e B a s eM o t o r . . . . . .
Replacing the Motor Brushes on the ShoulderMotor ,..
Replacing the Motor Brushes on t h e E l b o wM o t o r , . . . .
al-tt
4-7
4-8
{T-IU
4-t 1
4-L2
4-13
4-13
4-74
4-15
4-21
4-2r
4-2L
4-24
4-26
4-26
4-30
4-33
=
(D
(D
I
I
I
I
I
I
MAINTENANCE
PROCEDURES
AND TROUBLESHOOTING
INTRODUCTION
The Masterlab System requires minimal maintenenceto keep the system in
proper working condition, This section includes the following maintenance
and troubleshooting information for the robot and robot drive unit, and for
the system as a whole:
*
recommendations for both dailv and oeriodic eheeks for the
system'sroboti
*
a simple troubleshootingmethod for the robot;
*
a list of consumable parts;
*
proceduresfor preventive maintenance.
For maintenanceand troubleshootinginformation on either the system
controller (IBM PC) or the printer, please refer to the manualssuppliedwith
these units.
DAILYCHECKS
Make the following checksdaily, before operating the robot.
1.
Confirm that there are no loose screws or loose cable connections.
2.
Confirm that no dust, foreign matter or metal shavingshave
accumulatedaroundthe robot.
3.
Examine the connectionof the baseof the robot to the worksurface and
if it is loose, tighten it, Refer to the procedurein this section called
I'Securingthe Robot Baseto the Worksurface."
4-2
Examine the ventilation holes of the Robot Drive Unit to be certain
that they are not clogged.
5.
Maintain the ambient temperature and the temperature inside the
Robot Drive Unit housing panel in the 5-40oC range. If the
temperature is over 40oCreool the area with a fan or air conditioner.
o.
Check that the printer contains sufficient paper.
PERIODICMAINTENANCE
After approximately 2000 hours of operation, or wheneveryou observe
intermittent, jerky movement of the robot, eall your P-E Service
Representativefor replacementof the brusheson motors, the curled
cord, and the timing belts.
During robot operation, occasionally press the optional red remote
shutdown switch to be certain that the switeh is functioning properly'
Robot action shouldhalt immediately,
To restart the robot, refer to the procedure entitled, rrHowto Restert
Your Robot Following Depressionof the Remote ShutdownSwitch."
TROUBLESHOOTING
Symptom
Possible Cause
System hangs up
during initialization.
Power supply
indicator lamp
on drive unit
is not lit.
Robot does not
and emor message
appearson IBM PC
video display unit
1.
,
rt.
Corrective Action
Module cables are
not connected to
ports securely.
Robot Teach
Pendantis ON.
Connect the cables
seeurely.
Power supply eord not
plugged in.
Fuse is blown,
Power supply voltage
is ineorrect.
Plug cord into line power.
Cable conneetion
between the robot
and the IBM PC
is loose.
Turn the Teaeh Pendant
to OFF.
Replaeethe fuse.
Call Perkin-Elmer
serviee engineer.
Connect the cable
seeurely.
Symptom
Possible Cause
I CorrectiveAction
Interruption of
operation.
Cable connection to
robot is loose.
Power interruption
Remote shutdown
switch has been
pressedby mistake.
Conneet the cable
securely,
Restart the system.
Restart the system.
Repeatedpositioning errors.
Unexpectednoise.
Correct for positioning
errors by using the
NEST command every
30 minutes.
Tighten the screws
which secure the
base of the robot
to the worksurface.
Check robot orientation for any changes
of position.
Robot base is not
firmly securedto
the worksurface.
Abnormal noise.
Screwssecuring the
robot to the worksurfaee are loose.
Motor brushesworn.
Tighten the screws
firmly, Check robot
orientation for any
changesof position.
Preventive maintenance
required.
Current time
for the Grip selection command
is too short.
Cable connecting
hand to forearm
is disconnected.
Hand requires
replacement.
Inereasethe current time
for the Grip command.
Vesselsslip out
from robot grippers.
rrForceto Hold" is
too low.
Grippers are bent and
do not grip vessels
seeurely.
Increase rrForce to Holdrr
value.
Replace robot grippers.
No responseto key
depressionon
IBM PC.
The system is rrhung
PressCTRL, ALT and
DEL simultaneously
to return to DOS.
Reload PERL.
Hand doesnot open
and elose.
up.tt
Connect the cable
securely,
Replace the robot hand.
4-4
REPLACINGFUSES
Fuseon the RobotDriveUnit (Figure4-1)
To replace the fuse on the Robot Drive Unit' proceed as follows:
1)
Diseonnectthe power cord on the Robot Drive Unit from line power.
2)
Using a flat head screwdriverr rotate the fuse holder counter-clockwise
and remove it'
3)
Remove the old fuse and diseard it.
4a) On 120V, 50/60 Hz robot drive units, insert a new 5 amp' 110 volt fuse
(0998-1635)into the fuse holder.
4b) On 220V, 50 Hz robot drive units, insert a new 2'5 amp' 220 volt fuse
(0998-1?60)into the fuse holder.
5)
Replace the fuse holder and rotate it clockwise to seat it securely.
6)
Reconnect the power cord to Iine power.
oto
E
mB
H B
lrlu
$r
F igure 4- 1 - L ocation of F use on R ear P anel
of Robot Drive Unit
E
4-5
Fuseson the RearPanelof the DeviceInterfaceUnit (Figure4-2)
There are three (or four) fuses located on the rear panel of the deviee
interface unit which the user mav need to reolace. Thev are:
Fuse
P-E Part No.
1 0a m p ,2 5 0 V
3 amp,250V
5 amp,250V
0998-1753
1 . 5 a m p ,2 5 0 V
0998-1618
0998-1617
0998-1628
Quantity
1
2
2
2
Voltage and Part No. of
Device Interface Unit
120V, 60 Hz (N090-001s)
1.20V, 60 Hz (N090-0015)
230V, 50 Hz (N090-0016)
230V, 50 Hz (N090-0016)
To replace any of these fuses, proeeedas follows:
1)
Disconnectthe power cord on the Deviee Interface Unit from line
power.
2)
Using a flat head screwdriver, rotate the fuse holder counter-clockwise
and remove it.
3)
Remove the old fuse and discard it.
4)
Insert a new fuse into the fuse holder.
5)
Replaee the fuse holder and rotate it elockwise to seat it seeurely,
6)
Reconnectthe power eord to line power.
Figure 4-2 - Location of Fuseson Rear Panel
of Device Interface Unit, 120 V, 60 H z
P-E P art No. N090-0015
ft-o
Fuseon the DeviceInterfaceP.C.B.(Figure4-3)
There are three fuses loeated on the Device Interfaee P.C.B. (N090-9024)
which protect the internal power supply when moduleseonnectedexternally
malfunction. Thev are:
Fuse
P.E. Part No.
0.75A,250V
0 . ? 5 A2, 5 0 V
2.0A,250V
0999-163
8
0999-163
8
0998-1631
Location
Fl
E2
F3
Voltage
+12V
-LzV
+5V
To replace one of these fuses, proceedas follows:
1)
Diseonnectthe power cord from line power.
2)
Remove the four screws from the sidesof the cover assemblyof the
Device Interfaee Unit and remove the cover, The device interface
board is located directly below the eover.
3)
Locate the three fuses on the board. See Figure 4-3.
v
tnn
€^z
Puse(P3)
Figure 4-3 - Location of Fuseson Deyice lnterface P.C.B. (N090-9024)
4-7
4
Remove the blown fuse(s).
5)
Insert a new fuse into the fuse holder.
6)
Replace the cover assemblyon the deviee interface unit and secure the
cover to the baseusing the four screws removed in step 1, above.
7)
Reconneetthe power eord to line power.
YOURROBOTFOLLOWING
HOWTO RESTART
DEPRESSION
OF THE REMOTESHUTDOWNSWITCH
To restart robot operation:
1)
Pressthe shutdownswiteh again to releasethe switeh which latehes
following the initial depression.
2)
Pressthe ON button on the Robot Drive Unit.
3)
Reload PERL. Refer to the procedureentitled I'LoadingPERL
Software" in Section 3 of this manual.
4-8
REPLACING
THE ROBOTHAND (Figure4-4)
To replace the robot hand, proceed as follows:
1)
Disconnectthe eable on the hand unit from the connector on the robofls
forearm.
2)
Releasethe strain relief ctp on the cable.
3)
Slide the cable through the hole in the bracket on the top side of the
forearm.
4)
Unscrew the four Allen head screws that attaeh the robot hand to the
wrist and remove the hand. Retain the screws.
NOTE: Removal of the Allen head serewscan be facilitated by
fiiifltne
Teach Pendant to move the hand to a convenient
position,
Braeket (Porearm)
Strrin Reliel
a . /
fv
I
Plate
(wdst)
Allen Head
Screr (t)
Robot Eand
Figure 4-4 - Hand Replo,cement
4-9
5)
Mount the new hand to the plate at the end of the wrist and secure the
hand to the wrist using the four Allen head serews removed in step 4.
6)
Slide the connector on the end of the eable through the hole in the
braeket on the top of the forearm.
7)
Attaeh the cable to the forearm using the strain relief clip released in
step 2.
8)
Conneet the eable on the hand assemblyto the eonnector on the
forearm.
4-10
REPLACING
THE ROBOTGRIPPERS
(Figure4-5)
When the robot grippers are bent or when grippers of a different size are
required for the current applieation, folLow the procedure described below
to replace the grippers.
1)
Open the grippers, using either the tropenrt
commandor the Teach
Pendant.
2)
Unscrew the two screws which hold each gripper in place.
3)
Remove the old grippers. Plaee each new one in position, and secure it
with the two screws removed from the old one.
NOTE; The grippers are keyed to the holes in the hand assembly.
OnIy a right (or left) gripper ean seat properly in a right (or left)
bracket of the hand.
Itobot Hand
Finger 4-5 - GripperReplacemenL
4-11
SECURING
THE ROBOTBASETO THEWORKSURFACE
(Figure4-6)
If the robot is not atteehed securely to the worksurface, follow the
proceduredescribedbelow to secure it.
1)
Remove the four serewson the base eover of the robot. (Two are in the
front and two in the rear.)
2)
Remove the base eover by sliding each half of the cover to the side,
3)
Tighten the four hexagonalhead bolts that seeure the base of the robot
to the worksurface.
NOTE: Thesebolts are accessiblefrom beneath the worksurface.
Worksurface
Cable
Strain
Relief
rygle:
C@t !.e coDle st oln
relief here.
Base Covet
Screr (4)
Figure 4-6 - Securtng the Base of the Robot to the l0 orksurface
4-t2
4)
Slide the two halves of the base cover baek over the base,
t.,
Reattaeh the base cover to the base of the robot using the screws
removed in step 1, above.
6)
Before proceeding to run applieations programs, check the orientation
of the robot by moving it to several positions, for example, a test tube
rack, a mixer, and a syringe, to see if any ehangeshave occurred in its
positioning.
CONSUMABLEPARTS
The parts listed below are consumedduring normal operation of the
Masterlab System. Consumableparts for aceessoriesused with the
Masterlab System are listed in the manual suppliedwith the accessory.
P-E
Part No.
Description
N090-0041
N500-0030
N500-1409
Hand Assy.
Floppy diskettes, blank
Paper, Epson Printer
N500-2189
Ribbon Cartridge, Epson Printer
Fuses as follows:
0 , 7 5a m p , 2 5 0V , 3 A G n o r m a l ,
Device Interface Board, F1, F2
2.0 amp, 250 V, 3 AB normal
Device Interface Board, F3
5.0 amp, 110 V, normal
2.5 amp, 220 V, normal
10 amp, 250 V, slo-blo
3 a m p , 2 5 0V , 3 A G n o r m a 5 amp, 250 V, 3 AG slo-blo
1.5 amp, 250 V, 3 AG normal
Fingers Kit (Containsset of grippers)
0999-1638
0998-1631
0998-1635+
0998-17
60++
0998-1?
53 t
*
0998-1618
i' {'
0998-161?
0998-162I* *
N090-0117
+---Gecl on Robot Drive Unit (120V, 50/60 Hz)
++ Used on Robot Drive Unit (220V, 50 Hz)
*
Usedon Deviee Interface Unit (120 V, 60 Hz)
** Used on Device Interfaee Unit (220 V. 50 Hz)
Quantity
1
Pkg of 10
Box of 3200 sheets
(Z-foId)
1
I
1
1
1
2
2
1
/{- tJ
PREVENTIVE
MAINTENANCE
Routine preventive maintenanceis required to maintain the robot in proper
working condition and to ensurethe highest possiblelevel of performance.
You can perform the proceduresyourself, as describedin the pageswhich
follow, or you can have your loeal Perkin-Elmer Representativeperform
them for you. Refer to the schedulelisted below for the time when
maintenanceon individual componentsis required.
Preventive
Maintenance
Schedulefor The Robot
After Initial 500 Hours Of Operation
1.
Cheek for play in wrist gear. Adjust, if neeessary.
Every 2000 Hours Of Operation
1.
Cheek for play in wrist gear. Adjust, if necessary,
2,
Check for slack in elbow chain. Adjust, if necessary,
3.
Check tensionof aII drive belts and inspeet eaeh belt for signsof
wear. Replace,if necessary.
NOTE: Replaeementof the wrist drive belts shouldbe
performed by a P-E Service Engineer.
4.
Replace brushesin base,shoulderand elbow motors.
Every 4000 Hours Of Operation
1.
Replace wrist motors.
2.
Replaeewrist drive belts.
NOTE: Replacementof the wrist drive belts and wrist
motors shouldbe performed by a P-E Service Engineer.
4-L4
Partsand ToolsYou Need
To carry out the preventive maintenanceproceduresdescribedin the
following pages,you will need the tools and spare parts listed below.
Tools Required for Preventive Maintenanee
Set of Metric HexagonalWrenches
#1 Phillips Screwdriver
Wrist Gear AdjustrnentTool (0168-9316)
or
SDannerWrench
TABLE 4-1 - SPAREPARTSUSEDIN PREVENTIVEMAINTENANCE
P-E Part No,
Descriotion
0990-8771
0990-8772
0990-8?73
N090-1024
Wrist drive belt
Shoulderdrive belt/Elbow drive belt
Basedrive belt
Motor brush (2 required per motor)
1-r c
Adjustingthe WristGear
1)
With the hand stiil attaehed, use a hexagonalwrench to remove the
six set serewsand lock washerssecuringthe hand mounting flange to
the wrist assembly. PuIi the hand and mounting flange from the wrist.
Disconnectstrain relief. Refer to Figure 4-4. Detach the hand from
the wrist.
Figure 4-7 - D etaching the Hand Assembly
from the Wrist Assembly
4-r o
Using the wrist gear adjustment tool (or spannerwrench) rotate the
adjustment nut cloekwise to the point where there is no play between
the center gear and the drive gears. To eheck for play' firmly grasp the
eenter gear and try to wiggle it back and forth' There shouldbe no
movement.
2)
Adiuslment
Nul
WristGear
AdiuslmentTool
CenterGear
(Wrist Drive)
: ' 4
a,-"',
",
Figure 4-8 - Adjttsting the Wrist Gear
IMPOBTANT: Do not over tighten the adjustment nut. To
cause excessive wear of the gears.
do6G6i
3)
To Ioosenthe gears, baek off on the adjustment nut and tap the end of
the bolt with a small hammer or similar tool.
4)
Once the gear is properly adjusted, refit the hand/mountingflange
assembly,removed in step 1, to the wrist.
-.
4-r7
Adjustingthe ElbowTensionChain
1)
Remove the Elbow Drive Belt Cover by removing the four screws that
secure it to the uDDerarm.
Figure 4-9 - Dri\)eBelt Covers on the Robot
4-18
Extend the arm fully and remove four Phillips head serews that secure
the Robot Upper Arm Front Cover, Remove the cover. This gains
accessto the elbow chain.
Robot
UpperArm
FrontCover
F igure 4-10 - Robot Upper Arm F ront Cover
4-19
3)
With the shoulderextendedstraight up, move the elbow up and down
between its two limits. At no time should the Elbow Tension Chain
come in contact with the body of the Elbow Motor. If adjustment is
required, proceed with step 4.
TensionChain
Adjustmenl
Sprocket
Elbow Tension
Chain
Figure 4-11 - Elbow T ension ChainAdjustment
4-20
4)
Loosenthe nut on the Tension Chain Adjustment Sprocket' and slide the
sprocket to obtain the desired amount of ehain tension.
NOTE: If the ehain is stretched to the point where it cannot be
properly, it must be replaced.
G-nsioneO
5)
Double-checkthe chain tension by repeating step 3.
6)
Replace the Elbow Drive Belt Cover.
7\
Replace the Robot Arm Front Cover.
4-2t
Removingand Replacingthe DriveBelts
Drive Belt Temion
It is important that proper drive belt tension be maintained at all times. A
Ioose drive belt mBy slip, leading to positioning errors. The drive belt is
tensioned properly if the belt defleets no more than 2 mm when pressed
lightly with a finger. If the belt is stretched to the point where it can no
longer be adjusted properly, it must be replaeed.
To adjust the tension of a drive belt, simply loosen the mounting screws on
the appropriate motor 8.ndposition the motor so that belt tension is correct.
Refer to the figures below for motor loeations.
IMPORTANT: Do not overtighten the drive belts. This causes
uiil6T[-ress on the motor shafts and mav lead to damaEe of the
!notor.
Drive Belt in Base
1)
Remove the base cover after removing the four screws which seeure
the two halves of the base cover,
Robol BaseCover
'
Screw(4)
Figure 4-12 - Remowng the Base Cover
2)
Loosenthe four bolts securing the base drive motor to the base plate
and slide the motor forward to Dut slack on the drive belt.
Base Drive
Molor
Bolls Securing
Base Dlive
Motor (4)
Figure 4-13 - Loosening the Bolts Securing the Base Drtve Motor
4-23
NOTE: The drive belt can easily be removed by laying it flat
against the lower baseplate and sliding it under the pulleys one
end at a time.
3)
Remove the drive belt.
F igure 4-14 - Drive Belt on BaseMotor
4)
Install a new belt, secure the base drive motor and adjust belt tension.
5)
Refit the basehousing.
4-24
Drive Belts in Shoulder and Elbow
1)
Remove the drive belt eover whieh is seeuredby four serews. Refer
to Figure 4-9 for location of covers.
2)
Loosenthe four screws seeuringthe motor and slide the motor to put
slack on the drive belt.
ShoulderDriveMotor
-"i
ScrewsSecuring
ShoulderOrive
Molor
(2 Norshown)
,}'rr r;;: :
F igure 4-15 - ScrerrsSecuring the ShoulderDrive Motor
4-25
ScrewsSecuring
Elbow Drive
Figure 4-16 - ScrerusSecunng the Elbow Dri\)e Motor
3)
Remove the drive belt.
4)
InstaII new belt and adjust belt tension.
?,
With belt tension properly adjusted,tighten motor mounting screws and
refit the drive belt cover.
4-26
Replacingthe Motor Brushes
The motors for the base,shoulderand elbow joints utilize replaceable
brushes(2 brushesper motor) which you should changeafter every 2000
hours of motor operation. The wrist motor brushescannot be replaced and,
as a result, the entire wrist motor must be replaced. We recommendthat
you replace the wrist motors after every 4000 hours of motor operation.
Plastic caps cover and secure the brushesin the base, shoulderand elbow
motors. You can easily remove these eapsusing a small serewdriver. The
motor brushesare then accessiblefor reolacement.
Replacing the Motor Brushes on the Base Motor
1)
Remove the four Phillips head screws on the base cover. (Two are in
the front and two are in the rear, Refer to Figure 4-12.)
2)
Remove the base cover by sliding each half of the cover to the side.
3)
To replace the motor brush on the side of the base motor, proceed as
follows:
a)
Using a small screwdriver, remove the plastie cap that securesthe
motor brush (see Figure 4-17).
b)
Remove the motor brush.
e)
Carefully insert a new motor brush (see Figure 4-18).
d)
Replaee the plastic cap.
4-27
Figure 4-17 - Removing the Plostic Cap that Secures the
Motor Brush on the Side of the Base Motor
Figure 4-18 - lnserting a Motor Brush
in the Base Motor
4-28
4)
',;:'.
To aecessthe motor brush located on the rear of the base motor:
a)
Rotate the robot arm so that it s positioned 90o to the base.
b)
Use a hex wrench to loosenthe two screws that secure the cable
bracket to the base, shownin Figure 4-19. Remove the bracket.
:,. ;:,.:i::.'
ScrewsSecuring
Cable Bracket
to Robol Base
Figure 4-19 - Location of Screursthat Secure the Cable
Bmcket to Robot Base
4-29
5)
Repeat step 3 to replace the motor brush on the rear of the base motor.
PlasticCap
{Secureslilolor
Srushor Rear
ot BaseMolor)
Figure 4-20 - Location of Plastic Cap that Secures Motor
Brush on Rear of BaseMotor
6)
Replace the base eover.
4-30
Reptacing the Motor Brushes on the Shoulder Motor
1)
To accessthe shouldermotor:
a)
Remove the six screws (three on each side) securing the rear eover
to the shoulder. Remove the rear cover.
,i:
;:r
iii:l
'
ScrewsSecu:ing
Side Coverof
Shoulder
: S"r".r Securing
Top Coverol
Shoulder
ScrewsSecuring
RearCove: of
Shoulder
F igure 4-21 - Location of Screu,sSecuring
Covers of Shoulder
b)
Remove the four screws (two on each side) securing the top cover.
Carefully remove the cover by Lifting it from the rear and sliding it
back.
IMPORTANT: Do not attempt to lif t the top cover up as
doing so may damagethe dust shield.
e)
Raise the shoulderto its perpendieular position to release tension
on the two counter-balaneespfings.
o,
Loosen4 screws (two on each side) directly beneath the Robot logo
on each side of shoulder.
q-J
t
e)
Remove 2 bolts on robot body.
f)
Separatethe sidesof robot body and remove the spring mounting
bar (see Figure 4-22).
o)
Carefully move the arm (with the springsattaehed) forward.
Securing
Figure 4-22 - Removing the Top Coyer of the the Robot Shoutder
4-32
D
To replace the Motor Brushes:
a)
Using a small screwdriver, remove the plastie cap that secures
eaeh motor brush.
b)
Remove the motor brush.
c)
Carefully insert a new motor brush.
d)
Replace the plastic cap.
CapsSeeuring
Itotor Brushes
on Shoulder
Motor
Figure 4-23 - Location of Motor Brusheson Should.erMotor
3)
Replace the spring mounting bar.
4)
Tighten the screws that you loosenedin step 1d, above.
5)
Replace the top cover and the rear cover.
NOTE: Whenreplacing the top cover, be certain that the dust
shield slides between the cover and the roller guide. Refer to
FiEure 4-22.
Replacing the Motor Brushes on the Elbow Motor
1)
2)
To accessthe elbow motor:
a)
Removethe elbow drive belt cover (Figure4-9)by removingthe
four screwsthat secureit to the upperarm.
b)
Extendthe arm ful1yto exposethe eight screwsthat secwe the
upper arm front cover to the arm, (Refer to Figure 4-10,)
c)
Removethe eight screwsthat securethe upperarm front cover to
the arm and carefullyremove the cover.
To replacethe motor brushes:
a)
Usinga small screwdriver,remove the plastic cap that secures
each motor brush,
b)
Removethe motor brush,
e)
Carefully insert a new motor brush.
d)
Replacethe plastic cap.
Plaslic
Caps on
Molor
Brushes
Figure 4-24 - Locatiorl of Motor Brushes on Elboyr Motor
3)
Replacethe Upper Arm Front Cover and the Elbow Drive BeIt Cover
that you removedin step 1.
5
PREcAUToNs
PRECAUTIONS
Perkin-Elmer reeommendsthat you observethe following precautions when
operating the Masterlab System.
i
Wear safety glasseswhen operating the robot to eliminate the
possibility of eye injury.
*
Whenoperating the robot, remain outside its path.
*
If the robot is moving to a location and is about to eoltde with an
objeet, press the optional remote robot shutdownswitch immediately.
Perkin-Elmer recommends that you purchase and install this option to
the Masterlab System.
*
Never touch any moving parts of the robot with your handswhen the
robot is operating.
*
When you are working near the robot, do not plaee tools or other
equipment within the range of movement of the robot. In general, aII
unessentialequipmentshouldbe removed from the worksurface while
the robot is operating.
*
During operation, never manually turn or restrain the robotrshand or
grippers. Doing so can causedamageto the robot.
t
Do not allow water or other liquids, or metal objects to enter the robot,
robot drive electronies unit, device interface unit or system controller,
t
Provide adequateventing to evacuate any toxic, eorrosive,offensive or
flammable fumes which may be generatedduring samplepreparation
Droeedures.
A GLOSSARY
OF ROBOTICS
TERMS
o
vl
at
A GLOSSARY
O F R O B O T I C ST E R M S
This glossarycontains <iefinitionsof terms in genera-luse in the field of
robotics, as well as terms which pertain speeifically to the Perkin-Elmer
[lasterLab System.
Whereappropriate,a reference is given in parenthesesat the end of the
definition, telling you where in this or a related Perkin-Elmer Robotics
Manual you can find more information. The references r.rsethe following
abbreviations:
ML
PERL
DI
Masterlab SystemInstructions (this manual).
PERL Instructions
M asterDevice Interface Instructions
If you want more information on general robotics concepts,the following
booksand articles are recommended:
_D-e:s,yr
-R., lrlgbots in,the Laboratory: Part 1", Analytical Chemistry,
5 5 : 11 0 0 A - 1 1 0 8 (A1 9 8 3 ) .
Niccrattan,8.J., and D. J. Macero,rrlaboratoryRobotics:Past
Performance,Present Considerationsand Future Trendsr',American
Laboratory,16-13(1984).
Osborne, D.lvl., Robots: An Introduetion to Basic Concep!qjlg3!plj!g!i98,
l\ridwestScr=Te@
Osborne,D.M., Robots:The Application of Robots to Practical
lviidwestSci.Tech Publ.,Detroit, [rI, 1983,
G-2
nris - straight line about which a body rotates. The Perkin-Elmer robot has
five arm motion axes.
baud rate - the speed at which data is sent serially, defined in bits per
seeond,or bBud. A useful rule of thumb for determining the speedof
eommunicationis to divide the baud rate by 10 to determine the number of
charaeters per seeond. The SCU supportsbaud rates from 50 to 9600.
Cartesian robot - see robot eonfiguration.
configuration, robot - see robot eonfiguration.
eontinuous po.thteaching - process by whieh the robot is programmed to
remember the entire path through which it travels in the teaehing process'
It can later reproduce every movement it made. (See also point-tc?oint
teacNng.)
c![indrical
robot - see robot eonfiguration.
data bits - The number of data bits determine the length of the character
representationsent, and consequentlydeterminesthe eharacters that can be
se.tt, pSRL and the SCU support from 5 to 8 data bits. With 5 data bits' 32
unique combinationscan be sent, and with 8 data bits 256 unique
combinationscan be sent.
degree of freedom - one of a limited number of ways in which a robot can
mo1e. The Perkin-Elmer robot has five degreesof freedom; it can rotate on
its base.bend at the shoulder,bend at the elbow' bend at the wrist, and
rotate at the wrist.
device interface - a module of the Masterlab System which is used to
control or monitor other devices' It can control up to two AC devices and
up to twelve external switch closures,and monitor up to twelve external
inputs. You can program this control by meansof .commandscreated with
the deviceinterfaee Teach Program. (DI; PERL 3)
Directory - file (PERL.DIR) which contains the commandscreated with the
Teach Programs. It is accessedby pressingthe F4 (Dir) function key from
the PERL main menu screen.
Editor - portion of the PERL software used in creating and editing
applieatlonsprograms. It is accessedby pressingthe F2 (Edit) function key
from the pnRl main menu screen. (ML 3; PERL 5)
explieit programming - programming a robot by means of a program;ning
tanguage. fne programs aG then portable from one robot to another. (See
also lead-throrgh progtam mir€. )
G-3
fiBt-generation robot - robots which can be programmed to perform
particular operations,but whoseprogramscan not then be transported to
another robot; each must be individually programmed. They may have
memory, or they may be controlle<iby punchedcards or oigital switches.
(See also fixed sequeneerobot, variable segrence robot, numerical control
robot, and playback robot.)
fixed sequencerobot - first-generation robot which has the programming for
one sequenceof operationsbuilt into it, and cannot be readily
reprogramm ed.
handshaking- a hardware communication processfor determining when data
can and cannot be sent serially, The only handshakesupporteoby PERL and
the SCU is the data terminal reaciy/clearto send (DTR/CTS)protocol.
initialization sequence- the sequenceof characters that is sent to a oevice
when PERL is first loaded. l'his seoueneecan be anv charaeter or character
string.
input terminator - the end of string terminator sent by a device to the
System OontroIIer.
interactive program - a program which asks for and respondsto input from
the operator during its execution,
joint-articulated
robot - see robot configuration.
lead-through programming - programming a robot entirely by the use of a
teach pendant. The robot is placed in each successiveposition it is to
assume. It stores the positions,anc can later execute them in the order
they were taught. The programmingis not transportable to another robot.
This is a-lsoca-Iledon-line programming, (Seealso explieit programming.)
units that nlake up a system.
module- one of the independently-operable
The lvlasterlab System can include such modulesas the robot, the syringe,
the deviceinterface, the mixer, and the crimper.
numerical eontrol robot - a first-generation robot whosesequenceof
operationsis programmedby numerical data fed into it in the form of
punchedtapes, punchedcards, or digital switches.
off-line programming - see e:plieit programming.
orFline programming - see lead-through programming.
output terminator - the terminator for any string sent by the System
Lontroller to a oevice.
G-4
parity - ar error eheckingprotocol. Three types of parity are defined: no
parity (irlplying that parity checking is not used)iodd p€rity; ard even .
irarity. Pa-rityis determinbd by sumhing the number of high bits in a binary
itring tnat is sent. if the sum of the number of high bits is even' the string
is even. If even parity is used with an even string' the parity bit is sent -.
high; if even pariiy is-useowith an odd string, the parity bit is sent low' The
opposite will be true of odd parity.
PERL - Perkin-Elmer Robot Language'a software languagedevisedfor use
in the Mtasterlab Automatea Sample Preparation System. lt is specitically
intended to facilitate communication in a roboties system.
PERL Directory - see Directory.
PERL Editor - see Editor.
PERL programming environment - the PERL software facilities which are
usedin developingapplicatiors prograr,s for the Nlasterlab System. (PERL
playbaekrobot - a first-generation robot which has a memory. Once taught
a sequenceof operations,it can play back the information and repeat the
sequence.
point-to-point teaehing - process by which a robot is programmed for eaeh
successiveposition it is to assume. Whena program containing these
positionsis later executed, the robot moves from position to position by the
most direct path. The Perkin-Elmer robot is taught by the point-to-point
method. (See also continuous 1rathteaching.)
revolute robot - see robot configuration.
robot - a rrlechanicaldevice capableof carrying out tasks which woulo
otherwise be performed by human beings. T'heworo is cierivedlrom the
Ozech word "robotnik", meaninga slave or serf.
robot configuration - one of four possible arrangements of robot body' arm,
ano gripper (seeFigure G-1):
Oartesian robot - a robot which has three degreesof freedont, along the
Cartesian X, Y, and Z axes. Sucha robot works well in planar-oriented
applications.
cylindrical robot - robot which can move laterally along its base,and
can then rotate to reach toward objects at 360 degreesarouno the base.
j oint-articu.iatedrobot - robot which has an arm on a rotating base.
The arm is capable of bendingat shotlder, eibow, and wrist. Such
robots can reach over and around objects' The Perkin-Elmer robot is
revolute.
G-5
<-->
Cortesion
Sphericol
Cylindricol
loted
Joint-Articu
FUwe G- 1 - Robot C orf igwations
G-6
robot eonli guration (continued) Sphericalrobot - robot which can rotate aroundits base,and can also
swing it arm in an arc perpendicularto the base. It ean reach toward
obiedts around and aboveit.
Robot Drive Unit - device which contains the Masterlab robot electronics
and interfacesthe robot with the SystemControiler. (ML 2)
seeond-generation robot - robots which are program med wing either higtF
level robotics languagesor general purposeprogramminglarguages. The
programs may be usedwith any similar robot. The Perkin-Elmer robot is a
second-generationrobot.
Serial Commrrrication Facility - portion of the PERL sof tware which allows
comnrunicationwith external devicesvia RSz32ports. AIthoWh it is never
rsed directly by the applicationsprogrammer, it is the basisof all
corrrflruni
cati ons between the Masterlab software and externa] devices.
(PERL 1)
spherical robot - see robot configration.
stop bits - the number of bits terminating each character sent. Stop bits of
I and 2 are supportedby PERL and the SCU.
System Configuration File - A file createo by the System Configuration
Utility and stored on disk as PERL.SCF. The file contains the port address
of each device in the system, the initialization parametersfor the ports and
devices,and the spelling of system eommands. The computer reaG this file
each time PERL is loaded into memory. (lViL3)
System Configuation Utility - interactive PERL program which Bllows you
to describethe configuration of your system, It creates the System
Configuation File, which the eomputer reads each time PERL is loaded into
memory. (lVlL3)
S5rstemController - the computer which controls the Nlasterlab System by
meansof the PERL software.
teach pendant- a device usedto manually move a robot to a desiredposition
and then recoro the position in memory. By this processit "teaches" the
robot variouslocations in space. (lvtl,3; PERL 3)
Teach Program - an interactive PERL program used to ereate the comnrands
which wiii be neededin an applicationsprogram. Teach Programsexist for
each lvlasterlab System nrodulecapableof RS232communications: the
robot, the syringe, the <ieviceinterfaee, and the balance,(ML 3; PERL 3)
G-7
third-g€nenation robot - robots with sensory pereeption. They can detect
changesin themselvesor the work environment,and can make decisionson
the aetion to take in response. Such robots are primarily found in Artificial
Intelligence laboratories, ano are not yet widely available for industrial use.
timeout - the amount of time PERL will wait for aclcrowledgem
ent from a
device before assumingthat the device is not operating correc y.
work envelope - the space accessible to the robot grippers. IVIodules to be
serviced by the robot must be placed within the vrork envelope.(ML 2)
variable seqrence robot - a first-generation robot with a program for one
sequenceof operationsbuilt into it. The sequencecan be reaciiiy changed.

INSTRUCTIONS MODEL 9OOO MASTERLAB SYSTEM

Transcription

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