Lab-Volt 5250 Series Operating and maintenance instructions

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System shown with optional equipment
A
Automation and Robotics
SERVO ROBOT SYSTEM
SERIES 5250
GENERAL DESCRIPTION
The Lab-Volt Servo Robot System, Model 5250, provides
complete and affordable training in the programming and
operation of industrial robots. Through the curriculum and
hands-on experience with the Servo Robot System,
students learn to create automated work cells ideal for
Flexible Manufacturing Systems (FMS) and Computer
Integrated Manufacturing (CIM).
The precision-built, articulated arm of the Servo
Robot represents an important step in automation and
handling. It is driven by servo motors equipped with
optical encoders to provide feedback to the controller.
The Servo Robot has five axes of rotation plus a
gripper. All joints can be used simultaneously to perform
a sequence of moves. The Servo Robot can be operated
in the Articular mode, which allows each articulation to
be controlled and moved independently, or it can be
operated in the Cartesian mode where the gripper moves
linearly, parallel to a specified axis. The Servo Robot can
be controlled and programmed using a hand-held terminal
or from a PC host computer running the RoboCIM 5250
Software or the Robotics software.

SERVO ROBOT SYSTEM
SERIES 5250
2
RoboCIM 5250 Software and Robotics Software
Robot Controller Module
The Robot Controller module is provided with TTL
(Transistor-Transistor Logic) inputs for the monitoring of
input devices; TTL outputs to communicate with other
robot units or control external accessories such as a belt
conveyor; relay outputs for the control of external acces-
sories such as Signal Tower, Model 5924; output ports
for the control of external devices such as the Linear Slide
or Rotary Carousel; and serial communication port for
host control operation and for uploading and downloading
programs.
The Robot Controller module is also equipped with
CNC (Computerized Numerical Control) ports, which
enable communication with Lab-Volt Automation CNC
machines. This allows for a truly integrated flexible manu-
facturing system where the robot and CNC machines can
operate in “wait” mode until contacted by other equip-
ment. The Robot Controller also houses a floppy disk
drive for program storage.
The Hand-Held Terminal connects to the Robot
Controller via a serial communication port. It is used for
programming points, saving programs, and general
operation of the Servo Robot System.
The RoboCIM 5250 Software or Robotics software
can be used in place of the Hand-Held Terminal. The
Robotics software allows the user to point and click to
move the Servo Robot and select points. The editing and
labeling processes are very user-friendly. Furthermore,
the capability of Robotics to create task programs allows
the design of complex processes. With the RoboCIM
5250 Software, the motion of the Servo Robot can be
controlled or simulated. The software provides a
three-dimensional virtual environment and an easy-to-use
interface allowing students to easily learn the fundamen-
tals of robotics. Two programming modes are available:
an intuitive icon programming mode and a text program-
ming mode to create more complex tasks.
The Servo Robot and external devices offered as
options with the Servo Robot System are equipped with
location pins (or push-lock fasteners). These pins are
designed to be used with the metallic, perforated work
surfaces. This easy-to-use mechanism ensures the
position of the equipment when repeating programs.
TABLE OF CONTENTS
General Description ......................... 1
Table of Contents of the Student Manual ........ 4
ListofEquipment ........................... 4
Optional Kits ............................... 5
Optional Equipment ......................... 5
Module Description .......................... 6
Specifications ............................. 14
OrderingNumbers ......................... 19

3
Location pin on a Gravity Feeder
Robot Calibration Tools
The equipment supplied with the Servo Robot Sys-
tem, Model 5250-1, includes a Servo Robot, Robot Con-
troller, Hand-Held Terminal, Emergency Stop Button
module, RoboCIM 5250 Software, Robotics software,
Grids, Robot calibration tools, student and instructor
manuals, user guides, and all leads and cables required
to operate the system. The Servo Robot System,
Model 5250-2, is supplied with all the equipment of the
Model 5250-1 and two solid-metal perforated work sur-
faces that can be linked together using the provided
Spacers. They can be put atop a regular work table or
installed on one of the optional benches.
Many optional devices can be added to the system
to perform more complex processes. The optional devices
include a Rotary Carousel, Belt Conveyor, Gravity
Feeders, Pneumatic Feeders, a Signal Tower, and a
Linear Slide.
Features
Servo Robot
CHigh torque servo motors
CSteel and aluminum construction
CHTD (High Torque Drive) drive belts for power transfer
(enclosed for safety)
CEasily adjustable belt tension pulleys to maintain posi-
tional accuracy
COilite and UHMW (Ultra-High Molecular Weight) bush-
ings for durability, minimum maintenance, and lubrica-
tion
CBoundary and current limit protection on all axes
Robot Controller
COn-board microprocessor
CEight TTL input ports, color coded, and with LED status
indicators
CEight TTL output ports, color coded, and with LED
status indicators
CFour relays, each equipped with a set of normally open
and normally closed contacts and LED status indicators
CServo Robot and external motor release switch, and
LED status indicator
CFloppy-disk drive for program storage
CHand-Held Terminal communication port
Safety Features
CKey-Activated Emergency Stop Button module
Robotics Software
CEasy-to-use, menu-driven software
CDirect keyboard control over all robot axes and func-
tions
CControl output ports and read instruction channels
CTask commands include jump, loop, if-then-else, and
while-repeat conditions
CPoint-to-point and task programming
RoboCIM 5250 Software
CEasy-to-use, menu-driven software
CSimulation and control modes
CThree-dimensional (3D) virtual environment
CSeven predefined layout/camera view settings
CControl the movements of the Servo Robot using "artic-
ular" and "Cartesian" coordinates
CProgramming without actual equipment

SERVO ROBOT SYSTEM
SERIES 5250
1The ordering numbers shown apply to the English 120-V version. Other versions are available. Refer to the Ordering Numbers section.
2Includes RoboCIM 5250 Software, Robotics software, Hand-Held Terminal, Emergency Stop Button module, Robot calibration tools, and all leads and cables required to operate the system.
4
CPoint recorder panel to easily record, rename, view
coordinates, hide, and delete points
CCreate and run simple task programs using icons and
graphical tools (no keyboarding required)
CCreate and run simple and complex task programs by
entering all necessary commands using the keyboard
CPowerful set of task commands such as: Delay,
Do-Until, If-Else, Gosub, Home, Input, Output,
While-Repeat, and many others
TABLE OF CONTENTS OF THE STUDENT MANUAL
Introduction to Robotics (34175-00)
CIntroduction
CFamiliarization with the Servo Robot System
CPoint-to-Point Programs
CTask Programs
CProgram Editing
CControl Overview
CIndustrial Application Simulation Using a Gravity
Feeder
CIndustrial Application Simulation Using a Belt Conveyor
CIndustrial Application Simulation Using a Pneumatic
Feeder
CIndustrial Application Simulation Using a Rotary Carou-
sel
CIndustrial Application Simulation Using a Linear Slide
LISTS OF EQUIPMENT
SERVO ROBOT SYSTEM, MODEL 5250-1
QTY DESCRIPTION ORDERING NUMBER1
1 Robot Controller ................................................................ 5221-002
1 Servo Robot ................................................................... 5250-A0
1 Introduction to Robotics (Student Manual) ........................................... 34175-00
1 Introduction to Robotics (Instructor Guide) ........................................... 34175-10
1 Servo Robot System Model 5250 (User Guide) ....................................... 34175-E0
1 RoboCIM Software (User Guide) .................................................. 37864-E0
SERVO ROBOT SYSTEM, MODEL 5250-2
QTY DESCRIPTION ORDERING NUMBER
1 Robot Controller ................................................................ 5221-002
1 Servo Robot ................................................................... 5250-A0
2 Storage/Work Surface ............................................................ 6309-00
1 Introduction to Robotics (Student Manual) ........................................... 34175-00
1 Introduction to Robotics (Instructor Guide) ........................................... 34175-10
1 Servo Robot System Model 5250 (User Guide) ....................................... 34175-E0
1 RoboCIM 5250 Software (User Guide) .............................................. 37864-E0
2 Spacer....................................................................... 39035-00

3The Acoustic Alarm must be installed on a fully functional Signal Tower.
4The Work Surfaces are not included with the Bench.
5
OPTIONAL KITS
PNEUMATIC FEEDER KIT (SQUARE PARTS) MODEL 5122-A
QTY DESCRIPTION ORDERING NUMBER
1 Pneumatic Feeder (Square Parts) ................................................... 5122-10
1 Pneumatic Feeder Controller ...................................................... 5149-00
PNEUMATIC FEEDER KIT (CYLINDRICAL PARTS), MODEL 5142-A
QTY DESCRIPTION ORDERING NUMBER
1 Pneumatic Feeder (Cylindrical Parts) ................................................ 5142-10
1 Pneumatic Feeder Controller ...................................................... 5149-00
SIGNAL TOWER KIT, MODEL 5924-A
QTY DESCRIPTION ORDERING NUMBER
1 Connection Leads ............................................................... 5259-C0
1 Signal Tower ............................................................. 5924-00
1 DC Power Supply ........................................................ 6360-00
OPTIONAL EQUIPMENT
DESCRIPTION ORDERING NUMBER
Gravity Feeder (Square Parts) ............................................................ 5119-00
Gravity Feeder (Cylindrical Parts) ......................................................... 5121-00
RotaryCarousel....................................................................... 5208-10
Linear Slide .......................................................................... 5209-10
Linear Slide .......................................................................... 5209-A0
BeltConveyor ........................................................................ 5210-00
RoboCIM 5250 Software (additional license) ................................................. 5251-00
Accessories .......................................................................... 5259-00
Accessories .......................................................................... 5259-A0
Robot 5250 Software Development Kit ..................................................... 5274-00
Storage/Work Surface .................................................................. 6309-00
AirCompressor ....................................................................... 6410-A0
LocationPlate ....................................................................... 38001-00
Tray ............................................................................... 38002-00
Box ............................................................................... 38003-00
Storage ............................................................................ 38004-00
LocationTray........................................................................ 38685-00
Spacer (additional) ................................................................... 39035-00
Acoustic Alarm3...................................................................... 39303-00
Bench4............................................................................. 46601-10
Bench4............................................................................. 46601-20
Bench4............................................................................. 46601-30
WorkSurface........................................................................ 46604-00
Square Part (Plexiglass) ............................................................... 96474-00
Square Part (Wax) .................................................................... 96942-00

SERVO ROBOT SYSTEM
SERIES 5250
6
MODULE DESCRIPTION
Model 5119 – Gravity Feeder (Square Parts)
The Gravity Feeder (Square Parts) is designed to feed
square parts measuring 51 x 51 mm (2 x 2 in) with a
thickness between 13 and 38 mm (0.5 and 1.5 in). It has
a sensor switch and feedback cables for connection to
the Robot Controller.
Model 5121 – Gravity Feeder (Cylindrical Parts)
The Gravity Feeder (Cylindrical Parts) is designed to feed
cylindrical parts similar in form and dimensions to film
canisters. It has a sensor switch and feedback cables for
connection to the Robot Controller.

7
Model 5122-1 – Pneumatic Feeder (Square Parts)
The Pneumatic Feeder (Square Parts) is designed to feed
square parts measuring 50 x 50 x 12.5 mm (2 x 2 x 0.5 in).
It consists of storage and feeder sections and a pneumatic
cylinder. Both sections have limit switches to send feed-
back to the Pneumatic Feeder Controller. When the
Pneumatic Feeder Controller detects that the feeder
section is empty, it supplies compressed air to the pneu-
matic cylinder to push a part from the storage section into
the feeder section. This module requires a Pneumatic
Feeder Controller.
The Pneumatic Feeder (Square Parts), Model
5122-A, includes the Pneumatic Feeder Controller.
Model 5142-1 – Pneumatic Feeder (Cylindrical
Parts)
The Pneumatic Feeder (Cylindrical Parts) is designed to
feed cylindrical parts having a diameter of 19 mm (0.75
in) and a length of 63.5 mm (2.5 in). It consists of a stor-
age and feeder sections, and a pneumatic cylinder. Both
sections have limit switches to send feedback to the
Pneumatic Feeder Controller. When the Pneumatic
Feeder Controller detects that the feeder section is
empty, it supplies compressed air to the pneumatic cylin-
der to push a part from the storage section into the feeder
section. This module requires a Pneumatic Feeder Con-
troller.
The Pneumatic Feeder (Cylindrical Parts), Model
5142-A, includes the Pneumatic Feeder Controller.

SERVO ROBOT SYSTEM
SERIES 5250
8
Model 5149 – Pneumatic Feeder Controller
The Pneumatic Feeder Controller is used to control the
Pneumatic Feeders, Models 5122 and 5142. It includes
a pneumatic valve, which supplies compressed air to the
Pneumatic Feeders. The operation of the Pneumatic
Feeder Controller is controlled by the limit switches in the
feeder and storage sections of the Pneumatic Feeders.
This module requires compressed-air supply (available
from a local air supply or from the optional Air Compres-
sor, Model 6410-A.
Model 5208-1 – Rotary Carousel
The Rotary Carousel is used to demonstrate how parts
can be transferred to and from a robot in a repetitive,
rotational pattern. Its 457-mm (18-in) platter is driven by
a DC servo motor. The carousel has a closed loop feed-
back system and a limit switch feedback for hard home
capabilities. The operation of the Rotary Carousel is
controlled by the Robot Controller.
Model 5209-1 and Model 5209-A – Linear Slide
The Linear Slide is available in two models. Model 5209-1
is designed to provide 1145 mm (45 in) of linear travel to
the Servo Robot, while Model 5209-A provides
645 mm (25 in) of linear travel. The Linear Slide is driven
by a DC servo motor directly coupled to a precision ball
screw. It has a closed loop feedback system and a limit
switch feedback for hard home capabilities. The operation
of the Linear Slide is controlled by the Robot Controller.
Model 5210 – Belt Conveyor
The Belt Conveyor is used in material-handling experi-
ments. It has a self-contained power supply and interface
electronics. The control panel has inputs for interfacing
with the Robot Controller. The inputs enable the conveyor
to be remotely controlled. It can also be used as a
stand-alone unit. The Belt Conveyor comes with a mov-
able limit switch to detect the presence of parts on the
belt. The conveyor belt has a length of 1880 mm (74 in)
and a width of 127 mm (5 in).

9
Model 5221 – Robot Controller
The Robot Controller module contains the inputs and
outputs required for sending and receiving TTL signals
to/from the peripheral equipment and CNC machine tools.
The Robot Controller module is operated from the Hand-
Held Terminal, the RoboCIM 5250 Software, or the Ro-
botics software. The Robot Controller comes with
RoboCIM 5250 Software, Robotics software, Hand-Held
Terminal, Emergency Stop Button module, Robot calibra-
tion tools, and all leads and cables required to operate
the system.
Model 5250-A – Servo Robot
The Servo Robot has five axes of rotation plus a gripper.
It is driven by servo motors equipped with optical
encoders. All joints can be used simultaneously to per-
form a programmed move sequence. A Cartesian mode
allows to move the gripper linearly, parallel to a specified
axis. Movement of the mechanisms is accomplished by
belts through a series of gears and pulleys. The Servo
Robot has a load capacity of 4.5 kg (10 lb). Two grid
sheets are provided for the positioning of the Servo Robot
when perforated work surfaces are not available.

SERVO ROBOT SYSTEM
SERIES 5250
10
Model 5251 – RoboCIM 5250 Software
The RoboCIM 5250 Software is used to simulate and
control the operation of the Servo Robot System, Model
5250, and optional external devices such as Gravity
Feeders, Belt Conveyors, or Linear Slides. One of the key
features of the RoboCIM 5250 Software is that it simu-
lates the actual equipment with three-dimensional repre-
sentations. Sophisticated mathematical models accurately
simulate the mechanical and electrical characteristics of
the equipment. The RoboCIM 5250 Software allows users
to interactively control and view the motion of the system.
Programs can be created with the RoboCIM 5250 Soft-
ware to control the equipment using either the text pro-
gramming mode or the icon programming mode.
Model 5259 – Accessories
The Accessories consist of various pieces of equipment
designed to help move and position parts with the Servo
Robot System. The Accessories include two Location
Plates, Model 38001, a Tray, Model 38002, a Box, Model
38003, and a Storage, Model 38004.
Model 5259-A – Accessories
The Accessories consist of various pieces of equipment
designed to help moving and positioning parts with the
Servo Robot System. The Accessories include a Location
Plate, Model 38001, a Box, Model 38003, a Location
Tray, Model 38685, and two Spacers, Model 39035.
Model 5259-C – Connection Leads
The Connection Leads consist of extra-flexible electrical
leads terminated with stacking banana plugs. They are
supplied in three different lengths.
Model 5274 – Robot 5250 Software Development
Kit (SDK)
The Robot 5250 Software Development Kit is used for
developing applications for the Robot System. It includes
a CD-ROM with all the files required to build programs to
control the 5250 Servo Robot System using different
programming languages. The SDK package includes
program samples that show how to interface the Servo
Robot System with Visual C++, LabVIEW, MATLAB and
Simulink.
The Software Development Kit comes with a User Guide
giving the details for each function in the library. Since the
Robot 5250 Software Development Kit is intended for
developers, no instruction material is provided.
Model 5924 – Signal Tower