AL5B Arm Assembly Instructions Rev. 2.1

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<h1 class="asm">AL5B Arm Assembly Instructions Rev. 2.1</h1>

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<p><b>Updated December 2014</b></p>

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<p><span class="asm-warning">Safety first!</span> Wear eye protection and never touch a powered robot!</p>

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<p>This guide shows how to assemble the AL5B arm with either the SSC-32 or the SSC-32U servo controller. Calibration can be done using: SSC-32 Servo Sequencer Utility · RIOS (purchased separately or as part of a kit) · Lynxterm (legacy software)</p>

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<p>Note: Loctite / thread lock can be used on aluminum components, though not necessary if nuts are properly tightened. Do not use on Lexan or plastic.</p>

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<p style="font-size:12px; color:#666; margin-top:0.3rem;"><b>Complete arm (SSC-32 shown).</b></p>

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<div class="asm-step-name">AL5B — Lexan Preparation</div>

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<p>The Lexan pieces have a protective covering that must be removed before assembly. The laser cut melts the covering into the cut edge. Gently scrape the cut edge with a flat blade screwdriver to lift and peel off. On smaller pieces, use duct tape after scraping. For further information see <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/support/polycarbonate-info-page/" target="_blank">this page</a>.</p>

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<span>Lexan Preparation.</span>

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<div class="asm-step-name">AL5B — Base Bracket Assembly</div>

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<p>Connect the "C" bracket to the large "C" bracket as shown using two 2-56 x 1/4" screws and 2-56 nuts.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">2-56 x .250" Phillips screw</div></div>

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<span>Figure 1.</span>

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<div class="asm-step-name">AL5B — Mechanical Dampening Panels</div>

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<p>Install the mechanical dampening panels as shown using four 2-56 x 1/4" machine screws. Add the discs to the correct side and ensure the Lexan protective covering has been removed. Press down when screwing to ensure no gap between Lexan and aluminum.</p>

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<span>Figure 2.</span>

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<div class="asm-step-name">AL5B — Shoulder Pivot Screw</div>

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<p>Insert the 4-40 x .5" Phillips head screw through the hole in the multi-purpose bracket as shown. Secure with a steel nut.</p>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 x .500" Phillips screw</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 steel nut</div></div>

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<span>Figure 3.</span>

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<div class="asm-step-name">AL5B — Shoulder Dampener Lock Nut</div>

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<p>Slide the large "C" bracket end over the screw and secure with a nylon insert lock nut. Start loose — tighten only if the arm wobbles. <span class="asm-warning">Caution: do not over-tighten! If dampeners are too tight the servo WILL heat up and CAN be damaged!</span></p>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 nylon insert lock nut</div></div>

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<span>Figure 4.</span>

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<div class="asm-step-name">AL5B — Prepare Shoulder Servo Horn</div>

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<p>Replace the black servo horn on the HS-755HB mega servo with the round nylon servo horn. Remove the screw without rotating the horn, pull it off, press the nylon horn in place as shown, and replace the screw. The arrows point to the screw holes you will use.</p>

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<span>Figure 5.</span>

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<div class="asm-step-name">AL5B — Install Shoulder Servo</div>

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<p>Attach the HS-755HB servo to the base bracket using the 3mm hardware per the diagram below. Use two #2 x 1/4" tapping screws to secure the bracket to the servo horn. Route wires underneath the servo. Plug into channel 1 on the SSC-32. Rotate to an extreme and use a wire tie to take up cable slack.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">#2 x .250" tapping screw</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Hole position reference</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Bracket mounting diagram</div></div>

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<span>Figure 6.</span>

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<div class="asm-step-name">AL5B — Forearm Tubing Hubs</div>

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<p>Attach two tubing connector hubs to the short side of the "L" brackets using four 2-56 x .250 screws and 2-56 nuts (two each).</p>

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<div class="asm-part-info"><div class="asm-part-qty">4x (2 each)</div><div class="asm-part-name">2-56 x .250" Phillips screw</div></div>

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<span>Figure 7.</span>

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<div class="asm-step-name">AL5B — Connect Forearm Tube</div>

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<p>Connect the hubs to the <b>2.25" tube</b> using two 4-40 x .250" screws. Tighten firmly.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">4-40 x .250" hex socket screw</div></div>

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<span>Figure 8.</span>

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<div class="asm-step-name">AL5B — Attach Multi-Purpose Brackets</div>

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<p>Attach the tubing structure to two Multi-Purpose brackets as shown using four 2-56 x .250 screws and 2-56 nuts (two each).</p>

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<div class="asm-part-info"><div class="asm-part-qty">4x (2 each)</div><div class="asm-part-name">2-56 x .250" Phillips screw</div></div>

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<span>Figure 9.</span>

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<div class="asm-step-name">AL5B — Elbow Pivot Screw</div>

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<p>Insert the 4-40 x .5" Phillips head screw through the hole in the multi-purpose bracket as shown. Secure with a steel nut.</p>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 steel nut</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 x .500" Phillips screw</div></div>

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<span>Figure 10.</span>

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<div class="asm-step-name">AL5B — Elbow Dampener Lock Nut</div>

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<p>Slide the screw through the dampening discs and secure with a nylon insert lock nut. Start loose — tighten only if the arm wobbles. <span class="asm-warning">Caution: do not over-tighten! If dampeners are too tight the servo WILL heat up and CAN be damaged!</span></p>

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<div class="asm-part-info"><div class="asm-part-qty">1x</div><div class="asm-part-name">4-40 nylon insert lock nut</div></div>

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<span>Figure 11.</span>

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<div class="asm-step-name">AL5B — Verify Elbow Servo Horn Position</div>

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<p>Verify that your standard-size servo output horn is at center position as shown. The arrows point to the screw holes you will use.</p>

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<span>Figure 12.</span>

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<div class="asm-step-name">AL5B — Install Elbow Servo</div>

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<p>Attach the <b>HS-645MG</b> elbow servo to the bracket using the 3mm hardware per the diagram below. Use two #2 x 1/4" tapping screws to secure the bracket to the servo horn. Route wires over the servo. Plug into channel 2 on the SSC-32.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">#2 x .250" tapping screw</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Hole position reference</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Bracket mounting diagram</div></div>

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<span>Figure 13.</span>

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<div class="asm-step-name">AL5B — Attach Gripper Connector</div>

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<p>Attach the Little Gripper connector to the short "C" bracket using two 2-56 x .250" screws and 2-56 nuts.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">2-56 x .250" Phillips screw</div></div>

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<span>Figure 14.</span>

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<div class="asm-step-name">AL5B — Wrist Ball Bearing</div>

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<p>Attach the short "C" bracket to the other Multi-Purpose bracket as shown. Refer to the diagram below for detailed ball bearing installation.</p>

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<span>Figure 15.</span>

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<div class="asm-step-name">AL5B — Install Wrist Servo</div>

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<p>Attach the <b>HS-485HB</b> wrist servo to the bracket using the 3mm hardware per the diagram below. Use two #2 x 1/4" tapping screws to secure the bracket to the servo horn. Route wires over the servo.</p>

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<div class="asm-part-info"><div class="asm-part-qty">2x</div><div class="asm-part-name">#2 x .250" tapping screw</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Hole position reference</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">—</div><div class="asm-part-name">Bracket mounting diagram</div></div>

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<span>Figure 16.</span>

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<div class="asm-step-name">AL5B — Install Gripper & Extend Servo Cables</div>

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<div class="asm-step-num">Steps 17–18 / 28</div>

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<p><b>Step 17:</b> Attach the Little Grip to the Lexan using three 4-40 x .375" button head screws and acorn locking nuts (three only — the gripper servo body blocks the fourth). Align the HS-422 servo to mid-position with the gripper halfway open. Remove the servo screw and horn, slide the servo in from the bottom, reseat, and replace the screw. Tighten then unscrew half a turn — too much friction can bind the servo.</p>

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<p><b>Step 18:</b> Add a <b>12" extender</b> to the gripper servo and a <b>6" extender</b> to the wrist servo.</p>

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<div class="asm-part-info"><div class="asm-part-qty">3x (NOT four)</div><div class="asm-part-name">4-40 x .375" button head screw</div></div>

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<div class="asm-part-info"><div class="asm-part-qty">3x (NOT four)</div><div class="asm-part-name">4-40 acorn locking nut</div></div>

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<span>Figure 17.</span>

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<span>Figure 18.</span>

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<div class="asm-step-name">AL5B — Route Wrist Cables</div>

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<p>Carefully bend the wrist servo back as far as it will go and use wire ties to secure the cables as shown. Leave slack in the gripper cable — do not pull too tight.</p>

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<span>Figure 19.</span>

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<div class="asm-step-name">AL5B — Route Arm Cables & Plug In Servos</div>

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<p>Carefully stretch the arm forward as far as it will go and use wire ties to secure all cables. Leave slack — do not pull too tight. Plug the servos into the SSC-32 per Table 20.</p>

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<span>Figure 20.</span>

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<p style="font-weight:bold; margin-bottom:0.4rem;">SSC-32 Servo Channel Assignments (Table 20)</p>

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<tr><th>SSC-32 Ch.</th><th>Servo</th></tr>

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<tr><td>01</td><td>Shoulder</td></tr>

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<tr><td>02</td><td>Elbow</td></tr>

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<tr><td>03</td><td>Wrist</td></tr>

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<tr><td>04</td><td>Gripper</td></tr>

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<tr><td>05</td><td>Wrist Rotate (optional)</td></tr>

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<div class="asm-step-name">AL5B — Test Servos</div>

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<div class="asm-step-num">Steps 21a–21b / 28</div>

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<p><span class="asm-optional">SSC-32 (Serial) — Step 21a</span><br>

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Download and install <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/ses-software/lynxterm/" target="_blank">LynxTerm</a>. Connect the SSC-32 to the serial port and apply power. The green LED should light up. Run LynxTerm. Consult the <a href="https://community.robotshop.com/forum/t/serial-usb-to-serial-port-troubleshooting/17938" target="_blank">serial troubleshooting guide</a> if needed. Select each channel and test carefully using the slider bar.</p>

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Download and install the <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/ses-software/ssc-32-sequencer/" target="_blank">SSC-32 Servo Sequencer Utility</a>. Connect USB and power the board. Set baud rate to 9600. The software auto-detects the COM port with <a href="http://www.ftdichip.com/Drivers/VCP.htm" target="_blank">FTDI drivers</a>. Ensure servos 0–4 are checked, then use the sliders to verify each servo. See the <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/ses-software/ssc-32-sequencer/WebHome/SSC32%20Servo%20Sequencer.pdf" target="_blank">SSC-32 Servo Sequencer manual</a> for more information.</p>

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<span>Figure 21a (LynxTerm).</span>

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<span>Figure 21b (SSC-32 Utility).</span>

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<div class="asm-step-name">AL5B — Center All Servos</div>

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<div class="asm-step-num">Steps 22a–22b / 28</div>

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<p><span class="asm-optional">SSC-32 (Serial) — Step 22a</span><br>

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Click "All = 1500" in LynxTerm. The arm should look like Figure 22. If any joint is off by more than 15°, check your assembly. If you did not purchase RIOS, proceed to Step 27.</p>

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Click "Calibrate" in the SSC-32 Servo Sequencer Utility. Knobs appear next to each servo — click and drag up/down to fine-tune until the arm matches Figure 22 with correct angles. Once aligned, click "Calibrate" again to store the offset values. If you did not purchase RIOS, proceed to Step 27.</p>

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<span>Figure 22a (LynxTerm — All=1500).</span>

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<span>Figure 22 (target position).</span>

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<span>Figure 22b (SSC-32 Utility calibrate).</span>

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<div class="asm-step-name">AL5B — Adjust Elbow for RIOS</div>

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<span class="asm-optional">RIOS Users Only</span>

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<p>Remove the servo horn screw from the elbow servo. Pull the horn off, lift the arm two clicks (30°) at the elbow, and reattach the horn and screw. Note: the Hitec spline has 24 grooves — each groove is 15°.</p>

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<span>Figure 23.</span>

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<div class="asm-step-name">AL5B — Install & Calibrate RIOS</div>

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<span class="asm-optional">RIOS Users Only</span>

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<p>Install RIOS following the on-screen prompts. The serial number is on the back of the CD sleeve. Use the RIOS Help File (Steps 1–7). Perform an accurate calibration — if the on-screen virtual arm doesn't match the real arm, calibration is inaccurate. Study the RIOS manual to learn how to store and playback sequences.</p>

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<span>Figure 24 (RIOS).</span>

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<div class="asm-step-name">AL5B — Calibrate Shoulder in RIOS</div>

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<span class="asm-optional">RIOS Users Only</span>

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<p>To calibrate the arm's Shoulder servo, click the "SSC-32" button in RIOS.</p>

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<span>Figure 25 (RIOS).</span>

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<div class="asm-step-name">AL5B — Set Shoulder Min/Max in RIOS</div>

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<span class="asm-optional">RIOS Users Only</span>

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<p>Select Shoulder servo #2. Move the slider up (forward) until it looks like Figure 26-2. Set Min Deg to <b>-90°</b> and right-click to set as Min Position.</p>

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<p>Move the slider down (backward) until it looks like Figure 26-3. Set Max Deg to <b>90°</b> and right-click to set as Max Position.</p>

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<p>Read the RIOS users guide (Help icon on main screen or <code>C:\Program Files\RIOS_SSC-32\Help.pdf</code>) for full usage instructions.</p>

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<span>Figure 26-1 (RIOS).</span>

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