Brooks PreciseFlex 400

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5. Hardware Reference (Undefined variable: MyVariables.ProductName)

System Schematics Part Number: PF40-DI-00010 Rev. A

Figure 5-15: Assembly, TS4603N2068E100 PF400 J3 Motor

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Table of Contents6
Safety10
Safety Setup10
Authorized Personnel Only10
Explanation of Hazards and Alerts11
Safety Text11
Safety Icons11
Signal Words and Color11
Alert Example12
General Safety Considerations13
Mechanical Hazards15
Electrical Hazards16
Ergonomic Hazards17
Emergency Stop Circuit (E-Stop)19
Recycling and Hazardous Materials19
Introduction to the Hardware20
System Description and Overview20
Release History21
System Diagram and Coordinate Systems22
System Components24
Preciseflex 400 Robot24
Optional Linear Axis Module25
Mounting of Robot and Linear Axis Module26
Optional Gripper26
Guidance 1400B Controller26
Low-Voltage Power Supplies27
Energy Dump Circuit28
Remote Front Panel, E-Stop Box, and Manual Control pendant29
Optional RS-485 IO Module (GIO)29
Remote IO Module (Ethernet Version)30
Machine Vision Software and Cameras31
Machine Safety31
Safety and Agency Certifications31
Standards Compliance and Agency Certifications32
Moving Machine Safety32
Voltage and Power Considerations33
Mechanical and Software Limit Stops33
Stopping Time and Distance33
Releasing a Trapped Operator: Brake Release Switch34
Collaborative Robot Safety35
General Information35
Summary35
Background35
Determining a Machine's Required Performance Level (Plr)36
Maximum Allowable Forces to Prevent Operator Injury37
Types of Forces38
Robot Testing and Safety Circuits39
Controller Requirements40
Possible Preciseflex Controller Faults and Controller Testing40
Test Procedure for the PF40043
Robot Workcell Design44
Installation Information46
Environmental Specifications46
Facilities Connections46
System Dimensions47
Linear Axis Mounting Dimensions53
Unpacking and Handling Instructions54
Mounting Instructions54
Tool Mounting54
Accessing the Robot Controller55
Power Requirements55
Emergency Stop55
Hardware Reference56
System Schematics56
System Diagram and Power Supplies56
Facilities Panel74
E-Stop Connector76
MCP / E-Stop Interface76
Digital Input and Output Signals77
Gripper Controller Digital Inputs and Outputs80
Remote IO Module (GIO)81
Ethernet Interface81
RS-232 Serial Interface82
Gripper Serial Interface (for Bar Code and Other RS-232 Devices in Gripper)82
Software Reference84
Accessing the Web Server84
Loading a Project (Program) or Updating PAC Files86
Updating GPL (System Software) or FPGA (Firmware)88
Recovering from Corrupted PAC Files89
Controller Software Extensions91
Adding or Removing the Optional Linear Axis91
Controlling the Preciseflex Servo Grippers92
Overview92
Software Revision93
Controlling the Gripper93
Gripper Squeeze (Simple Method)93
Gripper Squeeze (Asymmetric Method)94
End of Travel Sensor95
Grip Test and Squeeze Check95
Servo Gripper Controller Digital Inputs and Outputs95
Optional Pneumatic or Vacuum Gripper97
G1400B Dedicated Digital Outputs99
Service Procedures101
Recommended Tools101
Troubleshooting101
Encoder Operation Error103
Replacing the Encoder Battery104
Calibrating the Robot: Setting the Encoder Zero Positions106
Replacing Belts and Motors109
General Belt Tensioning109
Tensioning the J1 (Z Column) Belts110
Tensioning the 1St Stage Belt110
Tensioning the 2Nd Stage Belt111
Tensioning the J2 Belt112
Tensioning the J3 Belt (before 2014)114
Tensioning the J4 Belt (before 2014)115
Tensioning the J3 and J4 Belts (2014)117
Tensioning the Belt on the Optional Linear Axis118
Replacing the Power Supplies, Energy Dump PCA, or J1 Stage Two (Output) Timing Belt119
Replacing the Robot Controller122
Replacing the Servo Gripper Controller125
Replacing the Agilent Servo Gripper Finger Pads127
Replacing the Gripper Spring or Cable128
Adjusting the Gripper Backlash or Centering Fingers129
Adjusting the Gripper Brake (for Grippers with Brake)131
Replacing the Electric Grippers or Slip Ring Harness132
Replacing the Linear Axis Controller134
Installing the Optional GIO Board136
Replacing the Main Harness139
Replacing the Outer Link Harness139
Replacing the Z-Axis Motor Assembly142
Replacing the J2 (Shoulder) Axis Motor or Timing Belt145
Replacing the J3 (Elbow) Axis Motor or Timing Belt149
Replacing the J4 (Wrist) Axis Motor or Timing Belt152
Replacing Servo Gripper with Pneumatic or Vacuum Gripper155
Appendices166
Appendix A: Product Specifications166
Appendix B: Environmental Specifications168
Appendix C: Spare Parts List169
Appendix D: Preventative Maintenance171
Appendix E: Belt Tensions, Gates Tension Meter173
Appendix F: Example Performance Level Evaluation175
Example Workcell Description175
Normal Operator Interaction with Robot175
Possible Low Frequency (Rare) Interaction with Robot175
Appendix G: TUV Verification of PF400 Collision Forces176

Brooks PreciseFlex 400 - Page 70

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