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PreciseFlex 400
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Brooks
Automation
5.
Hardw
are
Reference
Part
Number:
PF40-DI-00010
Rev.
A
System
Schemati
cs
Figure
5-18:
Assembly,
Pushbotton
Harness
Figure
5-19:
Assembly,
Brake
Solenoid
Harness
Copyright
©
2023,
Brooks
Automation
64
72
74
Table of Contents
Main Page
Table of Contents
6
Safety
10
Safety Setup
10
Authorized Personnel Only
10
Explanation of Hazards and Alerts
11
Safety Text
11
Safety Icons
11
Signal Words and Color
11
Alert Example
12
General Safety Considerations
13
Mechanical Hazards
15
Electrical Hazards
16
Ergonomic Hazards
17
Emergency Stop Circuit (E-Stop)
19
Recycling and Hazardous Materials
19
Introduction to the Hardware
20
System Description and Overview
20
Release History
21
System Diagram and Coordinate Systems
22
System Components
24
Preciseflex 400 Robot
24
Optional Linear Axis Module
25
Mounting of Robot and Linear Axis Module
26
Optional Gripper
26
Guidance 1400B Controller
26
Low-Voltage Power Supplies
27
Energy Dump Circuit
28
Remote Front Panel, E-Stop Box, and Manual Control pendant
29
Optional RS-485 IO Module (GIO)
29
Remote IO Module (Ethernet Version)
30
Machine Vision Software and Cameras
31
Machine Safety
31
Safety and Agency Certifications
31
Standards Compliance and Agency Certifications
32
Moving Machine Safety
32
Voltage and Power Considerations
33
Mechanical and Software Limit Stops
33
Stopping Time and Distance
33
Releasing a Trapped Operator: Brake Release Switch
34
Collaborative Robot Safety
35
General Information
35
Summary
35
Background
35
Determining a Machine's Required Performance Level (Plr)
36
Maximum Allowable Forces to Prevent Operator Injury
37
Types of Forces
38
Robot Testing and Safety Circuits
39
Controller Requirements
40
Possible Preciseflex Controller Faults and Controller Testing
40
Test Procedure for the PF400
43
Robot Workcell Design
44
Installation Information
46
Environmental Specifications
46
Facilities Connections
46
System Dimensions
47
Linear Axis Mounting Dimensions
53
Unpacking and Handling Instructions
54
Mounting Instructions
54
Tool Mounting
54
Accessing the Robot Controller
55
Power Requirements
55
Emergency Stop
55
Hardware Reference
56
System Schematics
56
System Diagram and Power Supplies
56
Facilities Panel
74
E-Stop Connector
76
MCP / E-Stop Interface
76
Digital Input and Output Signals
77
Gripper Controller Digital Inputs and Outputs
80
Remote IO Module (GIO)
81
Ethernet Interface
81
RS-232 Serial Interface
82
Gripper Serial Interface (for Bar Code and Other RS-232 Devices in Gripper)
82
Software Reference
84
Accessing the Web Server
84
Loading a Project (Program) or Updating PAC Files
86
Updating GPL (System Software) or FPGA (Firmware)
88
Recovering from Corrupted PAC Files
89
Controller Software Extensions
91
Adding or Removing the Optional Linear Axis
91
Controlling the Preciseflex Servo Grippers
92
Overview
92
Software Revision
93
Controlling the Gripper
93
Gripper Squeeze (Simple Method)
93
Gripper Squeeze (Asymmetric Method)
94
End of Travel Sensor
95
Grip Test and Squeeze Check
95
Servo Gripper Controller Digital Inputs and Outputs
95
Optional Pneumatic or Vacuum Gripper
97
G1400B Dedicated Digital Outputs
99
Service Procedures
101
Recommended Tools
101
Troubleshooting
101
Encoder Operation Error
103
Replacing the Encoder Battery
104
Calibrating the Robot: Setting the Encoder Zero Positions
106
Replacing Belts and Motors
109
General Belt Tensioning
109
Tensioning the J1 (Z Column) Belts
110
Tensioning the 1St Stage Belt
110
Tensioning the 2Nd Stage Belt
111
Tensioning the J2 Belt
112
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 Axis
118
Replacing the Power Supplies, Energy Dump PCA, or J1 Stage Two (Output) Timing Belt
119
Replacing the Robot Controller
122
Replacing the Servo Gripper Controller
125
Replacing the Agilent Servo Gripper Finger Pads
127
Replacing the Gripper Spring or Cable
128
Adjusting the Gripper Backlash or Centering Fingers
129
Adjusting the Gripper Brake (for Grippers with Brake)
131
Replacing the Electric Grippers or Slip Ring Harness
132
Replacing the Linear Axis Controller
134
Installing the Optional GIO Board
136
Replacing the Main Harness
139
Replacing the Outer Link Harness
139
Replacing the Z-Axis Motor Assembly
142
Replacing the J2 (Shoulder) Axis Motor or Timing Belt
145
Replacing the J3 (Elbow) Axis Motor or Timing Belt
149
Replacing the J4 (Wrist) Axis Motor or Timing Belt
152
Replacing Servo Gripper with Pneumatic or Vacuum Gripper
155
Appendices
166
Appendix A: Product Specifications
166
Appendix B: Environmental Specifications
168
Appendix C: Spare Parts List
169
Appendix D: Preventative Maintenance
171
Appendix E: Belt Tensions, Gates Tension Meter
173
Appendix F: Example Performance Level Evaluation
175
Example Workcell Description
175
Normal Operator Interaction with Robot
175
Possible Low Frequency (Rare) Interaction with Robot
175
Appendix G: TUV Verification of PF400 Collision Forces
176
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