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PreCise PF400 User Manual
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The PF400 and PF3400 Robots
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Version 5.04, August 9, 2017
Precise Automation Inc., 727 Filip
Road, Los Altos,
California 94024
www.preciseautomation.com
2
Table of Contents
Warning Labels
3
Table of Contents
4
Introduction to the Hardware
9
System Overview
9
System Description
9
PF3400: 3Kg Version
10
System Diagram and Coordinate Systems
11
System Components
12
Preciseflex 400 Robot
12
Optional Linear Axis Module
13
Mounting of Robot and Linear Axis Module
13
Optional Gripper
14
Guidance 1400B Controller
14
Low Voltage Power Supplies
14
Energy Dump Circuit
15
Remote Front Panel, E-Stop Box and Manual Control Pendant
15
Optional RS485 IO Module (GIO)
16
Remote IO Module (Ethernet Version)
16
Machine Vision Software and Cameras
17
Machine Safety
17
Safety and Agency Certifications
17
Standards Compliance and Agency Certifications
18
Moving Machine Safety
18
Voltage and Power Considerations
18
Mechanical and Software Limit Stops
19
Stopping Time and Distance
19
Releasing a Trapped Operator: Brake Release Switch
20
Collaborative Robot Safety
21
Summary
21
Background
21
Power and Force Limiting by Inherent Design or Control
22
Maximum Allowable Forces to Prevent Operator Injury
23
Limit Values
24
Types of Forces
24
Robot Testing and Safety Circuits
25
Controller Requirements
26
Possible Precise Controller Faults and Controller Testing
26
Safety Circuits, Failure Modes, and TUV Testing for the PF400 Robots
26
PF400 Maximum Forces, Newton
26
Test Procedure for the PF400
29
Vertical and Horizontal Test Setup
29
Free Space Collision Test and Linear Rail Test
29
Robot Workcell Design
30
Workcell Design Recommendations for the PF400
30
Normal Operator Interaction with Robot
31
Possible Low Frequency (Rare) Interaction with Robot
31
Appendix A: Example Performance Level Evaluation for PF400
31
Appendix B: TUV Verification of PF400 Collision Forces
32
Description of the Test Subject
33
Function
33
Technical Data
33
Order
34
Positive Test/Evaluation Results
34
Collision Force Table for PF3400
36
PAC Files Preciseflex 3400S
36
Table A2 from ISO/TS 15066: 2016
37
Biomechnical Limits
37
Safety Circuits for PF400 500Gm Payload
39
Safety Circuits for PF3400 3Kg Payload
40
PF400 500Gm Safety Circuits
41
PF3400 3Kg Safety Circuits
41
Installation Information
42
Environmental Specifications
42
Facilities Connections
42
System Dimensions
43
Working Volume
43
Mounting Dimensions for PF400, Standard Reach
43
Finger Mount Height from Base PF400
44
Gripper Flange Mount Height from PF3400
44
Linear Axis Mounting Dimensions
49
Mounting Instructions
50
Tool Mounting – Preciseflex 400
50
Accessing the Robot Controller
50
Power Requirements
51
Emergency Stop
51
Hardware Reference
52
System Schematics
52
System Diagram and Power Supplies
52
Schematic: System Overview
54
Schematic: FFC Boards Revision B PF400
55
Schematic: FFC Boards Revision C PF400
57
Schematic: FFC Boards 3Kg PF400
58
Schematic: Safety System Overview PF400 CAT3
60
Controller Power Amplifier Connectors
62
Control Board Connectors
62
Gripper and Linear Axis Controller Connectors
63
Facilities Panel
75
E-Stop Connector
76
MCP / E-Stop Interface
77
Digital Input Signals
77
Sinking Digital Input
78
Sourcing Digital Input
78
Digital Output Signals
79
Sinking Digital Output
79
Sourcing Digital Output
79
Gripper Controller Digital Inputs and Outputs
80
RS485 Remote IO Module (GIO)
80
PF3400 3Kg IO in Base of Robot (GIO)
81
Digital Outputs in the Outer Link
83
Ethernet Interface
83
RS-232 Serial Interface
83
Software Reference
85
Accessing the Web Server
85
Loading a Project (Program) or Updating PAC Files
87
Updating GPL (System Software) or FPGA (Firmware)
88
Recovering from Corrupted PAC Files
89
Adding or Removing the Optional Linear Axis
93
Controlling the Precise Servo Grippers
94
Software Revision
94
Controlling the Gripper
94
Gripper Squeeze (Simple Method)
94
Gripper Squeeze (Asymmetric Method)
95
End of Travel Sensor
96
Grip Test and Squeeze Check
96
Servo Gripper Controller Digital Inputs and Outputs
96
Optional Pneumatic or Vacuum Gripper
97
J4 and J7 on GSB Board
97
J14 and J15 on CPU Board
97
G1400B Dedicated Digital Outputs
98
Service Procedures
99
Recommended Tools
99
Trouble Shooting
99
Recommended Action
100
Encoder Operation Error
101
Replacing the Encoder Battery
102
Tools Required
102
Parts Required
102
Calibrating the Robot: Setting the Encoder Zero Positions
103
To Replace the Encoder Battery the User Must
103
Replacing Belts and Motors
108
General Belt Tensioning
108
Tensioning the J1 (Z Column) Belts
108
Tensioning the J2 Belt
110
Tensioning the J3 Belt (before 2014)
112
Tensioning the J4 Belt (before 2014)
113
Tensioning the J3 and J4 Belts (2014)
114
Motor Locking Screws
115
Tensioning the Belt on the Optional Linear Axis
116
To Tension the Linear Axis Belt the User Must
116
Replacing the Power Supplies
117
Spare Parts Required
117
Replacing the Robot Controller
120
Replacing the Servo Gripper Controller
122
Controller Installed in Inner Link
122
Wiring for 60N Gripper with Battery Pigtail
124
Wiring for Pneumatic Gripper
124
Wiring for Vacuum Gripper
125
Wiring for Vacuum-Pallet Gripper
125
Replacing the Agilent Servo Gripper Finger Pads
126
Replacing the Gripper Spring or Cable
127
Spare Parts Required: Spring or Cable Assembly
127
Adjusting the Gripper Backlash or Centering Fingers
128
Gripper Racks Centered in Fully Closed Position
129
Gripper Racks Centered in Fully Open Position
129
Adjusting the Gripper Brake (for Grippers with Brake)
130
Replacing the Electric Grippers or Slip Ring Harness
131
Replacing the Linear Axis Controller
134
Installing the Optional GIO Board
136
To Install the GIO in a Robot
136
Replacing the Main Harness
139
Replacing the Outer Link Harness
139
Replacing the Z Axis Motor Assembly
142
Replacing the J3 (Elbow) Axis Motor or Timing Belt
148
Replacing the J4 (Wrist) Axis Motor or Timing Belt
151
Replacing Servo Gripper with Pneumatic or Vacuum Gripper
153
Product Specifications
163
Preciseflex 400 Specifications
163
General Specification
163
Preciseflex 3400 Specifications
164
Appendix C: Spare Parts List
166
Appendix D: Preventative Maintenance
168
Check List
168
To Use the Tension Meter
169
Appendix E: Belt Tensions, Gates Tension Meter
169
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PreCise PF400 Specifications
General
Brand
PreCise
Model
PF400
Category
Robotics
Language
English
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