PreCise PF400 - Service Procedures; Recommended Tools; Trouble Shooting

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7. Open the “Config” folder and paste the backup copy of the PAC files into this folder.

8. Wait until the console prompt stops flashing, about 10-15 seconds.

9. Turn off robot power.

Main Page

Warning Labels3
Table of Contents4
Introduction to the Hardware9
System Overview9
System Description9
PF3400: 3Kg Version10
System Diagram and Coordinate Systems11
System Components12
Preciseflex 400 Robot12
Optional Linear Axis Module13
Mounting of Robot and Linear Axis Module13
Optional Gripper14
Guidance 1400B Controller14
Low Voltage Power Supplies14
Energy Dump Circuit15
Remote Front Panel, E-Stop Box and Manual Control Pendant15
Optional RS485 IO Module (GIO)16
Remote IO Module (Ethernet Version)16
Machine Vision Software and Cameras17
Machine Safety17
Safety and Agency Certifications17
Standards Compliance and Agency Certifications18
Moving Machine Safety18
Voltage and Power Considerations18
Mechanical and Software Limit Stops19
Stopping Time and Distance19
Releasing a Trapped Operator: Brake Release Switch20
Collaborative Robot Safety21
Summary21
Background21
Power and Force Limiting by Inherent Design or Control22
Maximum Allowable Forces to Prevent Operator Injury23
Limit Values24
Types of Forces24
Robot Testing and Safety Circuits25
Controller Requirements26
Possible Precise Controller Faults and Controller Testing26
Safety Circuits, Failure Modes, and TUV Testing for the PF400 Robots26
PF400 Maximum Forces, Newton26
Test Procedure for the PF40029
Vertical and Horizontal Test Setup29
Free Space Collision Test and Linear Rail Test29
Robot Workcell Design30
Workcell Design Recommendations for the PF40030
Normal Operator Interaction with Robot31
Possible Low Frequency (Rare) Interaction with Robot31
Appendix A: Example Performance Level Evaluation for PF40031
Appendix B: TUV Verification of PF400 Collision Forces32
Description of the Test Subject33
Function33
Technical Data33
Order34
Positive Test/Evaluation Results34
Collision Force Table for PF340036
PAC Files Preciseflex 3400S36
Table A2 from ISO/TS 15066: 201637
Biomechnical Limits37
Safety Circuits for PF400 500Gm Payload39
Safety Circuits for PF3400 3Kg Payload40
PF400 500Gm Safety Circuits41
PF3400 3Kg Safety Circuits41
Installation Information42
Environmental Specifications42
Facilities Connections42
System Dimensions43
Working Volume43
Mounting Dimensions for PF400, Standard Reach43
Finger Mount Height from Base PF40044
Gripper Flange Mount Height from PF340044
Linear Axis Mounting Dimensions49
Mounting Instructions50
Tool Mounting – Preciseflex 40050
Accessing the Robot Controller50
Power Requirements51
Emergency Stop51
Hardware Reference52
System Schematics52
System Diagram and Power Supplies52
Schematic: System Overview54
Schematic: FFC Boards Revision B PF40055
Schematic: FFC Boards Revision C PF40057
Schematic: FFC Boards 3Kg PF40058
Schematic: Safety System Overview PF400 CAT360
Controller Power Amplifier Connectors62
Control Board Connectors62
Gripper and Linear Axis Controller Connectors63
Facilities Panel75
E-Stop Connector76
MCP / E-Stop Interface77
Digital Input Signals77
Sinking Digital Input78
Sourcing Digital Input78
Digital Output Signals79
Sinking Digital Output79
Sourcing Digital Output79
Gripper Controller Digital Inputs and Outputs80
RS485 Remote IO Module (GIO)80
PF3400 3Kg IO in Base of Robot (GIO)81
Digital Outputs in the Outer Link83
Ethernet Interface83
RS-232 Serial Interface83
Software Reference85
Accessing the Web Server85
Loading a Project (Program) or Updating PAC Files87
Updating GPL (System Software) or FPGA (Firmware)88
Recovering from Corrupted PAC Files89
Adding or Removing the Optional Linear Axis93
Controlling the Precise Servo Grippers94
Software Revision94
Controlling the Gripper94
Gripper Squeeze (Simple Method)94
Gripper Squeeze (Asymmetric Method)95
End of Travel Sensor96
Grip Test and Squeeze Check96
Servo Gripper Controller Digital Inputs and Outputs96
Optional Pneumatic or Vacuum Gripper97
J4 and J7 on GSB Board97
J14 and J15 on CPU Board97
G1400B Dedicated Digital Outputs98
Service Procedures99
Recommended Tools99
Trouble Shooting99
Recommended Action100
Encoder Operation Error101
Replacing the Encoder Battery102
Tools Required102
Parts Required102
Calibrating the Robot: Setting the Encoder Zero Positions103
To Replace the Encoder Battery the User Must103
Replacing Belts and Motors108
General Belt Tensioning108
Tensioning the J1 (Z Column) Belts108
Tensioning the J2 Belt110
Tensioning the J3 Belt (before 2014)112
Tensioning the J4 Belt (before 2014)113
Tensioning the J3 and J4 Belts (2014)114
Motor Locking Screws115
Tensioning the Belt on the Optional Linear Axis116
To Tension the Linear Axis Belt the User Must116
Replacing the Power Supplies117
Spare Parts Required117
Replacing the Robot Controller120
Replacing the Servo Gripper Controller122
Controller Installed in Inner Link122
Wiring for 60N Gripper with Battery Pigtail124
Wiring for Pneumatic Gripper124
Wiring for Vacuum Gripper125
Wiring for Vacuum-Pallet Gripper125
Replacing the Agilent Servo Gripper Finger Pads126
Replacing the Gripper Spring or Cable127
Spare Parts Required: Spring or Cable Assembly127
Adjusting the Gripper Backlash or Centering Fingers128
Gripper Racks Centered in Fully Closed Position129
Gripper Racks Centered in Fully Open Position129
Adjusting the Gripper Brake (for Grippers with Brake)130
Replacing the Electric Grippers or Slip Ring Harness131
Replacing the Linear Axis Controller134
Installing the Optional GIO Board136
To Install the GIO in a Robot136
Replacing the Main Harness139
Replacing the Outer Link Harness139
Replacing the Z Axis Motor Assembly142
Replacing the J3 (Elbow) Axis Motor or Timing Belt148
Replacing the J4 (Wrist) Axis Motor or Timing Belt151
Replacing Servo Gripper with Pneumatic or Vacuum Gripper153
Product Specifications163
Preciseflex 400 Specifications163
General Specification163
Preciseflex 3400 Specifications164
Appendix C: Spare Parts List166
Appendix D: Preventative Maintenance168
Check List168
To Use the Tension Meter169
Appendix E: Belt Tensions, Gates Tension Meter169

PreCise PF400 - Service Procedures; Recommended Tools; Trouble Shooting

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