Brooks 609622 User manual

Guidance Input and Output (GIO) Module
User Manual
Part Number 609622, Revision A

Guidance Input and Output (GIO) Module
Part Number: 609622 Rev. A
Brooks Automation
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Brooks Automation
15 Elizabeth Drive
Chelmsford, MA
01824-2400
Tel: [phone]
Fax: [phone]
Brooks Automation, PreciseFlex Collaborative Robots
201 Lindbergh Avenue
Livermore, CA 94551
Tel: [phone]
2Copyright © 2023 Brooks Automation, Inc.

Brooks Automation
Part Number: 609622 Rev. A
Worldwide Headquarters
15 Elizabeth Drive
Chelmsford, MA 01824 U.S.A.
Brooks Automation,
PreciseFlex Collaborative Robots
201 Lindbergh Avenue
Livermore, CA 94551 U.S.A
For Technical Support:
Location Contact Website
North America
[phone] (Toll-Free)
[phone] (Local)
[phone] (PreciseFlexTM)
http://www.brooks.com/
Europe [email protected]
Japan [phone] (Toll Free)
[phone](Local)
China [phone]
Taiwan [phone] (Toll Free)
[phone] (Local)
Korea 1800-5116 (Toll Free)
Singapore [phone] (Toll Free)
[phone] (Local)
Copyright © 2023 Brooks Automation, Inc. 3

Guidance Input and Output (GIO) Module
Part Number: 609622 Rev. A
Revision History
Revision ECO Date Action Author
A EC147326 08/03/2023
Releasing manual at
Rev. A to follow standard
Brooks technical
publication styles.
M. Ashenfelder
4Copyright © 2023 Brooks Automation, Inc.

Brooks Automation
Part Number: 609622 Rev. A
Table of Contents
1. Safety 1
Safety Setup 1
Authorized Personnel Only 1
Explanation of Hazards and Alerts 2
Safety Text 2
Safety Icons 2
Signal Words and Color 2
Alert Example 3
General Safety Considerations 4
Mechanical Hazards 6
Electrical Hazards 7
Ergonomic Hazards 8
Emergency Stop Circuit (E-Stop) 10
Recycling and Hazardous Materials 10
2. Introduction to the Hardware 11
Guidance Input and Output (GIO) Module Overview 11
3. Installation, Configuration, and Software 13
Mounting and Installation 13
GIO Hardware and Software Configuration 14
GIO Board Unit Number 14
RS-485 Signal Termination 15
Controller Software Configuration 15
24VDC Logic Power Considerations 16
Communication Timing Considerations 16
Accessing GIO Remote DIO 17
4. Hardware Reference 18
Guidance Input and Output (GIO) Hardware Overview 18
Digital Input and Output Signals 19
RS-485 Signal / 24VDC Power Connector 24
RS-485 Termination Jumper 26
Status Red/Green LED 26
Unit Number Jumpers 27
GIO Board Jumpers 28
Appendix A:Product Specifications 31
Copyright © 2023 Brooks Automation, Inc. 5

1. Safety Guidance Input and Output (GIO) Module
Safety Setup Part Number: 609622 Rev. A
1. Safety
Safety Setup
Brooks uses caution, warning, and danger labels to convey critical information required for the safe
and proper operation of the hardware and software. Read and comply with all labels to prevent
personal injury and damage to the equipment.
Read the Safety Chapter
Failure to review the Safety chapter and follow the safety warnings can result in serious
injury or death.
lAll personnel involved with the operation or maintenance of this product must read
and understand the information in this safety chapter.
lFollow all applicable safety codes of the facility as well as national and
international safety codes.
lKnow the facility safety procedures, safety equipment, and contact information.
lRead and understand each procedure before performing it.
Authorized Personnel Only
This product is intended for use by trained and experienced personnel. Operators must comply with
applicable organizational operating procedures, industry standards, and all local, regional, national,
and international laws and regulations.
1Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 609622 Rev. A Explanation of Hazards and
Alerts
Explanation of Hazards and Alerts
This manual and this product use industry standard hazard alerts to notify the user of personal or
equipment safety hazards. Hazard alerts contain safety text, icons, signal words, and colors.
Safety Text
Hazard alert text follows a standard, fixed-order, three-part format.
lIdentify the hazard
lState the consequences if the hazard is not avoided
lState how to avoid the hazard.
Safety Icons
lHazard alerts contain safety icons that graphically identify the hazard.
lThe safety icons in this manual conform to ISO 3864 and ANSI Z535 standards.
Signal Words and Color
Signal words inform of the level of hazard.
Danger indicates a hazardous situation which, if not avoided, will result
in serious injury or death.
The Danger signal word is white on a red background with an
exclamation point inside a yellow triangle with black border.
Warning indicates a hazardous situation which, if not avoided, could
result in serious injury or death.
The Warning signal word is black on an orange background with an
exclamation point inside a yellow triangle with black border.
Caution indicates a hazardous situation or unsafe practice which, if not
avoided, may result in minor or moderate personal injury.
The Caution signal word is black on a yellow background with an
exclamation point inside a yellow triangle with black border.
Notice indicates a situation or unsafe practice which, if not avoided, may
result in equipment damage.
The Notice signal word is white on blue background with no icon.
Copyright © 2023 Brooks Automation, Inc. 2

1. Safety Guidance Input and Output (GIO) Module
Explanation of Hazards and Alerts Part Number: 609622 Rev. A
Alert Example
The following is an example of a Warning hazard alert.
Number Description
1. How to Avoid the Hazard
2. Source of Hazard and Severity
3. General Alert Icon
4. Signal Word
5. Type of Hazard
6. HazardSymbol(s)
3Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 609622 Rev. A General Safety Considerations
General Safety Considerations
Software
Software is not safety rated. Unplanned motion can occur as long as power is
supplied to the motors. Maximum torque could be momentarily applied that may
cause equipment damage or personal injury.
lOnly operate the robot with its covers installed.
lGuarantee that safety controller features are in place (for example, an
emergency stop button and protective stop).
lRegularly test safety components to prove that they function correctly.
Robot Mounting
Before applying power, the robot must be mounted on a rigid test stand, secure
surface, or system application. Improperly mounted robots can cause
excessive vibration and uncontrolled movement that may cause equipment
damage or personal injury.
lAlways mount the robot on a secure test stand, surface, or system before
applying power.
Do Not Use Unauthorized Parts
Using parts with different inertial properties with the same robot application can
cause the robot’s performance to decrease and potentially cause unplanned
robot motion that could result in serious personal injury.
lDo not use unauthorized parts.
lConfirm that the correct robot application is being used.
Copyright © 2023 Brooks Automation, Inc. 4

1. Safety Guidance Input and Output (GIO) Module
General Safety Considerations Part Number: 609622 Rev. A
Magnetic Field Hazard
This product contains magnetic motors that can be hazardous to implanted
medical devices, such as pacemakers, and cause personal harm, severe injury,
or death.
lMaintain a safe working distance of 30 cm from the motor when with an
energized robot if you use a cardiac rhythm management device.
Unauthorized Service
Personal injury or damage to equipment may result if this product is operated or
serviced by untrained or unauthorized personnel.
lOnly qualified personnel who have received certified training and have the proper
job qualifications are allowed to transport, assemble, operate, or maintain the
product.
Damaged Components
The use of this product when components or cables appear to be damaged may cause
equipment malfunction or personal injury.
lDo not use this product if components or cables appear to be damaged.
lPlace the product in a location where it will not get damaged.
lRoute cables and tubing so that they do not become damaged and do not present
a personal safety hazard.
Inappropriate Use
Use of this product in a manner or for purposes other than for what it is intended may
cause equipment damage or personal injury.
lOnly use the product for its intended application.
lDo not modify this product beyond its original design.
lAlways operate this product with the covers in place.
5Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 609622 Rev. A Mechanical Hazards
Seismic Restraint
The use of this product in an earthquake-prone environment may cause equipment
damage or personal injury.
lThe user is responsible for determining whether the product is used in an
earthquake prone environment and installing the appropriate seismic restraints in
accordance with local regulations.
Mechanical Hazards
Pinch Point
Moving parts of the product may cause squeezing or compression of fingers or hands
resulting in personal injury.
lDo not operate the product without the protective covers in place.
Automatic Movement
Whenever power is applied to the product, there is the potential for automatic or
unplanned movement of the product or its components, which could result in personal
injury.
lFollow safe practices for working with energized products per the facility
requirements.
lDo not rely on the system software or process technology to prevent unexpected
product motion.
lDo not operate the product without its protective covers in place.
lWhile the collaborative robotics system is designed to be safe around personnel,
gravity and other factors may present hazards and should be considered.
Copyright © 2023 Brooks Automation, Inc. 6

1. Safety Guidance Input and Output (GIO) Module
Electrical Hazards Part Number: 609622 Rev. A
Vibration Hazard
As with any servo-based device, the robot can enter a vibratory state resulting in
mechanical and audible hazards. Vibration indicates a serious problem. Immediately
remove power.
lBefore energizing, ensure the robot is bolted to a rigid metal chamber or stand.
Electrical Hazards
Refer to the specifications of the Guidance Controller Quick Start Guide for the electrical power.
Electrical Shock Hazard
Contact with electrical power can cause personal harm and serious injury.
lTo avoid electrical shock, disconnect the power before troubleshooting the
electrical components.
lCheck the unit's specifications for the actual system power requirements and use
appropriate precautions.
lNever operate this product without its protection covers on.
Electrical Burn
Improper electrical connection or connection to an improper electrical supply can result
in electrical burns resulting in equipment damage, serious injury, or death.
lAlways provide the robot with the proper power supply connectors and ground that
are compliant with appropriate electrical codes.
7Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 609622 Rev. A Ergonomic Hazards
Electrical Fire Hazard
All energized electrical equipment poses the risk of fire, which may result in severe injury
or death. Fires in wiring, fuse boxes, energized electrical equipment, computers, and
other electrical sources require a Class C extinguisher.
lUse a fire extinguisher designed for electrical fires (Class C in the US and Class E
in Asia).
lIt is the facility's responsibility to determine if any other fire extinguishers are
needed for the system that the robot is in.
Improper handling of the power source or connecting devices may cause component damage or equipment fire.
lConnect the system to an appropriate electrical supply.
lTurn off the power before servicing the unit.
lTurn off the power before disconnecting the cables.
Ergonomic Hazards
Heavy Lift Hazard
Failure to take the proper precautions before moving the robot could result in back injury
and muscle strain.
lUse a lifting device and cart rated for the weight of the drive or arm.
lOnly persons certified in operating the lifting device should be moving the product.
Tipover Hazard
This product has a high center of gravity which may cause the product to tip over and
cause serious injury.
lAlways properly restrain the product when moving it.
lNever operate the robot unless it is rigidly mounted.
Copyright © 2023 Brooks Automation, Inc. 8

1. Safety Guidance Input and Output (GIO) Module
Ergonomic Hazards Part Number: 609622 Rev. A
Trip Hazard
Cables for power and communication and facilities create trip hazards which may cause
serious injury.
lAlways route the cables where they are not in the way of traffic.
9Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 609622 Rev. A Emergency Stop Circuit (E-
Stop)
Emergency Stop Circuit (E-Stop)
The integrator of the robot must provide an emergency stop switch.
Emergency Stop Circuit
Using this product without an emergency stop circuit may cause personal injury.
lCustomer is responsible for integrating an emergency stop circuit into their
system.
lDo not override or bypass the emergency stop circuit.
Recycling and Hazardous Materials
Brooks Automation complies with the EU Directive 2002/96/EU Waste Electrical and Electronic
Equipment (WEEE).
The end user must responsibly dispose the product and its components when disposal is required.
The initial cost of the equipment does not include cost for disposal. For further information and
assistance in disposal, please email Brooks Automation Technical Support at
[email protected].
Copyright © 2023 Brooks Automation, Inc. 10

2. Introduction to the Hardware Guidance Input and Output (GIO) Module
Guidance Input and Output (GIO) Module Overview Part Number: 609622 Rev. A
2. Introduction to the Hardware
Guidance Input and Output (GIO) Module Overview
The Guidance Input and Output (GIO) module is a very compact device that connects to any
Guidance Controller and adds an additional twelve (12) optically isolated remote digital input
channels and eight (8) optically isolated remote digital output channels.
GIO modules interface to a controller via a two-wire, bi-directional, daisy chained RS-485 line, and
can be located up to approximately six (6) meters from the controller. Depending upon the timing
requirements of the application and the available 24VDC power, a mix of as many as eight (8 )
GIO's or Guidance Slave Boards (GSBs) may be connected to a RS-485 cable. (For PreciseFlex™
400 Sample Handlers with Linear Rails that include two internal GSBs, only two additional GIOs or
GSBs can be connected due to 24VDC power limitations.)
Figure 2-1: Guidance Input and Output (GIO) Module
The GIO contains unshielded 24VDC signals and pins. This product is intended to be
mounted in a cabinet or machine chassis that is not accessible when power is turned on.
11 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 2. Introduction to the Hardware
Part Number: 609622 Rev. A Guidance Input and Output
(GIO) Module Overview
Once the GIO and the Guidance Controller are interfaced, the on/off states of the GIO digital inputs
and outputs are automatically transferred to the controller via the PreciseFlex Servo Network
protocol. Application programs running on the controller can access the GIO input and output
values as though they were local to the controller. The only consideration is that GIO values are
delayed somewhat because they are periodically transferred via the network protocol.
For systems that require an even greater number of remote digital inputs and/or outputs or other
types of IO interfaces, or those that require that the I/O be located a greater distance from a
Guidance Controller, Brooks sells an Ethernet-based Remote Input and Output Module (RIO). For
detailed information on the Guidance Controller or the RIO, refer to the Brooks PreciseFlex Library.
Copyright © 2023 Brooks Automation, Inc. 12

3. Installation, Configuration, and Software Guidance Input and Output (GIO) Module
Mounting and Installation Part Number: 609622 Rev. A
3. Installation, Configuration,
and Software
Mounting and Installation
The Guidance Input and Output (GIO) module is an open frame device with exposed 24VDC and
must be mounted inside of a cabinet or other enclosure. The mounting holes are shown in Blue in
Figure 3-1 with dimensions in millimeters. There should be sufficient airflow across this board to
ensure that the components do not become excessively hot.
Figure 3-1: GIOMounting Holes
13 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 3. Installation, Configuration,
and Software
Part Number: 609622 Rev. A GIO Hardware and Software
Configuration
The GIO contains unshielded 24VDC signals and pins. This product is intended to be
mounted in a cabinet or machine chassis that is not accessible when power is turned on.
GIO Hardware and Software Configuration
GIO Board Unit Number
Up to a maximum of eight (8) GIOs or Guidance Slave Boards (GSBs) can be theoretically
interfaced to a Guidance Controller. Therefore, this section describes how to configure and address
up to 8 GIO or GSB boards. However, due to communication timing and 24VDC power
considerations, which are described below, a maximum combination of four (4) GIOs or GSBs is a
more practical limit except for special system configurations.
GIOs and GSBs can be connected to the RS-485 daisy chain in any order without altering their
operation or identification. A GIO or GSB is not identified by a unit number that is embedded in its
low-level communication messages. This unit number is specified by jumpers on the GIO. A GIO's
unit number is automatically combined with "GIO_" to generate a keyword that is used to configure
the communication protocol between the GIO and its master controller. The unit number can be
arbitrary selected and does not need to be sequentially assigned, but each GIO or GSB must have a
unique unit number within a given RS-485 system.
The setting of the GIO's Unit Number Jumpers is presented in Table 3-1 along with the
corresponding unit number and keyword identifier.
NOTE: The Unit Number Jumpers for the GIO are J7/J8/J9, whereas the GSB utilizes
J8/J9/J10.
J7 J8 J9 GIO Unit GIO Keyword
In In In 1 GIO_1
Out In In 2 GIO_2
In Out In 3 GIO_3
Table 3-1: The Setting of the GIO's Unit Number Jumpers
Copyright © 2023 Brooks Automation, Inc. 14

3. Installation, Configuration, and Software Guidance Input and Output (GIO) Module
GIO Hardware and Software Configuration Part Number: 609622 Rev. A
J7 J8 J9 GIO Unit GIO Keyword
Out Out In 4 GIO_4
In In Out 5 GIO_5
Out In Out 6 GIO_6
In Out Out 7 GIO_7
Out Out Out 8 GIO_8
RS-485 Signal Termination
There is one hardware configuration option that is dependent upon the ordering of modules in the
RS-485 daisy chain. For noise immunity, termination jumpers must be installed on the GIOs, GSBs,
or controller on the extreme ends of the RS-485 daisy chain. The termination jumpers must be
removed for all controllers or boards in between. On the GIO board, the Termination Jumper is
labeled J6. Consult the hardware description for a specific master controller to determine its RS-485
termination jumper location.
Controller Software Configuration
For the controller to communicate with an IO module, the GIO's GIO_Keyword must be entered into
the "Servo network node identifier" (DataID 151) parameter database array in the master controller.
This provides the controller with the information required to communicate with the GIO board. The
position of the GIO_Keyword in the DataID 151 array assigns the board a "network node number."
Within the controller's software environment, the network node number (and not the GIO's unit
number) is used to reference DIO on the GIO board. By convention, the first network node is always
the master controller and the first element of the DataID 151 is always the controller's serial number.
For example, if the GIO Unit Number Jumpers are set to select unit #4 (Keyword GIO_4), to define
the GIO as the second network node, DataID 151 should be defined as follows:
DataID 151: "<master>," "GIO_4", "", "", "", "", . . .
Normally, only elements at the end of the DataID 151 array can be blank and a blank entry cannot
precede any non-blank servo node entry. As a special case, blank entries may occur before a GIO
keyword. So the user could enter DataID 151 as follows:
DataID 151: "<master>", "", "", "", "", "GIO_4"
15 Copyright © 2023 Brooks Automation, Inc.