Brooks PreciseFlex 100 User manual

PreciseFlexTM 100 Robot
User Manual
Part Number 603988, Revision A

PreciseFlex 100 Robot
Part Number: 603988 Rev. A
Brooks Automation
Information provided within this document is subject to change without notice, and although believed to be accurate,
Brooks Automation assumes no responsibility for any errors, omissions, or inaccuracies.
AcuLigner™, Advan Tag™, AutoTeach™, ATR™, AXM™, BiSymmetrik™, CenterSmart™, Crate to Operate™,
CrossingConnect™, DARTS™, Enerta™, e-RMA™, e-Spares™, e-Volution™, Falcon™, FIXLOAD™, FrogLeg™,
GuardianPro™, Independent Twin Linear Exchange™, InCooler™, InLigner™, Isoport™, ITLX™, Jet™, Jet Engine™,
LEAP™, LeapFrog™, LowProfile™, LPT™, M2 Nano™, Marathon 2, Marathon Express, PASIV™, Pathway™,
PowerPak™, PowerTools™, PuroMaxx™, QuadraFly™, Radius™, Radient™, Radient Express™, Reliance™,
Reliance ATR™, RetroEase™, SCARA™, SmartPM™, SMIF-INX™, SMIF-LPT™, SPOTLevel™, The New Pathway
to Productivity™, Time Optimized Trajectory™, Time Optimal Trajectory™, Time Optimized Path™, TopCooler™,
TopLigner™, VacuTran™, VersaPort™, WaferEngine™, LEAP™, Pathway™, GIO, GSB, Guidance 6600, Guidance
6430, Guidance 6420, Guidance 6410, Guidance 6000, Guidance 3400, Guidance 3300, Guidance 3200, Guidance
2600, Guidance 2400, Guidance 2300, Guidance 2200, Guidance 1400, Guidance 1300, Guidance 1200, Guidance
0200 Slave Amplifier, Guidance 0006, Guidance 0004, Guidance Controller, Guidance Development Environment,
GDE, Guidance Development Suite, GDS, Guidance Dispense, Guidance Input and Output Module, Guidance
Programming Language, GPL, Guidance Slave Board, Guidance System, Guidance System D4/D6, PreciseFlex™
300, PreciseFlex™400, PreciseFlex™3400, PreciseFlex™1300, PreciseFlex™1400, PreciseFlex™DD4,
PreciseFlex™DD6, PreciseFlex™DDR, PreciseFlex™G5400, PreciseFlex™G5600, PreciseFlex™G6400,
PreciseFlex™G6410, PreciseFlex™G6420, PreciseFlex™G6430, PreciseFlex™G6600, PreciseFlex™GSBP
Slave Amp, PreciseFlex™PFD0, PrecisePlace 100, PrecisePlace 0120, PrecisePlace 0130, PrecisePlace 0140,
PrecisePlace 1300, PrecisePlace 1400, PrecisePlace 2300, PrecisePlace 2400, PrecisePower 300, PrecisePower
500, PrecisePower 1000, PrecisePower 2000, PreciseVision, and RIO logos are trademarks of Brooks Automation.
Fusion®, Guardian®, MagnaTran®, Marathon®, Razor®, Spartan®, Vision®, Zaris®, and the Brooks and design
logo are registered U.S. trademarks of Brooks Automation.
All other trademarks are properties of their respective owners.
© 2023 Brooks Automation. All rights reserved. The information included in this manual is proprietary information of
Brooks Automation, and is provided for the use of Brooks customers only and cannot be used for distribution,
reproduction, or sale without the express written permission of Brooks Automation.
This technology is subject to United States export Administration Regulations and authorized to the destination
only; diversion contrary to U.S. law is prohibited.
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: 603988 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

PreciseFlex 100 Robot
Part Number: 603988 Rev. A
Revision History
Revision ECO Date Action Author
A EC144813 07/24/2023
Released manual at Rev. A to follow
standard Brooks technical publication
styles.
M. Ashenfelder
4Copyright © 2023 Brooks Automation, Inc.

Brooks Automation
Part Number: 603988 Rev. A
Table of Contents
1. Safety 8
Safety Setup 8
Authorized Personnel Only 8
Explanation of Hazards and Alerts 9
Safety Text 9
Safety Icons 9
Signal Words and Color 9
Alert Example 10
General Safety Considerations 11
Mechanical Hazards 13
Electrical Hazards 14
Ergonomic Hazards 15
Emergency Stop Circuit (E-Stop) 17
Recycling and Hazardous Materials 17
2. Introduction to the Hardware 18
Overview 18
System Diagram and Coordinate Systems 20
System Components 22
Optional Gripper 22
Guidance 1400A Controller 22
Low Voltage Power Supplies 23
Energy Dump Circuit 23
Remote Front Panel, E-Stop Box and Manual Control Pendant 24
Optional RS485 IO Module (GIO) 25
Remote IO Module (Ethernet Version) 26
Machine Vision Software and Cameras 26
Machine Safety 27
Safety and Agency Certifications 27
Standards Compliance and Agency Certifications 27
Moving Machine Safety 27
Safety Zones 28
Voltage and Power Considerations 33
3. Installation Information 36
Environmental Specifications 36
Facilities Connections 36
Specifications and System Dimensions 36
Unpacking and Handling Instructions 46
Mounting Instructions 46
Tool Mounting 47
Accessing the Robot Controller 47
Power Requirements 47
Emergency Stop 48
4. Hardware Reference 49
Copyright © 2023 Brooks Automation, Inc. 5

PreciseFlex 100 Robot
Part Number: 603988 Rev. A
System Schematics, Diagram, and Power Supplies 49
Robot Inputs and Outputs 61
Robot Interfaces 61
MCP/E-Stop Interface 62
Digital Input Signals 63
Digital Output Signals 64
Gripper Controller Digital Inputs and Outputs 66
RS485 Remote IO Module (GIO) 67
Ethernet Interface 69
RS-232 Serial Interface 69
5. Software Reference 70
Accessing the Web Server 70
Loading a Project (Program) or Updating PAC Files 72
Updating GPL (System Software) or FPGA (Firmware) 73
Recovering from Corrupted PAC Files 74
Controller Software Extensions 76
Controlling the PreciseFlex Servo Gripper 77
Overview 77
Software Revision 77
Controlling the Gripper 77
Gripper Squeeze (Simple Method) 78
Gripper Squeeze (Asymmetric Method) 78
Grip Test and Squeeze Check 79
Servo Gripper Controller Digital Inputs and Outputs 80
Optional Pneumatic or Vacuum Gripper 81
Control of Status Lamp on Theta Cover 81
6. Service Procedures 82
Recommended Tools 82
Troubleshooting 82
Encoder Operation Error 84
Replacing the Encoder Battery 85
Calibrating the Robot: Setting the Encoder Zero Positions 87
Replacing Belts and Motors 90
General Belt Tensioning 90
Tensioning the X-axis Belt 91
Replacing the X-axis Motor Assembly 93
Replacing the X-axis Timing Belt 94
Replacing the Y-axis Motor or Belt Assembly 97
Replacing the Y-axis Belt Assembly (For XY robots only) 99
Tensioning the Z-axis Output Belt 100
Tensioning or Replacing the Z-axis Motor and Timing Belt 101
Replacing the Theta Axis Motor 102
Replacing the Power Supplies or Controller 104
Replacing the Main Harness 106
Replacing the Servo Gripper Controller 107
Wiring for Pneumatic Gripper 109
6Copyright © 2023 Brooks Automation, Inc.

Brooks Automation
Part Number: 603988 Rev. A
Replacing the Gripper Spring or Cable 111
Adjusting the Gripper Backlash 112
Replacing the Gripper Harness 113
Replacing the Gripper 114
Installing the Optional GIO Board 116
Appendices 118
Appendix A:Product Specifications 118
Appendix B: Environmental Specifications 120
Appendix C: Spare Parts List 121
Appendix D: Preventive Maintenance 122
Appendix E:Belt Tensions, Gates Tension Meter 123
Appendix F: Facilities Panel 125
Copyright © 2023 Brooks Automation, Inc. 7

1. Safety PreciseFlex 100 Robot
Safety Setup Part Number: 603988 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.
8Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 603988 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. 9

1. Safety PreciseFlex 100 Robot
Explanation of Hazards and Alerts Part Number: 603988 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)
10 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 603988 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. 11

1. Safety PreciseFlex 100 Robot
General Safety Considerations Part Number: 603988 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.
12 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 603988 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. 13

1. Safety PreciseFlex 100 Robot
Electrical Hazards Part Number: 603988 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.
14 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 603988 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. 15

1. Safety PreciseFlex 100 Robot
Ergonomic Hazards Part Number: 603988 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.
16 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 603988 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. 17

2. Introduction to the Hardware PreciseFlex 100 Robot
Overview Part Number: 603988 Rev. A
2. Introduction to the Hardware
Overview
The PrecisePlace 100 Robot is a collaborative 4-axis robot that includes an embedded Guidance
1400A 4-axis motion controller, one or more single axis controllers, a 48VDC motor power supply,
and a 24VDC logic power supply located inside the X-axis of the robot. In addition, it may optionally
include an electric gripper and electric gripper controller.
The robot is available in two basic configurations; an XZ configuration, and an XYZ configuration. A
theta rotation and electric gripper are available for both of these basic configurations. The Z-axis of
this robot is available with a standard travel of 229 mm for the XZ configuration and 260 mm for the
XYZ configuration. The robot is designed as tabletop unit and can carry a payload of up to 2 kg in
the gripper. These robots are low cost, extremely quiet and smooth, very reliable, and have
excellent positioning repeatability. To achieve these results, the axes are powered by brushless DC
motors with absolute encoders. With these characteristics, these robots are ideal for automating
applications in the Life Sciences, Medical Products, Semiconductor, and Electronics industries.
A number of communications and hardware interfaces are provided with the basic robot. These
include an RS-232 serial interface, an RS485 serial interface, an Ethernet interface, and a number
of digital input and output lines. In addition, the robot can be purchased with several types of
optional Precise peripherals. These include digital cameras, remote I/O, and a hardware manual
control pendant.
The controller is programmed by means of a PC connected through Ethernet. There are four
programming modes: a Digital IO mode (MotionBlocks), a Graphical Programming mode (Guidance
Motion), an Embedded Language mode (GPL), and a PC Control mode (TCP Command Server).
When programmed in the MotionBlocks, Guidance Motion, or GPL mode, the PC can be removed
after programming is completed and the controller will operate standalone. The PC is required for
operation in the TCP Command Server mode.
In all modes of operation, the controller includes a web-based operator interface. This interface is
used for configuring the system, starting and stopping execution, and monitoring its operation. The
web interface can be accessed locally using a browser or remotely via the Internet. This remote
interface is of great benefit in system maintenance and debugging. It is also possible to use a
wireless tablet or computer to access the web browser, if the controller is connected to a wireless
router.
18 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 2. Introduction to the Hardware
Part Number: 603988 Rev. A Overview
The optional machine vision system, "PreciseVision," can execute in a PC connected through
Ethernet or in an embedded PC inside the robot. PreciseVision requires cameras connected via
Ethernet or USB, allowing any processor on the network to obtain and process information from any
camera on the network, and provide the results to any networked motion controller.
Copyright © 2023 Brooks Automation, Inc. 19

2. Introduction to the Hardware PreciseFlex 100 Robot
System Diagram and Coordinate Systems Part Number: 603988 Rev. A
System Diagram and Coordinate Systems
The PrecisePlace 100 robot is available in several configurations, including XZ, XZTheta,
XZTheta+Gripper, and XY, XYZ, XYZTheta, and XYZTheta+Gripper. The orientation and origin of
its World Cartesian coordinate system are shown in Figure 2-1 and defined in Table 2-1.
Figure 2-1: PrecisePlace 100 Orientation & Origin of Its World Cartesian Coordinate
System
Axis Description of Motion
X Varies with model
Y 0 or 350 mm
Z 229 mm XZ, or 260 mm XYZ
Theta +/- 270 degrees
Gripper 76 to 136 mm
Table 2-1: Axis & Description of Motion
20 Copyright © 2023 Brooks Automation, Inc.