Brooks PreciseFlex 1300 User manual

PreciseFlexTM 1300/1400 Robot
Hardware Introduction and Reference Manual
Revision A

PreciseFlex 1300/1400 Robot
Part Number: PF10-DI-00010 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.
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© 2023 Brooks Automation. All rights reserved. The information included in this manual is proprietary information of
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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: PF10-DI-00010 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)
Revision History
Revision ECO Number Date Explanation of Changes
Rev 5.0.0 TBD April 9, 2022 The first Brooks version of the manual.
Rev 5.0.1 TBD July 14, 2023 Updated manual to follow standard
Brooks technical publication styles.
Copyright © 2023 Brooks Automation, Inc. 3

PreciseFlex 1300/1400 Robot
Part Number: PF10-DI-00010 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
System Overview 11
System Description 11
System Diagram and Coordinate Systems 12
System Components 13
PreciseFlex 1300/1400 Robots 13
Guidance 2400 Controller 14
Low-Voltage Power Supply 16
Intelligent Motor Power Supply 16
Remote Front Panel, E-Stop Box, and Manual Control Pendant 17
Remote IO Module 18
Machine Vision Software and Cameras 19
Controller Status LED 20
Machine Safety 21
Voltage and Power Considerations 21
Robot Controls Bay 22
Releasing a Trapped Operator: Brake Release Switch 23
Mechanical Limit Stops 23
E-Stop Stopping Time and Distance 24
Safety Zones 24
Safety Standards Reference Material 29
Standards Compliance and Agency Certifications 29
Moving Machine Safety 29
3. Installation Information 31
Environmental Specifications 31
Facilities Connections 31
System Dimensions 32
Mounting Instructions 33
Tool Mounting - PreciseFlex 1300/1400 34
4Copyright © 2023 Brooks Automation, Inc.

Brooks Automation
Part Number: PF10-DI-00010 Rev. A
Accessing the Controller and Power Supplies 35
Power Requirements 36
Emergency Stop 36
4. Hardware Reference 37
J1-Axis Housing Facilities Panel 37
Facilities Panel 37
Digital Input Signals 38
Digital Output Signals 41
Ethernet Interface 43
Remote Front Panel / MCP / E-Stop Interface 44
RS-232 Serial Interface 47
Outer Link and ZIO PCB 48
5. Software Reference 53
Controller Software Extensions 53
ZIO General Digital Inputs and Outputs 53
ZIO Dedicated Digital Outputs 54
6. Service Procedures 55
Troubleshooting 55
Setting the Encoder Zero Positions 55
General Belt Tensioning 58
J1-Axis Drive Procedures 59
Replacing the J1-Axis Motor Assembly 59
Replacing and Tensioning the J1-Axis Belts 61
Z-Axis Drive Procedures 64
Replacing the Z-Axis Motor Assembly 64
Replacing and Tensioning the Z-Axis Belts 66
J3-Axis and Theta Drive Procedures 69
Replacing the J3-Axis or Theta Motor Assembly 69
Replacing and Tensioning the J3-Axis Belts 71
Replacing and Tensioning the Theta Belts 74
Replacing Control Electronics Components 77
Appendices 80
Appendix A:Product Specifications 80
PreciseFlexTM 1300/1400 Specifications 80
PreciseFlexTM 1300/1400 Environmental Specifications 82
Appendix B:Frequently Asked Questions 83
Appendix C: Spare Parts Lists 84
Appendix D:System Schematics 85
Copyright © 2023 Brooks Automation, Inc. 5

1. Safety PreciseFlex 1300/1400 Robot
Safety Setup Part Number: PF10-DI-00010 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: PF10-DI-00010 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 PreciseFlex 1300/1400 Robot
Explanation of Hazards and Alerts Part Number: PF10-DI-00010 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: PF10-DI-00010 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 PreciseFlex 1300/1400 Robot
General Safety Considerations Part Number: PF10-DI-00010 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: PF10-DI-00010 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 PreciseFlex 1300/1400 Robot
Electrical Hazards Part Number: PF10-DI-00010 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: PF10-DI-00010 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 PreciseFlex 1300/1400 Robot
Ergonomic Hazards Part Number: PF10-DI-00010 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: PF10-DI-00010 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 PreciseFlex 1300/1400 Robot
System Overview Part Number: PF10-DI-00010 Rev. A
2. Introduction to the Hardware
System Overview
System Description
The PreciseFlex Robot Series includes the PreciseFlex embedded Guidance 2400C four-axis
motion controller, a PrecisePower 300 Intelligent Motor Power Supply, and a 24 VDC power supply
located inside the base of the robot.
The Z-axes of these robots are available in a standard length of 300 mm. For volume OEM
applications, custom lengths of up to 600 mm are possible. The robots were designed as tabletop
units and can carry a payload of up to 4 Kg. 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 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 Ethernet interface, a number of digital input and output lines,
and a remote front panel interface that provides IEC Category 3 (CAT-3) safety signals. 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 robot's integrated controller includes a web based operator interface that is viewed via a
standard browser. This interface is used for configuring the system, starting and stopping execution,
and monitoring its operation. The web interface can be accessed over a local network or remotely
via the Internet. This remote interface is of great benefit in system maintenance and debugging. It is
highly recommended that first time users read the Setup and Operation Quick Start Guide, PN
0000-DI-00010, for instructions on interfacing a PC to the robot's controller via the web interface
and for general controller operating instructions.
The controller is programmed by means of a PC connected through Ethernet. There are three
programming modes: a Digital IO (PLC) mode, an Embedded Language mode, and a PC Control
mode. When programmed in the PLC or Embedded Language mode, the PC can be removed after
programming is completed and the controller will operate standalone. A PC is required for operation
in the PC Control mode. For a complete description of the embedded language and its development
11 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 2. Introduction to the Hardware
Part Number: PF10-DI-00010 Rev. A System Overview
environment, please refer to the Guidance Programming Language, Introduction to GPL, PN
GPL0-DI-S0010 and the Guidance Development Environment, Introduction, and Reference
Manual, PN GDE0-DI-S0010.
The controller is designed to operate with an optional, easy-to-use machine vision software
package, "PreciseVision". This vision system can be executed in a PC connected through Ethernet
or (in the future) in the motion controller. It provides a complete set of image-processing,
measurement, inspection and object finder tools. For more information on vision, please refer to the
PreciseVision Machine Vision System, Introduction and Reference Manual, PN PVS0-DI-S0010.
For a complete description of the robot's controller hardware, please refer to the Guidance
3000/2000 Controllers, Hardware Introduction and Reference Manual, PN G3X0-DI-00010.
System Diagram and Coordinate Systems
The major elements of the PreciseFlex robot and the orientations of its World and Tool Cartesian
coordinate systems are shown in Figure 2-1.
Figure 2-1: Major Elements and Orientations
The first axis of the robot, J1, rotates the links of the robot about the World Z-axis.The primary
electronic components are mounted in a Controls Bay that slides into the base housing of the J1-
axis. This bay includes the Guidance 2400 Controller, the PrecisePower 300 Intelligent Motor
Power Supply and the 24 VDC logic power supply. The Guidance Controller not only controls the
robot but also provides extensive hardware interfaces including Ethernet and digital IO signals.
Copyright © 2023 Brooks Automation, Inc. 12

2. Introduction to the Hardware PreciseFlex 1300/1400 Robot
System Components Part Number: PF10-DI-00010 Rev. A
Electrical Shock Hazard
Contact with electrical power can cause serious personal injury or death. The Guidance
2400, the PrecisePower Motor Power Supply, and the 24 VDC power supply are open-
frame electrical devices that have exposed unshielded high voltage pins, components
and surfaces. In addition, the motor power supply provides 320 VDC volts and takes
about two minutes to bleed down after power is disconnected.
lDisconnect the AC power to the robot before accessing the Controls Bay.
When the J1-axis is centered within its range of motion, the axis will be at its 0 angle. This is the pos-
ition that is illustrated in the picture above. A positive change in the J1-axis angle results in a positive
rotation of the robot’s links about the World Z-axis.
The second axis produces a linear motion along the World Z-axis. When this axis is lowered as far
as possible, the axis’ position in the Joint Coordinate system will be approximately 0 and the robot’s
end-effector mounting flange will be at approximately Z=132 mm (3-axis robot) or Z=122 (4-axis
robot) in the World Coordinate system. As the Z-axis moves up, both the Z-axis joint position and
the end-effector’s World Z Coordinate increase in value.
The J3 (“elbow”) axis rotates the outer link about the direction of World Z. When the inner and outer
links point in the same direction, J3 is at its 0 position (as pictured above). A positive change in the
axis rotates the outer link in a positive rotation about the direction of the positive World Z-axis.
The optional Theta axis rotates the end-effector about the direction of the World Z-axis. A positive
change in the Theta angle results in a positive rotation about the direction of the negative World Z-
axis.
The outer link includes an IO board that provides electrical and air services for tooling. A yellow LED
is mounted at the top the outer link and blinks at a rate of once per second to indicate that the
controller is operational or at a rate of 4 times a second when power is being supplied to the motors.
The Z-axis includes a fail-safe brake. This brake must be released to move the Z-axis up and down
manually. There is a manual brake release button on the bottom of the inner link near the Z-axis.
Depressing this button when 24 VDC power is on will release the Z-axis brake while the button is
depressed. It is not necessary for the control system to be operating for the brake release to work,
the only requirement is providing 24 VDC to the controller.Care should be taken to support the Z-
axis when the brake release button is pushed, as the axis will fall due to gravity.
System Components
PreciseFlex 1300/1400 Robots
The PreciseFlex 1300 Robot (Figure 2-2) is a 3-axis SCARA robot composed of a J1-Axis with a
rotation of +/-176°, a Z-axis with a stroke ranging from a standard travel of 300 mm to a maximum of
13 Copyright © 2023 Brooks Automation, Inc.

Brooks Automation 2. Introduction to the Hardware
Part Number: PF10-DI-00010 Rev. A System Components
600 mm, and a J3-Axis with a rotation of +/-162°.
Figure 2-2: PreciseFlex 1300 Robot
The PreciseFlex 1400 is a 4-axis version of this robot. It is configured at the factory by adding a
Theta rotational axis to the PreciseFlex 1300 and a 4th motor driver to the robot’s embedded
controller. The PreciseFlex 1400 is visually nearly identical to the 1300 except that the tool
mounting flange extends 10 mm lower. The Theta axis is beneficial in applications where the
orientation of manipulated objects about the vertical axis (the World Z-axis direction) is important.
The Theta axis has a range-of-travel of +/- 270 degrees.
Both robots have a 20 mm hole in the top of the outer link that extends through the center of the tool
flange. This "through hole" facilitates the development of visual serving procedures. For example, in
a visual servoing application, this clear passage way permits a camera that is mounted above the
outer link to look through the tool mounting flange to view parts held in the end-effector with respect
to key alignment features. Alternately, this hole can be used to route cables to tooling and
instrumentation attached to the end-effector.
The outer link of both robots also contains a PCB (ZIO) and connectors that route digital IO and
Ethernet signals between the end-effector and the controller in the base. This DIO is available via a
DB25 connector that is mounted on the bottom of the outer link.
Guidance 2400 Controller
The Guidance 2400 Controller (Figure 2-3) is a four-axis general purpose motion controller that
contains four motor drives and eight encoder inputs. It must be attached to a heat sink, which in the
Copyright © 2023 Brooks Automation, Inc. 14

2. Introduction to the Hardware PreciseFlex 1300/1400 Robot
System Components Part Number: PF10-DI-00010 Rev. A
PreciseFlex robots is provided by the Controls Bay and the J1-axis base housing. This controller
includes digital IO, an RS232 serial port, 10/100 Mbit Ethernet ports and an interface for an optional
front panel. These interfaces can be used to connect to an optional Precise Remote IO module, an
optional hardware Manual Control Pendant and other peripherals. Analog input and output
interfaces are optionally available.
Electrical Shock
Improper electrical connection or connection to an improper electrical supply can result in
electrical shock, burns, fire, damage to the equipment, serious injury, and death. The
Guidance 2400, the PrecisePower Motor Power Supply, and the 24 VDC power supply
are open frame electrical devices that have exposed unshielded high voltage pins,
components and surfaces. In addition, the motor power supply provides 320 VDC volts
and takes about 2 minutes to bleed down after power is disconnected
lDisconnect AC power to the robot before accessing the Controls Bay.
Figure 2-3: Guidance 2400 Controller
In addition to the controller, a PrecisePower 300 Intelligent Motor Power Supply and a 125-watt 24
VDC power supply are necessary to power the motors and electronics. All three of these
components are housed in the robot's Controls Bay and are pictured in the System Diagram and
Coordinate Systems section.
For detailed information on the controller including interfacing information, please see the Guidance
3000/2000 Controllers, Hardware Introduction and Reference Manual.
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