Brooks PreciseFlex 400 User manual

PreciseFlexTM 400 Robots
User Manual
Part Number PF40-DI-00010, Revision A

(Undefined variable: MyVariables.ProductName)
Part Number: PF40-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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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

Brooks Automation
Part Number: PF40-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)
Copyright © 2023, Brooks Automation 3

(Undefined variable: MyVariables.ProductName)
Part Number: PF40-DI-00010 Rev. A
Brooks Automation, Inc.
15 Elizabeth Drive
Chelmsford, MA
01824-2400
Tel: [phone]
Fax: [phone]
www.brooks.com
Brooks Locations Worldwide:
Brooks Automation Inc.
46702 Bayside Parkway
Fremont,CA 94538
Tel: [phone]
Fax: [phone]
Brooks Automation Inc.
AIM Servicios Administrativos
S de RL de CV
Carretera Huinalá km 2.8
Parque Industrial Las Américas
66640 Apodaca, NL Mexico
Tel: [phone]
Brooks Automation
(Germany) GmbH
Ernst-Ruska-Ring 11
07745 Jena, Germany
Tel: [phone]
Fax: [phone]
Brooks Automation
(Germany) GmbH
Daimler-Straße 7
78256 Steißlingen, Germany
Tel: [phone]
Fax: [phone]
Brooks Automation, Inc.
9601 Dessau Road, Suite 301
Austin, TX 78754
Tel: [phone]
Toll-Free: [phone]
Brooks Automation
(Israel) Ltd.
Mevo Yerach 5
Kiryat-Gat 82000
Israel
Tel: [phone]
Fax: [phone]
Brooks Technology (Shanghai)
Limited
2nd Floor, No. 72,
887 Zuchongzhi Road
Zhangjiang Hi-Tech
Park Pudong, Shanghai
China 201203
Tel: [phone]
Fax: [phone]
Brooks Japan K.K.
HEADQUARTERS
Nisso Bldg. No 16, 9F
3-8-8 ShinYokohama, Kohoku-ku
Yokohama, Kanagawa 222-0033
Tel: [phone]
Fax: [phone]
Brooks Japan K.K.
YOKOHAMA TECHNICAL
CENTER
852-1 Kawamuko-cho, Tsuzuki-ku
Yokohama, Kanagawa 224-0044
Tel: [phone]
Fax: [phone]
Brooks Japan K.K.
KUMAMOTO SERVICE OFFICE
202 Mirai Office II
312-1 Tatsudamachi Yuge
Tatsuda, Kumamoto 861-8002
Tel: [phone]
Fax: [phone]
Brooks CCS Japan K.K.
CONTAMINATION CONTROL
SOLUTIONS
Nisso Bldg. No 16, 9F
3-8-8 ShinYokohama, Kohoku-ku
Yokohama, Kanagawa 222-0033
Tel: [phone]
Fax: [phone]
Brooks Automation Ltd.
TAIWANHEADQUARTERS
5F-5, No.32, Tai-Yuen Street
Chu-Pei City
Hsinchu County 302, Taiwan,
R.O.C.
Tel: [phone]
Fax (G&A): [phone]
Fax (Sales): [phone]
Brooks Automation Korea, Inc.
#35 Giheungdanji-Ro 121Beon-
Gil
Giheung-Gu, Yongin-Si
Gyeonggi-Do, 17086
Korea
Tel : [phone]
Fax: [phone]
Brooks Automation CCS RS
AG
Lohstampfestrasse 11
CH-8274 Tagerwilen, Switzerland
Tel: + 41 71-666-72-10
Fax: + 41 71-666-72-11
Brooks Automation Korea, Inc.
#35 Giheungdanji-Ro 121Beon-
Gil
Giheung-Gu, Yongin-Si
Gyeonggi-Do, 17086
Korea
Tel : [phone]
Fax: [phone]
Brooks Automation (S) Pte Ltd
51-18-C1 Menara BHL,
57 Jalan Ahmad Shah,
10050, Penang,
Malaysia
Tel: [phone]
Fax: [phone]
Brooks Automation
(Singapore) Pte Ltd
Blk 5008 Ang Mo Kio Avenue 5
#05-08, Techplace II
Singapore 569874
Tel: [phone]
Fax: [phone]
Brooks Automation Ltd.
TAINAN OFFICE
3F., No.11, Nanke 3rd Rd., Xinshi
Dist.
Tainan Science Park
Tainan City 74147, Taiwan
(R.O.C.)
TEL: [phone]
FAX: [phone]
Brooks Automation
Precise Collaborative Robotics
201 Lindbergh Drive
Livermore, CA 94551
Tel: [phone]
4Copyright © 2023, Brooks Automation

Brooks Automation
Part Number: PF40-DI-00010 Rev. A
Revision History
Revision ECO Date Action Author
A TBD 08/04/2023
Released manual at Rev. A
to follow standard Brooks
technical publication styles.”
M. Ashenfelder
Copyright © 2023, Brooks Automation 5

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Part Number: PF40-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 Description and Overview 11
Release History 12
System Diagram and Coordinate Systems 13
System Components 15
PreciseFlex 400 Robot 15
Optional Linear Axis Module 16
Mounting of Robot and Linear Axis Module 17
Optional Gripper 17
Guidance 1400B Controller 17
Low-Voltage Power Supplies 18
Energy Dump Circuit 19
Remote Front Panel, E-Stop Box, and Manual Control Pendant 20
Optional RS-485 IO Module (GIO) 20
Remote IO Module (Ethernet Version) 21
Machine Vision Software and Cameras 22
Machine Safety 22
Safety and Agency Certifications 22
Standards Compliance and Agency Certifications 23
Moving Machine Safety 23
Voltage and Power Considerations 24
Mechanical and Software Limit Stops 24
Stopping Time and Distance 24
Releasing a Trapped Operator: Brake Release Switch 25
3. Collaborative Robot Safety 26
General Information 26
Summary 26
Background 26
Determining a Machine’s Required Performance Level (PLr). 27
6Copyright © 2023, Brooks Automation

Brooks Automation
Part Number: PF40-DI-00010 Rev. A
Maximum Allowable Forces to Prevent Operator Injury 28
Types of Forces 29
Robot Testing and Safety Circuits 30
Controller Requirements 31
Possible PreciseFlex Controller Faults and Controller Testing 31
Test Procedure for the PF400 34
Robot Workcell Design 35
4. Installation Information 37
Environmental Specifications 37
Facilities Connections 37
System Dimensions 38
Linear Axis Mounting Dimensions 44
Unpacking and Handling Instructions 45
Mounting Instructions 45
Tool Mounting 45
Accessing the Robot Controller 46
Power Requirements 46
Emergency Stop 46
5. Hardware Reference 47
System Schematics 47
System Diagram and Power Supplies 47
Facilities Panel 65
E-Stop Connector 67
MCP / E-Stop Interface 67
Digital Input and Output Signals 68
Gripper Controller Digital Inputs and Outputs 71
RS-485 Remote IO Module (GIO) 72
Ethernet Interface 72
RS-232 Serial Interface 73
Gripper Serial Interface (for Bar Code and other RS-232 devices in Gripper) 73
6. Software Reference 75
Accessing the Web Server 75
Loading a Project (Program) or Updating PAC Files 77
Updating GPL (System Software) or FPGA (Firmware) 79
Recovering from Corrupted PAC Files 80
Controller Software Extensions 82
Adding or Removing the Optional Linear Axis 82
Controlling the PreciseFlex Servo Grippers 83
Overview 83
Software Revision 84
Controlling the Gripper 84
Gripper Squeeze (Simple Method) 84
Gripper Squeeze (Asymmetric Method) 85
End of Travel Sensor 86
Grip Test and Squeeze Check 86
Servo Gripper Controller Digital Inputs and Outputs 86
Copyright © 2023, Brooks Automation 7

(Undefined variable: MyVariables.ProductName)
Part Number: PF40-DI-00010 Rev. A
Optional Pneumatic or Vacuum Gripper 88
G1400B Dedicated Digital Outputs 90
7. Service Procedures 92
Recommended Tools 92
Troubleshooting 92
Encoder Operation Error 94
Replacing the Encoder Battery 95
Calibrating the Robot: Setting the Encoder Zero Positions 97
Replacing Belts and Motors 100
General Belt Tensioning 100
Tensioning the J1 (Z Column) Belts 101
Tensioning the 1st Stage Belt 101
Tensioning the 2nd Stage Belt 102
Tensioning the J2 Belt 103
Tensioning the J3 Belt (Before 2014) 105
Tensioning the J4 Belt (Before 2014) 106
Tensioning the J3 and J4 Belts (2014) 108
Tensioning the Belt on the Optional Linear Axis 109
Replacing the Power Supplies, Energy Dump PCA, or J1 Stage Two (Output) Timing Belt 110
Replacing the Robot Controller 113
Replacing the Servo Gripper Controller 116
Replacing the Agilent Servo Gripper Finger Pads 118
Replacing the Gripper Spring or Cable 119
Adjusting the Gripper Backlash or Centering Fingers 120
Adjusting the Gripper Brake (for Grippers with Brake) 122
Replacing the Electric Grippers or Slip Ring Harness 123
Replacing the Linear Axis Controller 125
Installing the Optional GIO Board 127
Replacing the Main Harness 130
Replacing the Outer Link Harness 130
Replacing the Z-axis Motor Assembly 133
Replacing the J2 (Shoulder) Axis Motor or Timing Belt 136
Replacing the J3 (Elbow) Axis Motor or Timing Belt 140
Replacing the J4 (Wrist) Axis Motor or Timing Belt 143
Replacing Servo Gripper with Pneumatic or Vacuum Gripper 146
Appendices 157
Appendix A: Product Specifications 157
Appendix B: Environmental Specifications 159
Appendix C: Spare Parts List 160
Appendix D: Preventative Maintenance 162
Appendix E: Belt Tensions, Gates Tension Meter 164
Appendix F: Example Performance Level Evaluation 166
Example Workcell Description 166
Normal Operator Interaction with Robot 166
Possible Low Frequency (rare) Interaction with Robot 166
Appendix G: TUV Verification of PF400 Collision Forces 167
8Copyright © 2023, Brooks Automation

Brooks Automation
Part Number: PF40-DI-00010 Rev. A
Appendix H: Table A2 from ISO/TS 15066: 2016, Biomechanical Limits 171
Appendix I: Safety Circuits for PF400 500gm Payload 173
Appendix J: Robot Anatomy 174
Copyright © 2023, Brooks Automation 9

1. Safety (Undefined variable: MyVariables.ProductName)
Safety Setup Part Number: PF40-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

Brooks Automation 1. Safety
Part Number: PF40-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 2

1. Safety (Undefined variable: MyVariables.ProductName)
Explanation of Hazards and Alerts Part Number: PF40-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

Brooks Automation 1. Safety
Part Number: PF40-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 4

1. Safety (Undefined variable: MyVariables.ProductName)
General Safety Considerations Part Number: PF40-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

Brooks Automation 1. Safety
Part Number: PF40-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 6

1. Safety (Undefined variable: MyVariables.ProductName)
Electrical Hazards Part Number: PF40-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

Brooks Automation 1. Safety
Part Number: PF40-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 8

1. Safety (Undefined variable: MyVariables.ProductName)
Ergonomic Hazards Part Number: PF40-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

Brooks Automation 1. Safety
Part Number: PF40-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 of 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 10

2. Introduction to the Hardware (Undefined variable: MyVariables.ProductName)
System Description and Overview Part Number: PF40-DI-00010 Rev. A
2. Introduction to the Hardware
System Description and Overview
NOTE: See Appendix J: Robot Anatomy for detailed illustrations.
The PreciseFlex 400 Robot is a 4-axis robot that includes an embedded Guidance 1400B 4-axis
motion controller, a 48 VDC motor power supply, and a 24 VDC logic power supply located inside
the base of the robot. In addition, it may optionally include an electric gripper and electric gripper
controller.
The Z-axis of this robot is available with a standard travel of 400 mm and an optional travel of 750
mm. The robot is designed as tabletop unit and can carry a payload of up to 500 grams in the
standard version with a servo gripper and 1200 grams in the standard version without a 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 RS-485 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 PreciseFlex peripherals. These include digital cameras, remote I/O, and a hardware
manual control pendant.
A number of communications and hardware interfaces are provided with the basic robot. These
include an RS-232 serial interface, an RS-485 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 PreciseFlex 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 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. The PC is required for
operation in the PC Control mode.
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