Brooks PreciseFlex PFDD6 User manual

PreciseFlex™ DDR Collaborative Robots
Hardware Introduction and Reference Manual
P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022
PFDD6
PFDD4

PreciseFlex™ DDR Collaborative Robots
P/N: PFD0-DI-
00010, Rev 5.0.0, April 9, 2022
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Copyright © 2022, Brooks Automation, Inc.
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 6410, Guidance
6420, Guidance 6430, Guidance 6000, Guidance 6600, 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 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.
© 2021 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
Precise Collaborative
Robotics
201 Lindbergh Avenue
Livermore, CA 94551
Tel: [phone]
Brooks Automation
15 Elizabeth Drive
Chelmsford, MA
01824-2400
Tel: [phone]
Fax: [phone]
Brooks Automation
(Germany) GmbH
Daimler-Straβe 7
78256 Steiβlingen,
Germany
Tel: [phone]
Fax: [phone]-
200
Brooks Automation
46702 Bayside Pkwy
Fremont, CA 94538
Tel: [phone]
Fax: [phone]

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Copyright © 2022, Brooks Automation, Inc.
Corporate Headquarters
15 Elizabeth Drive
Chelmsford, MA 01824 U.S.A.
Brooks Automation
Precise Collaborative Robotics
201 Lindbergh Avenue
Livermore, CA 94551 U.S.A
For Technical Support:
Location Contact Number Website
North America
[phone] (Precise)
[phone] (Toll Free)
[phone] (Local)
http://www.preciseautomation.com
Europe
[phone] (Toll Free Germany)
[phone] (Has Toll)
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)

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Copyright © 2022, Brooks Automation, Inc.
Revision History
Revision
ECO
Number
Date Explanation of Changes
Rev 1.1
May 20, 2020
Working draft
Rev 1.2
Sept. 8, 2020
Working draft, gripper detail added
Rev 1.3 Jan. 4, 2021
Working draft
1. CALPP detail updated.
2. PAC file and GPL update changed for Windows 10.
3. Added unpacking instructions.
Rev 1.4 Dec. 28, 2021
Working draft
1. Environmental spec updated.
2. Minor edits
Rev 5.0.0
TBD
April 9, 2022
Working draft. first version as Brooks

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Copyright © 2022, Brooks Automation, Inc.
Warning Labels
The following warning and caution labels are utilized throughout this manual to convey critical information
required for the safe and proper operation of the hardware and software. It is extremely important that all
such labels are carefully read and complied with in full to prevent personal injury and damage to the
equipment.
There are four levels of special alert notation used in this manual. In descending order of importance,
they are:
DANGER: This indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING: This indicates a potentially hazardous situation, which, if not
avoided, could result in serious injury or major damage to the equipment.
CAUTION: This indicates a situation, which, if not avoided, could result in minor
injury or damage to the equipment.
NOTE: This provides supplementary information, emphasizes a point or
procedure, or gives a tip for easier operation

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Table Of Contents
Introduction to the Hardware___________________________________________________10
System Overview 10
System Description 10
Release History 11
PFDD Robots 11
System Diagram and Coordinate Systems 12
System Diagram 14
Control System Overview 14
Power Supplies and Power Considerations 15
Energy Dump Circuit 16
Remote Front Panel, E-Stop Box and Manual Control Pendant 16
Remote IO Module (Ethernet Version) 17
Machine Vision Software and Cameras 17
Machine Safety 18
Safety and Agency Certifications 18
Standards Compliance and Agency Certifications 18
Moving Machine Safety 18
Mechanical and Software Limit Stops 19
Stopping Time and Distance 19
Releasing a Trapped Operator: Brake Release Switch 20
Collaborative Robot Safety ____________________________________________________21
General Information 21
Robot Testing and Safety Circuits 25
Test Procedure for the PFDD Robots 28
Verification of PFDD Collision Force 29
Robot Workcell Design 30
Appendix A: Example Performance Level Evaluation for PFDDR, Update for PFDD example 31
Appendix B: Table A2 from ISO/TS 15066: 2016 33
Appendix C: Safety Circuits for PFDD Robots 35

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Installation Information _______________________________________________________37
Environmental Specifications 37
Facilities Connections 37
System Dimensions 38
Mounting Instructions 44
Tool Mounting 44
Accessing the Robot Controller 44
Power Requirements 45
Hardware Reference __________________________________________________________46
System Schematics 46
System Diagram and Power Supplies 46
Facilities Panel 65
E-Stop Connector 66
MCP / E-Stop Interface 67
15 Pin D-Sub Signals 67
Digital Input and Output Signals 68
25 Pin D-Sub Signals 71
Slave Amplifier (GSBP) Digital Inputs and Outputs 71
Ethernet Interface 72
RS-232 Serial Interface 73
Gripper Serial Interface (for Bar Code and other RS232 devices in Gripper) 73
Software Reference___________________________________________________________75
Accessing the Web Server 75
Loading a Project (Program) or Updating PAC Files 77
Updating GPL (System Software and Firmware) 78
Recovering from Corrupted PAC Files 79
Gripper Support _____________________________________________________________82
Gripper Introduction 82
Controlling the Precise Servo Grippers 82
Servo Gripper Controller Digital Inputs and Outputs 85

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Optional Pneumatic or Vacuum Gripper 87
Ethernet Connector in the Outer Links 91
Service Procedures___________________________________________________________92
Recommended Tools 92
Trouble Shooting 92
Encoder Operation Error 93
Replacing the Encoder Batteries 95
Calibrating the Robot: Setting the Encoder Zero Positions 97
Replacing Belts and Motors 102
General Belt Tensioning 103
Tensioning or Replacing the J2 (Z Column) Belts 103
Tensioning the 1st Stage Belt 103
Tensioning the 2nd Stage Belt 104
Replacing the Z column Stage One Timing Belt 105
Replacing the Z column Stage Two Timing Belt 107
Tensioning or Replacing the Belts in the PFDD4 108
Tensioning the Belts in the PFDD4 Outer Link 108
Replacing the Belts in the PFDD4 Outer Link 109
Replacing the Outer Link Motors or Harmonic Drives in the PFDD6 111
Replacing the Robot Main Controller 112
Replacing the Z axis Slave Controller 114
Replacing the J3 axis Slave Controller 116
Replacing the J4 or Gripper Slave Controller in PFDD4 117
Replacing the Gripper and Slip Ring in PFDD4 119
Replacing the Gripper Spring or Cable 121
Adjusting the Gripper Backlash or Centering Fingers 122
Replacing the Main Harness 124
Replacing the J3 Clock Spring Harness to the J4 Motor 124
Replacing the J4 to Gripper Controller Harness in the PFDD4 127
Replacing the J4 slave controller in the PFDD6 128
Replacing the J4 to J5 Controller Harness, the J5 to J6 Controller Harness, OR the J5 OR J6 slave
controller in the PFDD6 129
Replacing the J6 Motor Pigtail Harness 133

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Appendix A: Product Specifications____________________________________________135
Appendix B: Environmental Specifications ______________________________________137
Appendix C: Spare Parts List__________________________________________________138
Appendix D: Preventative Maintenance _________________________________________140
Appendix E: Belt Tensions, Gates Tension Meter _________________________________141
Appendix F: Unpacking the Robot _____________________________________________143

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Introduction to the Hardware
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Introduction to the Hardware
System Overview
System Description
The PFDD Direct Drive Robots are available in either a four-axis or six-axis configuration. Both robots
include embedded motion controllers, a 48VDC motor power supply, and a 24VDC logic power supply
located inside the robot. In addition, they may optionally include an electric gripper and electric gripper
controller, or solenoid valves to support pneumatic grippers.
The Z axis of these robots is available with a standard travel of 500 mm, and optional travels of 1000mm
and 1420mm. The 6-axis robot can carry a payload of up to 5kg and the 4-axis robot can carry a payload
up to 7.0kg. These robots are 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, Automotive, and Electronics industries.
In general, assuming a collaborative gripper with no sharp edges or other dangerous features, is
attached to the robot, these robots can make horizontal motions at tip speeds up to 1.5 -2.0 m/sec,
and bump into a person without causing a severe injury. For vertical motions, the Z speed should
be limited to 150mm/sec when the robot comes within 100mm of a rigid surface, as the effective
moving mass in Z is much greater than the effective moving mass in the horizontal plane. More
detail is provided in the Collaborative Robot section of this manual.
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 (PLC) mode, a Graphical User Programming Mode (Guidance Motion),
an Embedded Language mode (GPL), and a PC Control mode (TCS). When programmed in the PLC,
Graphical User Mode 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, which is implemented through a command-server interface.
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.

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The optional machine vision system, “PreciseVision”, can execute either in a PC connected through
Ethernet. 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.
Release History
The PFDD Direct Drive robots are being released in 2020, with Beta and Pilot versions scheduled for
release this year.
Beta Units, designated by Serial Numbers FD0-yymm-AA-zzzzz, were released in early 2020, and are for
customer feedback and evaluation, while factory testing is completed. Some improvements may be
incorporated into Pilot Units, below.
Pilot/Production Units, designated by Serial Numbers FD0-yymm-xB-zzzzz, will be released in the
spring of 2021
Yy – year
Mm – month
X – controller rev
Y – robot rev
Zzzzz – unique number
PFDD Robots
The PFDD6 has a rated payload of 6kg, including the gripper. The PFDD4 has a rated payload of 8kg.
Note that for the PFDD robots, it is very important to set the correct value for the payload in the
Dynamic Feed Forward parameter 16071 (or use the GPL “Robot.Payload” property). The payload
can also be set using the operator Web Interface (see “Control Panels > Robot Rayload”). This is
very important prior to entering “Free Mode” as a drastically incorrect payload can cause the Z
axis gravity compensation to be incorrect and thus cause the Z axis to start to move up or sag
down, until the velocity restrict safety limit cuts in to stop any excessive speed. For the 6-axis
robot 100% equals 6kg for the gripper and payload mass. For the 4-axis robot 100% equals 8kg for the
gripper and payload mass. For lighter masses, this value should be reduced. Setting the payload
correctly is important both for optimal dynamic performance of the robot and for proper gravity
compensation, including “free” mode. For pick and place applications, the property “robot.payload” can
be set by the application program to change the payload.
Also, it is important to set the correct tool X, Y, Z offset distance in mm in the first 3 values of parameter
16051 and tool Yaw, Pitch, and Roll in values 4-6, for the distance of the center of mass of the gripper
and payload from the J6 axis of rotation. For example, for a horizontal tool, if the center of a 2kg mass is
150mm from the center of rotation of axis 4 (the wrist), this parameter should be set to 0, 0,150, 0, 90, 0
for the Dynamic Feed Forward calculations to compute the correct feed forward motor torques and
achieve optimal performance. For a vertical gripper with the same offset, this parameter should be 0, 0,
150,0, 0, 0. The tool offset length must also be set in the Dynamic Feed Forward parameter 16068 value

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8 for the PFDD6 and value 6 for the PFDD4. The tool mass, in kg, must be set in parameter 16067 value
8 for the PFDD6 and value 6 for the PFDD4, in order for the Dynamic Feed Forward to work properly.
Note that when setting the payload and gripper payload offset parameters in the database, these values
must be entered, saved to flash, and the controller must be re-booted for them to take effect.
See the software documentation about Parameters 16051, 16071, 16067, 16068, and the “Robot.Tool”
and “Robot.Payload” properties for more a more detailed explanation.
These robots have 12 inputs and 8 outputs available at the base connector panel in a 25 pin D-
subminiature connector and have 2 digital outputs and up to 3 digital inputs available in the outer link
when the pneumatic version is ordered. A belt encoder input is available on the connector panel.
These robots are nominally quoted and shipped with a standard ISO flange, and a single solenoid valve
mounted in the outer link for users to add pneumatic or vacuum grippers of their design. Optionally, an
additional solenoid can be ordered, or a 23N squeeze, 60mm travel electric gripper can be ordered. See
the “system dimensions” section for reference dimensions on these options.
System Diagram and Coordinate Systems
The major elements of the PFDD Direct Drive robots and the orientation and origin of their World
Cartesian coordinate systems are shown in the diagrams below.

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The first axis of the robot, J1, rotates the robot column about the Z-axis. When inner link is closest to the
bottom, the Z-axis is at its 0 position in the Joint Coordinate system and in the World Coordinate system.
As the robot arm moves upwards, both its joint position and the World Z Coordinate increase in value.
The Z column also contains the 24VDC and 48VDC power supplies. The main PreciseFlex™ controller is
located inside the base housing of the robot, and joint controllers are located near the various joint
motors, distributed throughout the robot.
When the Inner Link is centered on its range of motion the J1 axis is at its 0-degree joint angle. A positive
change in the axis angle results in a positive rotation about the World Z-axis.
The J3 rotary axis (elbow) rotates the outer link about the J3 axis. A positive change in the axis angle
results in a positive rotation about the J3-axis. When the link is centered, it is at its 0-degree joint angle,
however there is a hard stop at 10 degrees, so the link cannot reach the center position. The outer link
can rotate underneath the inner link, allowing the robot to change configuration from a “left hand” robot to
a “right hand” robot without swinging the J3 axis (elbow) through the zero position. This allows the robot
to work in very compact workcells, and minimizes the radius to the payload, and therefore the kinetic
energy of the payload, when moving across a workcell. This helps minimize potential collision forces.
The J4 rotary axis rotates the outer link about its axis. Its travel is asymmetric to allow J5 to be oriented
+/- 180 degrees without hitting a J4 hard stop. The J5 pitch axis provides pitch control for the tool. The
J6 rotary axis rotates the tool about the tool axis.

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For the PFDD4, the J4 axis is at the end of the outer link and is parallel to the J1 axis. A positive change
in the J4 axis angle results in a positive rotation about the World Z-axis.
The outer link may include a gripper controller that provides control of the optional electric gripper. It is
also possible to order the robot with a pneumatic gripper; in which case the outer link will house a
solenoid to control air to the pneumatic gripper. A light bar is mounted at the top of the elbow and blinks
at a rate of once per second to indicate that the controller is operational and 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 24VDC 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 function; the
only requirement is providing 24VDC 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 Diagram
Control System Overview
The PFDD Robots are controlled by a distributed control system (see below). The main control board
(PFD0) is located in the base casting behind the connector panel. This board contains various IO
functions, the main CPU, RAM and Flash memory, and the motor drive for the J1 motor. The 24VDC and
48VDC power supplies are located on the back of the Z column. A flexible ribbon cable is routed around
the robot to provide 24VDC, Gnd, 48VDC, Gnd, Ethernet, and RS485. Ethernet is routed to the outer link
and is available for certain gripper applications. A series of smart amplifiers (GSBP) are distributed
around the robot and located near each motor to minimize wiring through the robot. These are connected
by means of an RS485 network.

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Power Supplies and Power Considerations
The PFDD controllers require two DC power supplies, a 24 VDC power supply for the processor and user
IO, and a separate 48VDC motor power supply.
DANGER: The 24 VDC power supply is an open frame electrical device that
contains unshielded high voltage pins, components and surfaces. These
products are intended to be mounted in a cabinet or machine chassis that is
not accessible when AC line power is turned on.
The PFDD robots power supplies have an input range of 100 to 240 VAC, +/- 10%, 50/60 Hz. Inrush
current can be as high as 40 Amps at 240 VAC for short periods of time. The power supplies are

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protected against voltage surge to 2000 volts. Transient over voltage (< 50 µs) may not exceed 2000 V
phase to ground, as per EN61800-31996. The power supplies have over-current protection, and over-
voltage protection.
The robot consumes less than 500 Watts during normal operation. With the motor power turned off the
controller consumes about 20 Watts. With the motor power on and the Z brake released, the robot
consumes about 80 Watts. The PFDD6 running at 60% speed consumes about 150 Watts. These
numbers may be useful when mounting this robot on mobile platforms.
The Precise controller can monitor motor power through its datalogging function. Intermittent power
dropouts can be detected by setting a trigger in the data logger which can record and time-stamp power
fluctuations.
Energy Dump Circuit
The 48 VDC supply has a regulated output and an overvoltage protection circuit that is triggered if the
voltage reaches 60 volts. Rapid deceleration of the robot motors can generate a Back EMF voltage that
can pump up the motor voltage bus. In order to avoid bus pump up, an Energy Dump Circuit is included
in the base controller board and connected to the 48 VDC bus.
Remote Front Panel, E-Stop Box and Manual Control Pendant
For users that wish to have a hardware E-Stop button, Precise offers an E-Stop Box or a portable
Hardware Manual Control Pendant that includes an E-Stop button. The E-Stop box can be plugged into
the 9 pin D-Sub connector in the connector panel in the base casting. The E-Stop box completes a circuit
from Pin 1 (Estop 1) to Pin 6 (FE Out 1) and from Pin 2 (Estop 2) to Pin 7 (FE Out2) in this connector. If
this circuit is not completed it is not possible to enable motor power to the robot. The FE Out signals
allow each Estop circuit to be toggled during the CAT3 startup sequence to make sure both circuits are
working. If no E-Stop box or Manual Control Pendant is connected, jumpers must be connected between
these four pins to enable robot motor power. For those applications where an operator must be inside the
working volume of the robot while teaching, a second teach pendant with a 3-position run hold switch is
available. The Manual Control Pendants can be plugged directly into the 9 pin Dsub connector mounted
on the robot's Facilities Panel in the base of the robot.

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Remote IO Module (Ethernet Version)
For applications that require a large number of Inputs and Outputs, a Precise Remote IO (RIO) module
may be purchased. The RIO interfaces to any PFDD robot and its embedded PreciseFlex™ Controller
via 10/100 Mb Ethernet and requires 24 VDC power. Up to 4 RIO's can be connected to a controller.
The basic RIO includes: 32 isolated digital input signals, 32 isolated digital output signals and one RS-232
serial line. An enhanced version of the RIO adds 4 analog input signals, a second RS-232 port and one
RS-422/485 serial port.
The Enhanced RIO module is pictured below.
Machine Vision Software and Cameras
The PreciseFlex™ Controllers support the PreciseVision machine vision system. This is a vision software
package than can run in a PC.
Cameras must be connected via Ethernet or USB. Vendors such as DALSA already offer a variety of
Ethernet machine vision cameras. In addition, other vendors offer USB cameras that are supported in
PreciseVision.
Precise offers an Arm-Mounted Camera Option for certain robots. Contact Precise for details.

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Machine Safety
Safety and Agency Certifications
Precise systems can include computer-controlled mechanisms that are capable of moving at high speeds
and exerting considerable force. Like all robot and motion systems, and most industrial equipment, they
must be treated with respect by the user and the operator.
This manual should be read by all personnel who operate or maintain Precise systems, or who work
within or near the work cell.
We recommend that you read ENISO 10218-1:2011 and 10218-2:2011 Robots for Industrial
Environments, Safety Requirements, ISO/TS 15066 “Robots and Robotic Devices – Collaborative
Robots” and ISO 13849-1:2006 Safety of machinery — Safety-related parts of control systems.
Standards Compliance and Agency Certifications
The PFDD robots are intended for use with other equipment and are considered a subassembly rather
than a complete piece of equipment on their own. They meet the requirements of these standards:
EN ISO 10218-1-2011 Robots for Industrial Environments, Safety Requirements
EN 610204-1 Safety of Machinery, Electrical Equipment of Machines
EN 61000-6-2 EMC Directive (Immunity)
EN 61000-6-4 EMC Directive (Emissions)
To maintain compliance with the above standards the robot must be installed and used in accordance
with the regulations of the standards, and in accordance with the instructions in this user’s guide.
In addition to the above standards, the PF400 and PF3400 robots have been designed to comply with the
following agency certification requirements, and (will) carry the CE and CSA marks.
CE
CSA
FCC Class A
ANSI/RIA R15.06 Safety Standard
Moving Machine Safety
The PFDD robots can operate in Manual Control Mode, in which an operator directly controls the motion
of the robot, or Computer Control Mode in which the robot operation is automatic. Manual Control Mode is
often used to teach locations in the robot workspace. The robot’s speed is limited in Manual Control Mode
to a maximum of 250mm per second for safety. It is important that operators wear safety glasses when
inside the robot’s operating volume.

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In Computer Mode, the robot can move quickly. The PFDD robots have been designed to be “hand-safe”
even in computer mode, and in some cases a risk assessment of the application may indicate that it can
be used without operator safety screens. However, safety glasses should be worn at all times when an
operator is within the robots working volume. Please refer to the EN ISO 10218-2-2011 Robots for
Industrial Environments, Safety Requirements for information on recommended safe operating practices
and enclosure design for robots of various sizes and payloads.
Mechanical and Software Limit Stops
All joints have hard limit stops at the end of travel which are factory installed. The soft-limit stops must be
set within the range of these hard stops. The wrist axis in the PFDD4 has a slip ring when the electric
gripper is installed, allowing +/- 240 degrees rotation. Since the robot has absolute encoders with battery
backup, even if the robot is turned off, the encoders keep track of joint position. The joint position can be
viewed either on the optional Manual Control Pendant, or in the Virtual Manual Control Pendant in the
Web Based Operator Interface. (See Guidance Controller Setup and Operation Quick Start Guide).
Stopping Time and Distance
The robot control system responds to two types of E-Stops.
A Soft E-Stop initiates a rapid deceleration of all robots currently in motion and generates an error
condition for all GPL programs that are attached to a robot. This property can be used to quickly halt all
robot motions in a controlled fashion when an error is detected. A soft E-stop is typically generated by an
application program under conditions determined by the programmer.
This function is similar to a Hard E-Stop except that Soft E-Stop leaves High Power enabled to the
amplifiers and is therefore used for less severe error conditions. Leaving power enabled is beneficial in
that it prevents the robot axes from sagging and does not require high power to be manually re-enabled
before program execution and robot motions are resumed. This function is also similar to a Rapid
Deceleration feature except that a Rapid Deceleration only affects a single robot and no program error is
generated.
If set, the SoftEStop property is automatically cleared by the system if High Power is disabled and re-
enabled.
A Hard E-Stop is generated by one of several hardware E-Stop inputs and causes motor power to be
disabled. However, there is a parameter that determines a delay between the time the Hard E-Stop
signal is asserted and the time the motor power supply relay is opened. This delay is nominally set at 1.0
seconds. It may be adjusted by an operator with administrator privileges. On the web-based operator
interface menu, go to Setup/Parameter Database/Controller/Operating Mode/ and set parameter 267 to
the desired delay. If this delay is set to 0, the motor power will be disabled within 1ms.
For the PFDD6 robot, the base rotation, elbow, and J6 axes do not have mechanical brakes. For the
PFDD4 robot, the base rotation, elbow, and J4 axes do not have mechanical brakes. Therefore, leaving
the motor power enabled for 1.0 sec allows the servos to decelerate the robot. The servos are set to
decelerate the robot at 0.015G, or 150mm/sec2. If the robot is moving at a joint speed of 100

Introduction to the Hardware
PreciseFlex™ DDR Collaborative Robots
P/N: PFD0-DI-
00010, Rev 5.0.0, April 9, 2022
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Copyright © 2022, Brooks Automation, Inc.
degrees/sec, the distance traveled will be about 30 degrees to reach a full stop, and the time will be
0.66sec. These settings provide a smooth deceleration and stop with full payload. If a faster deceleration
is desired, contact Precise application engineering to increase the deceleration setting for Estop.
Releasing a Trapped Operator: Brake Release Switch
Should a hard E-Stop be triggered, the Z brake will engage, and motor power will be disconnected from
all motors. As the J1, J3, and J6 axes on the PFDD6, and the J1, J3, and J4 axes on the PFDD4 do not
have brakes, they may be freely pushed by the operator. To release the Z brake, the operator may press
the brake release switch, under the inner link, as long as 24VDC is present. It is not necessary for motor
power to be on for the brake release to work. Note the J4 and J5 brakes on the PFDD6 are not released
by the brake release switch to prevent unexpected sagging of the payload.