PreCise PF400 Quick user guide

The PF400 and PF3400 Robots
HardwareReferenceManual
Version 5.04, August 9, 2017
Precise Automation Inc., 727 Filip Road, Los Altos, California 94024
www.preciseautomation.com

Document Content
The information contained herein is the property of Precise Automation Inc., and may not be copied,
photocopied, reproduced, translated, or converted to any electronic or machine-readable form in whole or
in part without the prior written approval of Precise Automation Inc. The information herein is subject to
change without notice and should not be construed as a commitment by Precise Automation Inc. This
information is periodically reviewed and revised. Precise Automation Inc., assumes no responsibility for
any errors or omissions in this document.
Copyright © 2004-2016 by Precise Automation Inc. All rights reserved.
The Precise Logo is a registered trademark of Precise Automation Inc.
Trademarks
Guidance 3400, Guidance 3300, Guidance 3200, Guidance 2400, Guidance 1400, Guidance 1300,
Guidance 1200, Guidance Controller, Guidance Development Environment, GDE, Guidance
Development Suite, GDS, Guidance Dispense, Guidance Programming Language, GPL, Guidance
System, PrecisePlace 1300, PrecisePlace 1400, PrecisePlace 2300, PrecisePlace 2400, PreciseFlex
1300, PreciseFlex 1400, PreciseFlex 400, PrecisePower 500, PrecisePower 2000, PreciseVision, RIO
are either registered or trademarks of Precise Automation Inc., and may be registered in the United
States or in other jurisdictions including internationally. Other product names, logos, designs, titles,
words or phrases mentioned within this publication may be trademarks, service marks, or trade names of
Precise Automation Inc. or other entities and may be registered in certain jurisdictions including
internationally.
Any trademarks from other companies used in this publication are the property of those respective
companies. In particular, Visual Basic, Visual Basic 6 and Visual Basic.NET are trademarks of Microsoft
Inc.
Disclaimer
PRECISE AUTOMATION INC., MAKES NO WARRANTIES, EITHER EXPRESSLY OR IMPLIED,
REGARDING THE DESCRIBED PRODUCTS, THEIR MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE. THIS EXCLUSION OF IMPLIED WARRANTIES MAY NOT APPLY TO YOU.
PLEASE SEE YOUR SALES AGREEMENT FOR YOUR SPECIFIC WARRANTY TERMS.
Precise Automation Inc.
727 Filip Road
Los Altos, California 94024
U.S.A.
www.preciseautomation.com

iii
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, could 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
g
ives a tip for easier operation

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TableofContents
Introduction to the Hardware ___________________________________________________1
System Overview 1
System Description 1
Release History 1
PF3400: 3kg Version 2
System Diagram and Coordinate Systems 3
System Components 4
PreciseFlex 400 Robot 4
Optional Linear Axis Module 5
Mounting of Robot and Linear Axis Module 5
Optional Gripper 6
Guidance 1400B Controller 6
Low Voltage Power Supplies 6
Energy Dump Circuit 7
Remote Front Panel, E-Stop Box and Manual Control Pendant 7
Optional RS485 IO Module (GIO) 8
Remote IO Module (Ethernet Version) 8
Machine Vision Software and Cameras 9
Machine Safety 9
Safety and Agency Certifications 9
Standards Compliance and Agency Certifications 10
Moving Machine Safety 10
Voltage and Power Considerations 10
Collaborative Robot Safety____________________________________________________13
Robot Testing and Safety Circuits 17
Robot Workcell Design 22
Appendix A: Example Performance Level Evaluation for PF400 23
Appendix B: TUV Verification of PF400 Collision Forces 24
Appendix C: Table A2 from ISO/TS 15066: 2016 29
Appendix D1: Safety Circuits for PF400 500gm Payload 31
Appendix D2: Safety Circuits for PF3400 3kg Payload 32
Installation Information_______________________________________________________34
Environmental Specifications 34

Table Of Contents
v
Facilities Connections 34
System Dimensions 35
Linear Axis Mounting Dimensions 41
Mounting Instructions 42
Tool Mounting – PreciseFlex 400 42
Accessing the Robot Controller 42
Power Requirements 43
Emergency Stop 43
Hardware Reference _________________________________________________________44
System Schematics 44
System Diagram and Power Supplies 44
Facilities Panel 67
E-Stop Connector 68
MCP / E-Stop Interface 69
Digital Input Signals 69
Gripper Controller Digital Inputs and Outputs 72
RS485 Remote IO Module (GIO) 72
PF3400 3kg IO in Base of Robot (GIO) 73
Digital Outputs in the Outer Link 75
Ethernet Interface 75
RS-232 Serial Interface 75
Software Reference__________________________________________________________77
Accessing the Web Server 77
Loading a Project (Program) or Updating PAC Files 79
Updating GPL (System Software) or FPGA (Firmware) 80
Recovering from Corrupted PAC Files 81
Controller Software Extensions 85
Adding or Removing the Optional Linear Axis 85
Controlling the Precise Servo Grippers 86
Servo Gripper Controller Digital Inputs and Outputs 88
Optional Pneumatic or Vacuum Gripper 89
G1400B Dedicated Digital Outputs 90
Service Procedures__________________________________________________________91
Recommended Tools 91

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vi
The following tools are recommended for these service procedures: 91
Trouble Shooting 91
Encoder Operation Error 93
Replacing the Encoder Battery 94
Calibrating the Robot: Setting the Encoder Zero Positions 95
Replacing Belts and Motors 100
General Belt Tensioning 100
Tensioning the J1 (Z Column) Belts 100
Tensioning the 1st Stage Belt 100
Tensioning the 2nd Stage Belt 101
Tensioning the J2 Belt 102
Tensioning the J3 Belt (Before 2014) 104
Tensioning the J4 Belt (Before 2014) 105
Tensioning the J3 and J4 Belts (2014) 106
Tensioning the Belt on the Optional Linear Axis 108
Replacing the Power Supplies, Energy Dump PCA, or J1 Stage Two (Output) Timing Belt 109
Replacing the Robot Controller 112
Replacing the Servo Gripper Controller 114
Wiring for 60N Gripper with Battery Pigtail 116
Wiring for Pneumatic Gripper 116
Wiring for Vacuum Gripper 117
Wiring for Vacuum-Pallet Gripper 117
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 126
Installing the Optional GIO Board 128
Replacing the Main Harness 131
Replacing the Outer Link Harness 131
Replacing the Z Axis Motor Assembly 134
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 145

Table Of Contents
vii
Appendix A: Product Specifications ___________________________________________155
Appendix B: Environmental Specifications _____________________________________157
Appendix C: Spare Parts List _________________________________________________158
Appendix D: Preventative Maintenance_________________________________________160
Appendix E: Belt Tensions, Gates Tension Meter ________________________________ 161
Revisions _____________________________________________________________163

PreciseFlex_Robot
1
Introduction to the Hardware
System Overview
System Description
The PreciseFlex 400 Robot is a four-axis robot which includes an embedded Guidance 1400B four-axis
motion controller, a 48VDC motor power supply, and a 24VDC 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 750mm.
The robot is designed as tabletop unit and can carry a payload of up to 500 grams in the standard version
with servo gripper, 1200 grams in the standard version without a gripper, and 2500 grams in the 3kg
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 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 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.
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.
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 PF400 was released in 2011. Since the initial release, designated by SN F0X-wwww-xy-zzzzz

PreciseFlex_Robot
2
two significant upgrades have been released.
Revision B, designated by Serial Numbers F0B-wwww-xy-zzzzz, was released in 2014, and improved
the high-speed, continuous duty performance of the robot. The main changes in this revision were a
wider timing belt in J2 (12mm replaced 9mm), changing to all steel drive pulleys from aluminum to
improve the bond strength of the drive pulleys to the motor shaft, and changing the slip ring in the wrist for
improved reliability.
Revision C, designated by Serial Numbers F0C-wwww-xy-zzzzz, was released in the fall of 2016, and
improved the resistance of the robot to high-speed crashes by adding clamp rings and beveled retaining
rings to the J2, J3, and J4 bearings, so that these bearings cannot come loose in a high-speed crash. In
addition, improved support for pneumatic grippers and control of solenoid valves in the outer link is
provided, and some longer life cam followers for the J2 timing belt are installed. In January 2017, a
longer life Ethernet cable is expected to be released which should last for the life of the robot running
continuous duty for at least 3 years.
PF3400: 3kg Version
In 2017 a heavier payload version of the PF400 was released. This version, which appears very similar
to the standard versions, is designated by Serial Numbers FO2, and has a rated payload of 3kg grams
without a gripper. In this version, the torque for J1 remains the same, however the torque for J2 is
increased 100%, and the torques for J3 and J4 are both increased 65%. J2 and J4 have larger motors
and J2 has a 20mm wide timing belt versus 12mm wide to handle the increased torque. The Z linear
bearing width has been increased from 24mm to 42mm to support the heavier payload. These units have
the same top speeds as the standard versions. However, with the full 3kg payloads, the accelerations
are somewhat slower than the standard version with the servo gripper and 500 gram payload. If these
units are used with payloads less than 3kg, accelerations greater than 100% may be commanded to
increase the accelerations to values equal or greater than the standard version robot. The 3kg payload
includes the gripper. For example, the optional 60N Electric Gripper weighs 1kg, so with this gripper the
workpiece payload is 2kg.
Note that for the PF3400 3kg version, 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). 100% equals 3kg
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 also for proper gravity
compensation, including “free” mode. Also, it is important to set the correct offset distance in value 5 of
parameter 16068, in mm, for the distance of the center of mass of the gripper and payload from the J4
axis of rotation. For example, if the center of a 2kg mass is 100mm from the center of rotation of axis 4
(the wrist), this value should be set to 100mm, for the Dynamic Feed Forward calculations to compute the
correct feed forward motor torques and achieve optimal performance. For pick and place applications,
the property “robot.payload” can be written by the application program to change the payload. 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.
In addition, the 3kg version has 8 inputs and 8 outputs available at the base connector panel in a 25 pin
Dsubminiature connector and has 4 digital outputs and up to 4 digital inputs available in the outer link
when the pneumatic version is ordered.
The 3kg version is 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 60N squeeze, 40mm travel electric gripper can be ordered, or a
dual 23N squeeze, 60mm electric gripper can be ordered. See the “system dimensions” section for
reference dimensions on these options.

Introduction to the Hardware
3
System Diagram and Coordinate Systems
The major elements of the PreciseFlex robot and the orientation and origin of its World Cartesian
coordinate system are shown in the diagram below.
The first axis of the robot, J1, moves the robot arm up along the Z Column, which is 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
Z=30mm 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 and the connector panel. The
Guidance controller is located inside the inner link of the robot, and the gripper controller is located inside
the outer link.

PreciseFlex_Robot
4
When the Inner Link is centered on its range of motion the J2 axis is at its 0 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 world Z-Axis. A positive change in the axis
angle results in a positive rotation about the World Z-axis. When the link is centered, it is at its 0 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.
The J4 rotary axis (wrist) rotates the gripper about the World Z-axis. A positive change in the 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 shoulder cover (or
column for some robots) 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 Components
PreciseFlex 400 Robot
The PreciseFlex 400 Robot (pictured below) is a 4-axis robot that may optionally include an electric or
pneumatic gripper.

Introduction to the Hardware
5
Optional Linear Axis Module
The PF400 and PF3400 robots may be attached to an optional Linear Axis Module. The Linear Axis
Module may be ordered in 1000mm, 1500mm and 2000mm travel distances. The module length is about
380mm longer than the travel distance. All cables and controls are contained inside the Linear Axis
Module, which is equipped with drip proof covers and tape seals. Power entry, a power switch, Pendant,
and IO connectors are extended from the base of the robot to the end cap of the Linear Axis Module. The
Linear Axis Module is driven by a servo amplifier located in the carriage. This servo amp gets both power
and commands from the controls in the robot, so the Linear Axis Module must be slaved to a robot in
order to work, and cannot be purchased as a standalone module at this time.
The picture below shows a 750mm vertical travel PF400 on a 1000mm Linear Axis Module. The robot is
positioned in the middle of travel, which is defined as the zero position in the linear axis. The robot may
be mounted in this orientation, in which case the linear axis moves along the Y axis in the robot’s
coordinate system with the linear axis extending the robot’s Y axis by plus or minus 500mm. The robot
may also be rotated 90 degrees so that it faces the connector end cap of the Linear Axis. In this case the
Linear Axis extends the robot’s X axis travel, if the appropriate SW parameter is changed. See the
Software Reference section.
Mounting of Robot and Linear Axis Module
The Robot Base Plate contains a mounting hole pattern for 4 M6 Screws along with reference surfaces
for locating the robot on a table or work cell surface. The Linear Axis Module contains mounting patterns
for both M6 and ¼-20 screws. See Installation section for details.

PreciseFlex_Robot
6
Optional Gripper
The robot may be ordered with an optional Gripper. The Gripper may be either electric, pneumatic, or
vacuum. Several options are available.
Guidance 1400B Controller
The Guidance 1400B Controller is a four-axis general purpose motion controller that contains four motor
drives and four encoder inputs. It must be attached to a heat sink. The heat sink is provided by the inner
link housing. The controller includes local digital IO. It also supports RS232 and RS 485 serial
communication and an optional Precise Remote IO module. It contains two Ethernet ports. The controller
and power supplies are shown in the system diagram below.
For detailed information on the controller including interfacing information, please see the "Guidance
1000A/B Controllers Manual P/N: G1X0-DI-A0010".
Low Voltage Power Supplies
The PreciseFlex 400 Robot has an integrated 125-watt, 24VDC Power Supply that accepts a range of AC
input from 90V to 264V and an integrated 365W, 48VDC Power Supply for the motors.

Introduction to the Hardware
7
DANGER: In addition to exposed high voltage pins and components, the
heat sinks on the Power Supplies are not grounded and expose high
voltage levels. AC power to the robot must be disconnected prior to
accessin
g
these units.
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
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 green Phoenix connector in the connector panel in the base of the robot. The E-Stop box completes
a circuit from the top pin, Pin 1 (24VDC) to Pin 2 (E-Stop) in this connector. If this circuit is not completed
it is not possible to enable motor power to the robot. If no E-Stop box or Manual Control Pendant is
connected, a jumper must be connected between these two 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. The E-Stop connections are also present on the 9 pin Dsub connector and each of these units
provides the hardware signals to permit power to be enabled and disabled.

PreciseFlex_Robot
8
Optional RS485 IO Module (GIO)
For users who wish to have IO available at the base of the robot, an optional IO module may be added.
This module provides 12 digital inputs and 8 digital outputs in a 25 pin Dsub connector at the robot
connector panel and is connected via RS485 to the robot controller.
Optional Digital IO Module (GIO)
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 PreciseFlex robot and its embedded Guidance 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.

Introduction to the Hardware
9
The Enhanced RIO module is pictured below.
WARNING: The RIO contains unshielded 24 VDC signals and pins. This
product is intended to be mounted in a cabinet or machine chassis that is
not accessible when power is turned on.
Machine Vision Software and Cameras
The Guidance 1400 Series 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.
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.

PreciseFlex_Robot
10
Standards Compliance and Agency Certifications
The PreciseFlex 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 controller 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 carry the CE and CSA marks.
CE
CSA
FCC Class A
ANSI/RIA R15.06 Safety Standard
Moving Machine Safety
The PreciseFlex 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. While the PreciseFlex 400 is a light-duty
robot that can only apply approximately 20-60 Newtons of force, it is very important for operators to keep
their hands, arms and especially their head out of the robot’s operating volume. It is important that
operators wear safety glasses when inside the robot’s operating volume.
In Computer Mode, the robot can move quickly. The PF400 and PF3400 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.
Voltage and Power Considerations
The Guidance 1400B controller requires two DC power supplies, a 24 VDC power supply for the
processor and user IO, and a separate 48VDC motor power supply.
DANGER: The Guidance 1400, the 48 VDC and the 24 VDC power
supplies are all open frame electrical devices that contain 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
A
C line power is turned on.

Introduction to the Hardware
11
The PreciseFlex 400 power supplies have a dual input range of 90 to 132 VAC and 180 to 264 VAC
50/60 Hz. Inrush current can be as high as 100 Amps at 240 VAC for short periods of time. The power
supplies are protected against voltage surge to 2000 volts. Transient over voltage (< 50 µs) may not
exceed 2000 V phase to ground, as per EN61800-31996. Revisions A and B of the robot are protected
against over current by two 4.0 amp, 250V slow blow fuses, for example Littlefuse 0215004.MXP. For
Revision C and the 3kg version, these fuses have been removed to provide for better filtering in the
power entry connector. The power supplies have over-current protection, and over-voltage protection.
The robot consumes less than 200 Watts during normal operation.
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.
Mechanical and Software Limit Stops
The Z column, shoulder, and elbow 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 has a slip ring when
the electric gripper is installed, allowing unlimited rotation. However, software stops limit rotation to plus
or minus 970 degrees. Since the robot has absolute encoders with battery backup, even if the robot is
turned off, the encoders keep track of joint position. If the wrist axis is rotated manually beyond the 970
degree software limit stops, it will be necessary to rotate it back to within the allowed software limits
before the robot will run. 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) For pneumatic configurations a sliding hard stop limits the wrist
rotation to 540 degrees.
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 0.5
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 high-power relay will be disabled within 1ms.

PreciseFlex_Robot
12
For the PreciseFlex 400 robot, the shoulder, elbow, and wrist axes do not have mechanical brakes.
Therefore, leaving the motor power enabled for 0.5 sec allows the servos to decelerate the robot. The
servos will typically decelerate the robot at 0.12G, or 1250mm/sec2. If the robot is moving at a speed of
500mm/sec, the distance traveled will be 100mm to reach a full stop, and the time will be 0.4sec.
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 J2, J3, and J4 axes have no 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.