PreCise PF400 Hardware Reference Manual
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PreCise PF400 Hardware Reference Manual

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

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Summary of Contents for PreCise PF400

  • Page 1 The PF400 and PF3400 Robots Hardware Reference Manual Version 5.04, August 9, 2017 Precise Automation Inc., 727 Filip Road, Los Altos, California 94024 www.preciseautomation.com...
  • Page 2 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.
  • Page 3 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.
  • Page 4 Collaborative Robot Safety ____________________________________________________ 13   Robot Testing and Safety Circuits   Robot Workcell Design   Appendix A: Example Performance Level Evaluation for PF400   Appendix B: TUV Verification of PF400 Collision Forces   Appendix C: Table A2 from ISO/TS 15066: 2016  ...
  • Page 5 Recovering from Corrupted PAC Files   Controller Software Extensions   Adding or Removing the Optional Linear Axis   Controlling the Precise Servo Grippers   Servo Gripper Controller Digital Inputs and Outputs   Optional Pneumatic or Vacuum Gripper   G1400B Dedicated Digital Outputs  ...
  • Page 6 PreciseFlex Robot   The following tools are recommended for these service procedures:   Trouble Shooting   Encoder Operation Error   Replacing the Encoder Battery   Calibrating the Robot: Setting the Encoder Zero Positions   Replacing Belts and Motors   General Belt Tensioning  ...
  • Page 7 Table Of Contents   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  ...
  • Page 9 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.
  • Page 10 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.
  • Page 11 Introduction to the Hardware 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.
  • Page 12 PreciseFlex_Robot 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.
  • Page 13 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...
  • Page 14 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.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 PreciseFlex_Robot 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/sec .
  • Page 21 Collaborative Robot Safety Summary. The PF400 and PF3400 robots have been designed to be safe for collaborative use by means of inherent design and control when evaluated under ISO/TS 15066 “Robots and Robotic Devices – Collaborative Robots” released February 15, 2016. In all free space collisions (transient contact), up to its maximum speed and payload, these robots do not exceed the forces in the standard.
  • Page 22 P2 for a hazard that may be difficult to avoid (for example a sudden, non-repetitive motion that may trap an operator). An example of determining PL for a PF400 workcell is given in Appendix A of this section, where it is shown that a PL of “a” is sufficient for the workcell.
  • Page 23 Introduction to the Hardware EN/ISO 13849-1 defines a reliability level of any safety components in a machine by performance level in terms of average probability of dangerous failure per hour. It then attempts to provide a statistical method to compute this number for safety systems based on failure rates for various system components to determine the actual Performance Level (PL), which can be compared to the Required Performance Level (PLr).
  • Page 24 PreciseFlex_Robot Figure 2 Types of forces There are four types of forces that should be considered and tested when designing a “Collaborative” robot workcell. These are: 1. Clamping/squeezing force. This is the quasi-static case of the robot pressing a compliant part of the human body against a surface.
  • Page 25 +X, +Y, and –Z (downwards) is generally sufficient to characterize robot forces. Precise uses a test stand, to which a certified force gage can be attached in either the vertical or horizontal direction, for testing forces. A “compliance plate” assembly is attached to the robot to simulate the compliance of the human hand of 75N/mm.
  • Page 26 S1 is typically selected which directs the evaluation to a PLr of a, b, or c. In Appendix A of this section an example risk assessment is provided for a PF400 robot with a 500 gram payload and the PL is determined to be “a”.
  • Page 27 All motors except certain gripper motors in Precise robots are 3 phase brushless motors. These motors require a rotating electrical field which must switch between the 3 phases in order for the motor to turn.
  • Page 28 This is a CAT 3 compliant function. TUV has verified this fail-safe operation. 10. Motor overheating. Precise controllers have a “motor duty cycle” monitor which computes the average power level in a motor and shuts down the motor power if a maximum permissible power level is exceeded.
  • Page 29 (for the PF400 any distance over 20mm is adequate for the person to stop the robot with a force less than 40N in the horizontal plane and approximately 60N in the –Z direction.
  • Page 30 Workcell Layout. The PF400 is designed so that the gripper is the lowest point on the robot and cannot descend all the way to the mounting surface (table). Because of this feature, the workcell designer typically does not need to worry about the outer link or inner link of the robot trapping an operator’s...
  • Page 31 Untrained operator reaches into workcell while robot is moving into instrument tray and hand is trapped between robot and instrument tray. From PF400 Table 1 max trapping force in downwards Z direction at 50mm/sec (10% of max speed of 500mm/sec) is 80N.
  • Page 32 PreciseFlex_Robot Appendix B: TUV Verification of PF400 Collision Forces...
  • Page 33 Introduction to the Hardware...
  • Page 34 PreciseFlex_Robot...
  • Page 35 Introduction to the Hardware...
  • Page 36 ‐61 ‐230 Config for J2 Rotation (max velocity) ‐1 ‐334 100% Joint Speed 500mm/s 90deg/s 720deg/s 720deg/s 400mm/s 750mm/s 100% Joint Accel 1800 1100 1200 4000 10000 1000 100% XYZ Speed 100% XYZ Accel 2000 PF400 Collisions at Gripper, 50mm programmed interference Z deceleration % Speed Manual Control Free Space Collision Rigid Surface Collision 100% X cart Y cart ‐Z 1kg X cart Y cart ‐Z 1.0kg X cart Y cart J2 rot ‐Z 1.0kg ‐Z 1.0kg...
  • Page 37 Introduction to the Hardware Appendix C: Table A2 from ISO/TS 15066: 2016...
  • Page 38 PreciseFlex_Robot Table A2, Continued...
  • Page 39 Introduction to the Hardware Appendix D1: Safety Circuits for PF400 500gm Payload 14‐Jun‐17 PF400 500gm Safety Circuit Notes Estop No Yes No 50% 92 Estop turns off  amp enable  and PWM Stopping robot with hand turns off amp enable and PWM to amp Encoder Feedback Yes No Yes 90% 58 Startup test checks encoder communication, prevents mtr power if fault Serial update at 8Khz w checksum, comm check, accel check Counter embedded in position word to confirm CPU read from FPGA CPU Monitor No Yes 99% 100 Yes FPGA watchdog timer turns off amp enable and PWM Position Envelope Error Yes Yes Yes 90% 57...
  • Page 40 PreciseFlex_Robot Appendix D2: Safety Circuits for PF3400 3kg Payload 14‐Jun‐17 PF3400 Safety Circuit Notes (PF3400t has redundant Estop and 48V power supply enable) Estop Yes Yes No 99% 100 Yes Startup test forces Estop, checks 48V power disable, zero amp current Dual Estop circuits turns off amp enable and PWM Dual Estop circuits turnS off 48V power Stopping robot with hand turns off amp enable, PWM and 48V Encoder Feedback Yes No Yes 90% 58 Startup test checks encoder communication, prevents mtr power if fault Serial update at 8Khz w checksum, comm check, accel check Counter embedded in position word to confirm CPU read from FPGA CPU Monitor Yes Yes Yes 99% 100 Yes Startup test forces CPU WD low, checks 48V power disabled Independent dual watchdog timers turn off amp enable, PWM and 48V Processor on safety board monitors main CPU.  Disables 48V if failure.
  • Page 41 Introduction to the Hardware PF400 500gm Safety Circuits PF3400 3kg Safety Circuits...
  • Page 42 PreciseFlex_Robot Installation Information Environmental Specifications The PreciseFlex robots must be installed in a clean, non-condensing environment. Light fluid splashing around the base of the robot is acceptable, but this robot is not intended for use in a washdown or spray environment.
  • Page 43 System Dimensions Both top and right views are shown below. All dimensions are in millimeters. Mounting Dimensions for PF400, Standard Reach (Increase height by 22mm for PF3400) (For XR robot, R575 increases to R731 and inner link length increases from 225 to 302mm)
  • Page 44 PreciseFlex_Robot Finger Mount Height from Base PF400 Gripper Flange Mount Height from PF3400...
  • Page 45 Installation Information...
  • Page 46 PreciseFlex_Robot...
  • Page 47 Installation Information...
  • Page 48 PreciseFlex_Robot...
  • Page 49 Installation Information Linear Axis Mounting Dimensions The linear axis has both an M6 and ¼-20 hole pattern inside the extrusion. You must loosen the connector end cap slightly and remove the top cover to access these holes patterns. When replacing the top cover, be sure the tape seals are inside the slot in the top cover and not crushed.
  • Page 50 The Precise Flex 400 is typically supplied with an electric gripper. In some cases, a pneumatic gripper may be supplied by Precise or by the end user. However, the standard robot does not include pneumatic lines, so if pneumatic tooling is needed, the robot must be ordered with pneumatic lines installed. The outer link has a flange for users to attach grippers or tooling.
  • Page 51 Installation Information Power Requirements The PreciseFlex robots contain auto-ranging power supplies that operate between 90 to 132 and 180 to 264 VAC, 50 or 60Hz. The robots are equipped with an IEC electrical socket that accepts country specific electrical cords. Power requirements vary with the robot duty cycle, but do not exceed 200 watts RMS. Emergency Stop It is necessary to wire an Emergency Stop Button to the controller.
  • Page 52 PreciseFlex_Robot Hardware Reference System Schematics System Diagram and Power Supplies The robot has a 24VDC and 48VDC power supply located in the Z column. For Revisions A and B, the AC input to these power supplies is fused, with two fuses in a pull-out fuse drawer in the IEC type power entry module.
  • Page 53 Hardware Reference that performs this function under computer power so that the brake can be released manually without motor power being enabled.
  • Page 54 PreciseFlex_Robot Schematic: System Overview...
  • Page 55 Hardware Reference Schematic: FFC Boards Revision B PF400...
  • Page 56 PreciseFlex_Robot...
  • Page 57 Hardware Reference Schematic: FFC Boards Revision C PF400...
  • Page 58 PreciseFlex_Robot Schematic: FFC Boards 3kg PF400...
  • Page 59 Hardware Reference...
  • Page 60 PreciseFlex_Robot Schematic: Safety System Overview PF400 CAT3...
  • Page 61 Hardware Reference...
  • Page 62 PreciseFlex_Robot Controller Power Amplifier Connectors Control Board Connectors...
  • Page 63 Hardware Reference Gripper and Linear Axis Controller Connectors...
  • Page 64 PreciseFlex_Robot...
  • Page 65 Hardware Reference...
  • Page 66 PreciseFlex_Robot Schematic: Slip Ring for 60N Gripper...
  • Page 67 Hardware Reference...
  • Page 68 PreciseFlex_Robot...
  • Page 69 Hardware Reference...
  • Page 70 PreciseFlex_Robot...
  • Page 71 Hardware Reference...
  • Page 72 PreciseFlex_Robot...
  • Page 73 Hardware Reference Motor 60N Gripper...
  • Page 74 PreciseFlex_Robot...
  • Page 75 Hardware Reference Facilities Panel The Facilities Panel is located at the base of the robot. To simplify interfacing, most of the electrical interfaces provided by the robot's embedded Guidance Controller are available on the Facilities Panel. These include:  Digital input signals ...
  • Page 76 PreciseFlex_Robot Each of these interfaces is described in detail in the following sections. In addition, the robot's controller, which is mounted in the inner link of the robot, may contain additional interfaces (e.g. inputs or outputs). Please refer to the Guidance 1000A/B Controllers, Hardware Introduction and Reference Manual for additional information.
  • Page 77 Hardware Reference MCP / E-Stop Interface The MCP interface includes the signals necessary to connect a Manual Control Pendant, secondary E- Stop circuit, or an external RS485 Remote IO Module. These signals are provided in a DB9 female connector mounted on the robot’s Facilities Panel, and on the end cap of the optional Linear Axis. Note the E-Stop pins on the MCP Interface are in series with the E-Stop signals on the Phoenix E-Stop connector.
  • Page 78 PreciseFlex_Robot This input signal can be configured as "sinking" or "sourcing". If an input signal is configured as "sinking", the external equipment must pull its input high to 5VDC to 24VDC to indicate a logical high value or must allow it to float to no voltage for a logical low. This input is configured at the factory as “sinking”. By setting Jumpers on the CPU (MIDS4) board, the four output signals can be individually configured as "sinking"...
  • Page 79 Hardware Reference sinking or sourcing. For more information on configuring the jumpers, please see the Guidance 1000A/B Controllers, Hardware Introduction and Reference Manual. Digital Output Signals The PreciseFlex robot provides 4 general-purpose optically isolated digital output signals at the G1400B controller.
  • Page 80 PreciseFlex_Robot GPL Signal Description Number Digital Output 1 Digital Output 2 Digital Output 3 Digital Output 4 24 VDC output 10001 Digital Input 1 10002 Digital Input 2 10003 Digital Input 3 10004 Digital Input 4 AMP 1658622-1 or Molex 22-55-2101 or 90142- 0010.
  • Page 81 The DIO signals addresses are determined by a base address set by a DIP switch on the DIO board. For the PF400 robot without the linear axis option the DIO option is located at the robot connector panel and for both this location and also for the location at the end of the optional linear axis, all the address jumpers will NOT be installed, which sets the address of this module to “8”.
  • Page 82 PreciseFlex_Robot The software addresses will then be as follows. GPL Signal Description Number 810001 Digital Input 1 810003 Digital Input 3 810005 Digital Input 5 810007 Digital Input 7 810009 Digital Input 9 (Not available PF3400) 810011 Digital Input 11 (Not available PF3400) 24VDC 800013 Digital Output 1...
  • Page 83 Digital Outputs in the Outer Link In the Revision C and 3kg versions of the PF400 the motor interface board in the outer link can be connected by means of a flat ribbon cable to the controller digital inputs and digital outputs, providing support for both pneumatic and vacuum grippers where desired.
  • Page 84 PreciseFlex_Robot The connector for this interface is a standard RJ11 serial interface connector that has pin assignments compatible with standard PC "com" ports. For this robot it is only used for debugging and special service procedures.
  • Page 85 Software Reference Accessing the Web Server Many OEM customers run the PF400 using a PC to provide an application-specific operator interface. In order to update software in the controller, and view certain error messages, it is necessary to access the Web Server Interface embedded in the controller.
  • Page 86 PreciseFlex_Robot It may be necessary to enter a password if your company has protected access to the Web Interface. Once the password has been entered, click on “Admin” to access all the features to perform system upgrades. The window below will open up. Click on “Control Panels”, then “Operator Control Panel”.
  • Page 87 If an application is running, the “System Running” panel will display in green. In order to run diagnostics, you must stop the application from running. Click “Stop Application” and then “Perform Operation”. This will stop the application from running. You should click the “Disable Power” button to be sure motor power is off.
  • Page 88 Both GPL (the system software) and the FPGA firmware may be upgraded in the field. To perform an upgrade: 1. Obtain the appropriate upgrade software from Precise, in the form of a .bin file. 2. In the Operator Interface, go to the Utilities/System Upgrade menu.
  • Page 89 Precise maintains a record of PAC files shipped with each robot Serial Number. If the PAC files have been corrupted, it is possible to get a back up copy from Precise. The backup copy will contain the factory configuration and calibration data, but will not contain any changes, including any new calibration data, made after the robot has left the factory.
  • Page 90 PreciseFlex_Robot 4. Cycle robot power to reboot the controller. 5. In the Web Based Operator Interface, select “Utilities/Backup and Restore 6. Click on Start File Manager. It may be necessary to hold down the Control Key to allow the pop- up.
  • Page 91 7. Open the “Config” folder and paste the backup copy of the PAC files into this folder. 8. Wait until the console prompt stops flashing, about 10-15 seconds. 9. Turn off robot power.
  • Page 92 PreciseFlex_Robot 10. Restore Jumper J8 to its previous position. 11. Reboot the robot. The PAC files should be restored and the robot should run. 12. If the robot has ever been recalibrated since the back up PAC files were created, it will be necessary to recalibrate the robot, as the calibration files will be out of date.
  • Page 93 Adding or Removing the Optional Linear Axis The optional Linear Axis may be added to existing PF400 robots by simply placing the robot on the Linear Axis and plugging in the connectors from the Linear Axis stage. However the GPL version must be 3.2.H4 or later and the PAC files must be changed to support the robot with Linear Axis.
  • Page 94 Precise has created a GPL software routine that controls the spring gripper. This routine includes features for controlling the gripper squeeze force and detecting if a plate is present during a grip. Precise makes this routine available to customers upon request. This routine is also available in the Precise Command Server Software for the PF400.
  • Page 95 selected to allow enough motor torque to overcome the spring and still provide reasonable opening force for inside grips. The motor for the 23N gripper can apply about 18N of force at its rated current of 1.26A. When closing the fingers the motor adds its force to the spring force, so a maximum closing force of about 24-26N is possible, depending on portrait or landscape gripping.
  • Page 96 End of Travel Sensor The Precise 23N EGripper includes a sensor to detect the gripper closed to hard stop position. The spring will return the gripper to this position if power is off and there is no plate in the gripper. This sensor is wired to Digital Input 2 on the Gripper Controller Board which can be read at Digital Input 210002.
  • Page 97 must be correctly installed to connect RS232 to the GSB. On the CPU board, shown below, J14 and J15 must be connected to pins 2 and 3 to connect the TXD and RXD inputs from the GSB to the serial inputs in the CPU.
  • Page 98 PreciseFlex_Robot While some grippers for OEM customers differ slightly from the following, in general for the pneumatic gripper controller digital output 1 will open the gripper. Controller digital input 1 goes high when the gripper is open and input 2 goes high when the gripper is closed. (See the section on controller digital input and output signals for the software assignments of these signals.) For vacuum grippers, digital output 1 turns on vacuum and digital output 2 turns on blowoff air.
  • Page 99 7. M5 socket driver or M5 open end wrench or pliers Trouble Shooting Precise robots and controllers have an extensive list of error messages. Please refer to the HTML document Precise_Documentation_Library.chm to search for a specific error message and cause. Listed...
  • Page 100 PreciseFlex_Robot Symptom Recommended Action System error message generated “ESTOP not Enabled” Check both Phoenix plug and 9 pin Dsub for Estop jumpers. “Encoder Battery Low” Replace absolute encoder battery in base of robot If encoder cable has been disconnected, recalibrate robot. If “Encoder Battery Down”...
  • Page 101 Encoder Operation Error The PF400 robot is equipped with absolute encoders that keep track of the robot position even when AC power to the robot is disconnected. There is a battery in the base of the robot that provides standby power to the encoders.
  • Page 102 PreciseFlex_Robot Calibrating the Robot), or another known position, and check the joint angles in the Virtual Pendant in the Web Operator Interface. The joint angles in the Calibration Position are: Z Axis: -1mm (-2mm for Beta robots) J2 or Shoulder: -90 J3 or Elbow: 179.99 J4 or Wrist: -180 If the robot joints after this procedure followed by homing are different from the above, then the...
  • Page 103 2. Set of 3 Calibration Dowel Pins, located in plastic bag inside the hollow slot in the front cover. The following describes the procedure for defining the zero positions of the PF400 robot axes using Cal_PP. 1. Enable power to the robot’s controller, but do not turn on power to the motors.
  • Page 104 PreciseFlex_Robot 3. Manually move the robot into the configuration shown below. a. The top cover of the outer link will need to be removed by removing the 4 M3 X 20 SHCS that are located in counter bores under the outer link. b.
  • Page 105 10. With the CALPP application loaded, select “Start Application”, then press “Perform Operation” a. Application should start and prompt user to confirm correct robot position for calibration...
  • Page 106 PreciseFlex_Robot b. The CALPP application takes about 1 minute to run.
  • Page 107 11. After calibration is complete, use the brake release button and move the Z-axis up from the hard stop. Failing to do this will produce an error as the robot is outside of the soft stop limits. 12. Make sure the pins are removed. 13.
  • Page 108 PreciseFlex_Robot Replacing Belts and Motors The timing belts and motors are designed to last the life of the robot. It is not expected that they will need to be replaced in the field. In most cases, if a belt or a motor needs to be replaced, the robot should be returned to the factory.
  • Page 109 M4 Locking Screws M4 Tension Screw Tensioning the 2 Stage Belt Tools Required: 1. Gates Sonic Belt Tension Meter, Model 507C 2. 3.0mm hex driver or hex L wrench 3. 2.5mm hex driver or hex L wrench To tension the 2 Stage J1 Belt the user must: 1.
  • Page 110 PreciseFlex_Robot Tension Adjust Screw Z Axis Idler Plate M5 Shoulder Screw M4 Locking Screws Measure this side so that the span is correct. Measure this side only if using Alternate Method for long Z strokes. 5. The tension is set to the value in Appendix E by adjusting the M5 set screw which pushes on a spring in the Z Axis Idler Plate.
  • Page 111 1. Move the robot arm to the top of the Z Column travel. 2. Turn off the robot power and remove the AC power cord. 3. Remove the Top Plate of the robot by removing the 4 M5 socket head screws from the top plate of the robot that attach the top plate to the Z column.
  • Page 112 PreciseFlex_Robot Tension Spring Clamping Screws Measure Tension This Span 6. Loosen the 3 M3 SHCS and 1 M4 Shoulder screw clamping the J2 Motor Mount Plate to the Z Carriage. It may be necessary to remove the tie wrap securing the J2 Motor cables to the Z carriage in order to access the clamping screw under these cables.
  • Page 113 1. Loosen the 2 Motor Locking Screws on the bottom of the Inner Link. One screw requires a 2.5mm driver and the second requires a 3.0mm driver. 2. Tighten the 2 screws again. The J3 belt is automatically re-tensioned. 3. The above procedure is an approximate procedure. Its accuracy is limited by the fact that the J3 belt tension will vary according the orientation of the J3 output pulley.
  • Page 114 PreciseFlex_Robot 5. Measure the belt tension, every 10 degrees of rotation of the gripper to find the minimum tension. 6. Adjust the minimum belt tension to the value in Appendix E. This may be possible by just releasing and re-tightening the Motor Locking Screws. It may require adjusting the Belt Tension Screw.
  • Page 115 Motor Locking Screws Motor Locking Screws Microphone on Pluck belt gently belt tension with L key to meter measure tension.
  • Page 116 PreciseFlex_Robot Tensioning the Belt on the Optional Linear Axis Tools Required: 1. Gates Sonic Belt Tension Meter, Model 507C 2. 3.0mm hex driver or hex L wrench To tension the Linear Axis Belt the user must: 1. Remove the linear axis cover by sliding the carriage to one end of travel, remove 4 M4 X 30 SHCS from the end caps retaining the cover.
  • Page 117 Replacing the Power Supplies, Energy Dump PCA, or J1 Stage Two (Output) Timing Belt DANGER: Before replacing the power supplies, the AC power should be removed. Tools Required: 1. 3.0mm hex driver or hex L wrench 2. 2.5mm hex driver or hex L wrench Spare Parts Required: 1.
  • Page 118 PreciseFlex_Robot M5 Set Screw M4 Locking Screws M5 Shoulder Screw M5 Shoulder Screw Z Carriage Inner Cover 5. Lay the robot down on its back side on a table where there is room to work. 6. Remove the Idler Plate Assembly by removing the M5 set screw that compresses the Idler Plate Spring, the 2 M4 SHCS that clamp the Idler Plate, and the M5 Shoulder Screw that forms the Idler Plate pivot.
  • Page 119 J1 Encoder Connector J1 Motor Connector Battery Connector Splash Guard 11. Remove the J1 motor and encoder connectors that plug into the J1 Motor Interface Board. 12. Remove the Battery connector that plugs into the J1 Motor Interface Board. 13. Loosen the M4 SHCS screws attaching the Z bearing rail to the Z Extrusion. 14.
  • Page 120 PreciseFlex_Robot Replacing the Robot Controller DANGER: Before replacing the Robot Controller, the AC power should be removed. Tools Required: 1. 2.5mm hex driver or hex L wrench 2. 2.0mm hex driver or hex L wrench 3. Small flat bladed screw driver, with 1.5mm wide blade typ 4.
  • Page 121 the upper board. Be careful to gently press in the compression latch on the FFC encoder connectors with your finger, not a sharp object. 9. Make sure the EtherNet cable folds back along the under the upper circuit board but does not obstruct the board to board connector.
  • Page 122 2.5mm hex driver or hex L wrench Spare Parts Required: For the 23N PF400 Servo Gripper: Guidance Gripper Controller P/N G1X0-EA-T1100 or G1X0-EA-T1101 For the 60N PF3400 Servo Gripper: G1100T Slave Controller (“GSB3-DIFF”) G1X0-EA-T1101-4D To replace the Gripper Controller the user must:...
  • Page 123 1. Turn off the robot power and remove the AC power cord. 2. Remove the Outer Link Cover. 3. Remove the Gripper Controller by removing 4 M3 X 10mm SHCS and unplugging the cables. 4. Replace the Gripper Controller and re-attach the harness. 5.
  • Page 124 PreciseFlex_Robot Wiring for 60N Gripper with Battery Pigtail Wiring for Pneumatic Gripper...
  • Page 125 Wiring for Vacuum Gripper Wiring for Vacuum-Pallet Gripper...
  • Page 126 PreciseFlex_Robot Replacing the Agilent Servo Gripper Finger Pads Tools Required: 1. 1.3mm hex driver or hex L wrench Spare Parts Required: 1. Guidance G1400B Controller PN P/N PF0A-MA-00011, set of 4 pads. To replace the Gripper Finger Pads the user must: 1.
  • Page 127 Replacing the Gripper Spring or Cable Tools Required: 1. 1.3mm hex driver 2. 2.5mm hex driver 3. 7mm open end wrench 4. Loctite 222 Spare Parts Required: Spring or Cable Assembly To replace the spring or cable the user must: 1.
  • Page 128 PreciseFlex_Robot Adjusting the Gripper Backlash or Centering Fingers Tools Required: 1. 1.3mm “stubby” hex L wrench 2. 1.5mm “stubby” hex L wrench Spare Parts Required: none To adjust the gripper backlash the user must: 1. Remove the Gripper Cover by removing 6 M2 X 6mm FHCS. 2.
  • Page 129 Gripper racks centered in fully closed position Gripper racks centered in fully open position...
  • Page 130 PreciseFlex_Robot Adjusting the Gripper Brake (for Grippers with Brake) Tools Required: 5. 1.3mm hex driver 6. 5.5mm open end wrench 7. Loctite 222 Spare Parts Required: none To adjust the gripper brake the user must: 4. Remove the Gripper Cover by removing 6 M2 X 6mm FHCS. 5.
  • Page 131 Spare Parts Required for Gripper, one of the following: 1. Low Profile 23N Electric Gripper” Precise P/N PF0A-MA-00001 (Agilent). 2. PF400 23N Servo Gripper without fingers Precise P/N PF0S-MA-00001 (Standard) 3. PF3400 60N Servo Gripper without fingers PF3S-MA-00001 Rev A1 Spare Parts Required for Slip Ring, one of the following: 1.
  • Page 132 PreciseFlex_Robot M3 Screws that attach slip ring 5. Rotate the Gripper so that the 3 M3 X 6 BHCS which attach the Slip Ring to the J4 Output Pulley can be removed one by one thru the notch in the Outer Link Belt Cover. 6.
  • Page 133 11. After the slip ring is installed, rotation of the wire bundle must be prevented by attaching a black Delrin clamp around the slip ring hub. This clamp is slotted so that it can be slipped over the wires and attached to the hub with a M2.5 X 6mm SHCS. Some older slip rings had heat shrink tube over the hub.
  • Page 134 PreciseFlex_Robot Replacing the Linear Axis Controller Tools Required: 2.5 mm hex driver or hex L wrench 2.0 mm hex driver Spare Parts Required: G1100T Slave Controller (“GSB3-DIFF”) see “Spare Parts List”. Note this part has differential encoder inputs and is NOT the same part as the GSB3-SE for the gripper, which has single ended encoder inputs. To replace the Linear Axis Controller the user must: Remove the linear axis cover by sliding the carriage to one end of travel, remove 4 M4 X 30 SHCS from the end caps retaining the cover.
  • Page 135 Battery wires for absolute encoder Linear Axis Controller (GSB Rev 2) J7 jumper Remove J8 pins 1 & 2 (Address Bit 0) (LED not used) Remove J6 (RS485 term) J3 jumper pins 2 & 3 (Connect 48V) Battery Pin 1 + 3.6VDC Linear Axis Controller Rev2 (GSB Rev 3)
  • Page 136 Installing the Optional GIO Board Precise sells a digital IO board that provides 12 inputs and 8 outputs as an option. This board may be installed either in the Z column of the robot for standalone PF400 robots, or in the Linear Axis extrusion for robots with the Linear Axis option.
  • Page 137 25conductor cable to here 4. Disconnect the Ethernet cable and move it out of the way if necessary. 5. Remove the 25 pin Dsub blank cover plate from the connector panel by removing the M3 BHCS. These screws are retained by M3 nylon insert hex nuts on the back of the front connector panel. 6.
  • Page 138 PreciseFlex_Robot Digital Outputs 1-8 J5: Digital Inputs 19-12 Default Position is sinking. Moving sourcing position both jumpers up 1 pin for sourcing J1: Digital/Analog Input 11 Connect Pins 1&2 for digital input Install J6 (RS485 Term) J4: Digital Inputs 5-8 Remove J7, J8, sourcing position J9, J10...
  • Page 139 Harness is intended to last for the life of the robot. Replacing the Outer Link Harness The Outer Link Harness is comprised of 3 cables: Harness, FFC, J4 Motor, (Precise P/N PF0H-MA- 00002-02-E3), Harness, FFC, J4 Encoder (Precise P/N PF0H-MA-00005-02-E3), and Harness, Gripper Controller (Precise P/N PF0H-MA-00014).
  • Page 140 PreciseFlex_Robot 7. Remove the Harness Retaining Clip from the Robot Controller Mount Plate to release the controller end of the harness. 8. Remove the 4 M2.5 X 16mm standoffs attaching the lower circuit board in the Robot Controller. Gently tip the lower circuit board upwards and disconnect the motor and encoder cables from the lower circuit board.
  • Page 141 12. Attach the Harness Retaining Clip near the Robot Controller to retain the Robot Controller end of the Harness. 13. Coil the replacement harness into 3 loops. 14. Fold the ends of the harness down at a right angle to replicate the replaced harness. 15.
  • Page 142 PreciseFlex_Robot 17. Attach the J3 Harness Retaining Clip to the J3 Output Pulley. 18. Attach the connectors to the circuit boards in the Outer Link. 19. Attach the J4 Motor Interface circuit board. 20. Replace the covers. 21. After replacing the harness the robot must be re-calibrated. See Calibrating the Robot. Replacing the Z Axis Motor Assembly DANGER: Before replacing the Z Axis Motor, the AC power should be removed.
  • Page 143 The J1 Motor Assembly is comprised of the J1 motor, connectors, and a timing belt pulley. The user must: 1. Remove AC power and connectors from the base of the robot. 2. Unfasten the robot from its mounting surface by removing 4 M6 SHCS. 3.
  • Page 144 PreciseFlex_Robot M4 Locking Screws and lock washers M4 Tension Screw 10. Remove the Base Mounting Plate by removing 4 M5 SHCS. The right splash guard is attached to the base mounting plate. 11. Remove the M4 Locking Screws that attach the J1 Motor Mount Bracket to the Z Column. 12.
  • Page 145 3. 3.0mm hex driver or hex L wrench 4. 2.5 mm hex driver or hex L wrench 5. 2.0mm hex driver or hex L wrench 6. Fine point tweezers 7. .06 in flat blade screwdriver Spare Parts Required: 1. J2 Motor Assembly PN PF02-MA-00011 or J2 Timing Belt PN PF00-MC-X0005. 2.
  • Page 146 PreciseFlex_Robot 10. Remove the J2 Motor Interface PCA by removing 2 M3 X 8 SHCS. Cut the tie wrap securing the J2 motor cables to the Z Carriage. Unplug the J2 motor and encoder cable from the J2 Motor Interface PCA. J2 Motor Interface Board Check Belt Tension on this segment of belt by plucking...
  • Page 147 Tension Spring Clamping Shoulder Screw 3 Clamping Screws 15. Loosen the 3 M3 SHCS and 1 M4 shoulder screw that attach the J2 motor bracket. 16. Measure and record the distance from the back of the Tension Spring to the carriage, then remove the M4 X 20 SHCD and washer that compress the Tension Spring.
  • Page 148 PreciseFlex_Robot Replacing the J3 (Elbow) Axis Motor or Timing Belt DANGER: Before replacing this motor, the AC power should be removed. Tools Required: 1. 3.0mm hex driver or hex L wrench 2. 2.5 mm hex driver or hex L wrench 3.
  • Page 149 Z Carriage Inner Cover Light Bar 7. Remove the Light Bar by removing 3 M3 X 8 SHCS and unplugging the connector from the J2 Motor Interface PCA. 8. Remove controller from inner link. 9. Detach the inner link from the Z carriage by removing 6 M3 X 35 SHCS and lock washers. Harness retaining clips.
  • Page 150 PreciseFlex_Robot 10. Remove round Pulley Mount Plate from the Inner Link by removing 5 M3 X FHCS. 11. Remove the J3 Controller Mount Plate from the Inner link by removing 4 M3 X 5 SHCS. Pulley Mount Plate. Controller Mount Plate. Belt Tension Screw.
  • Page 151 Replacing the J4 (Wrist) Axis Motor or Timing Belt DANGER: Before replacing this motor, the AC power should be removed. Tools Required: 1. 3.0mm hex driver or hex L wrench 2. 2.5 mm hex driver or hex L wrench 3. 2.0mm hex driver or hex L wrench 4.
  • Page 152 PreciseFlex_Robot 6. Rotate the Outer Link clockwise (viewing from above) until it hits the hard stop. This will expand the harness coil and the link will be position as shown below, about 10 degrees from straight out. 7. Remove the J4 Motor Interface Board in the Outer Link and unplug the cables. 8.
  • Page 153 Belt Tension Screw Replacing Servo Gripper with Pneumatic or Vacuum Gripper DANGER: Before replacing this motor, the AC power should be removed. Tools Required: 1. 3.0mm hex driver or hex L wrench 2. 2.5 mm hex driver or hex L wrench 3.
  • Page 154 PreciseFlex_Robot robots older than Revision C (2016) . You will need to obtain different PAC files from Precise as one servo axis is deleted. This modification should only be performed by a trained service technician. It requires a robot that has an air line pre-installed at the factory.
  • Page 155 8. Remove the 3 M3 X BHCS that retain the slip ring. (Do not try to remove slip ring yet!) 9. Unplug the slip ring connectors inside the servo gripper. 10. Rotate the slip ring slightly to expose the M2 counter bores in the J4 output pulley. Using a M1.5 hex driver, remove 6 M2 X 16 SHCS that attach the gripper.
  • Page 156 PreciseFlex_Robot 11. Remove the slip ring. 12. Loosen the M3 screw that attaches the harness cable clamp to the J3 output pulley until the clamp can be pulled all the way up to provide access to the M3 X 8 BHCS that closes the clamp. Remove this screw and the rubber pad on the harness.
  • Page 157 15. Add air harness along with IO harness and clamp as shown, after routing cables back down to outer link. Note order of folds in cable. White encoder cable is on inside, then blue shielded motor cable, then IO 10 conductor ribbon cable. Add .010 in UHMW strip and clamp strip, wire harness and air harness by squeezing this clamp...
  • Page 158 PreciseFlex_Robot 17. Route air tube under IO cable and connect to air tube in inner link with plastic barbed connector. 18. Bend rotating metal clip inwards towards motor as far as possible. Rotate outer link and check that air harness does not bind on controller connectors as rotating clip passes controller. Make sure air harness does not bind in this position...
  • Page 159 20. Install Delrin bumper for sliding stop in threaded hole under end of outer link with 4-40 X 3/8 Steel Socket Head Cap Screw and Loctite 222. 21. Add slider for pneumatic or vacuum gripper to top of gripper and attach gripper to J4 output pulley by tightening 6 M2 SHCS after threading wires and hoses from gripper thru pulley.
  • Page 160 PreciseFlex_Robot 23. Replace outer link sheet metal belt cover, by sliding under cables from motor and inner link, but do not install screws yet. 24. Install vacuum generator as shown for vacuum-pallet gripper and for vacuum gripper. For vacuum-pallet gripper, vacuum gripper and pneumatic gripper rotate gripper until it is centered under outer link.
  • Page 161 25. Wiring and fold detail for interface board. 26. Vacuum gripper configuration with vacuum interface board. IO Cable Installed in J4 Interface/IO Board...
  • Page 162 PreciseFlex_Robot 27. Pneumatic gripper configuration 28. Dual pneumatic gripper configuration (with Rev C sheet metal, 2016) 29. After installing the appropriate gripper, check Digital Input 1 for Pneumatic Gripper open sensor, Digital Input 2 for Pneumatic Gripper close sensor, and Digital Input 4 for vacuum present sense, if these sensors are installed.
  • Page 163 Appendix A: Product Specifications PreciseFlex 400 Specifications General Specification Range Range of Motion & Resolution J1 (Z) Axis 400mm or 750mm J2 Axis ± 90 degrees J3 Axis ± 167 degrees J4 Axis +/- 970 degrees Linear Axis 1000mm, 1500mm, 2000mm Gripper Travel 74 to 133mm Spring Gripper Force...
  • Page 164 PreciseFlex_Robot PreciseFlex 3400 Specifications General Specification Range Range of Motion & Resolution J1 (Z) Axis 400mm, 750mm, 1160mm J2 Axis ± 90 degrees J3 Axis ± 167 degrees J4 Axis +/- 970 degrees with 60N servo gripper, +110/-470 with ISO mounting flange Linear Axis 1000mm, 1500mm, 2000mm Gripper Travel...
  • Page 165 Appendix B: Environmental Specifications The PreciseFlex Robots must be installed in a clean, non-condensing environment with the following specifications: General Specification Range & Features Ambient temperature 4ºC to 40ºC Storage and shipment temperature -25ºC to +55ºC Humidity range 10 to 90%, non-condensing Altitude Up to 5000m...
  • Page 166 J4 30W Motor Assembly PF04-MA-00011 J4 50W Motor Assembly (PF3400) PF04-MA-00023 J4 Belt PF00-MC-X0004 PF400 23N Servo Gripper with Spring, without fingers PF0S-MA-00001 PF400 23N Servo Gripper with Brake, without fingers PF0A-MA-00001 Fingers for PF400 Servo Gripper PF0S-MA-00010 Finger Pads for PF400 Servo Gripper...
  • Page 167 Fuse 4.0A PF00-EC-F0002 J1 Motor Interface PCA PF00-EA-00001-J1 J1 Motor Interface PCA (PF3400) PF00-EA-00001-J1IO With IO integrated J2 Motor Interface PCA PF00-EA-00001-J2 MIDS Interface PCA PF00-EA-00001-MI MIDS Interface PCA (PF3400) Connector changed J4 Motor Interface PCA PF00-EA-00001-J4 J4 Motor Interface PCA (PF3400) Connector Added Energy Dump PCA PF00-EA-00001-ED...
  • Page 168 PreciseFlex_Robot Appendix D: Preventative Maintenance Every 1 to 2 years, the following preventative Maintenance procedures should be performed. For robots that are continuously moving 24 hours per day, 7 days a week at moderate to high speeds, a one-year schedule is recommended. For robots with low duty cycles and low to moderate speeds, these procedures should be performed at least once every two years.
  • Page 169 Appendix E: Belt Tensions, Gates Tension Meter In some cases it may be desirable to confirm the belt tension of one of the axes in the robot. This is not normally required, as the robot has been designed with spring tensioners that only require loosening and then re-tightening some clamping screws to reset the belt tensions.
  • Page 170 PreciseFlex_Robot M in Mass Width Span Tension Tension Frequency Frequency Belt (g/m) (mm) (mm) Min Hz Max Hz Z S1 Z S2 Z S2 Z S2 1290 J2 CE* J2 PF3400 J3 S J3 S Hatch J4 S J4 S Hatch J3 X J3 X Hatch...
  • Page 171 Rev 4.27 16908: Updated Slip Ring with Sensor Drawing, changed serial labels to TXD and RXD Rev 5.01 170114: Updated for Rev C and 3kg robot release Rev 5.02 170608: Updated for “PF3400” product name for 3kg version of PF400 Rev 5.03 170714: Added PF3400 collision table, some more spare parts...

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