Page 1 PFDD4 PFDD6 PreciseFlex™ DDR Collaborative Robots Hardware Introduction and Reference Manual P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022...
Page 2 © 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.
Page 3 +49 364 176 9999 6 (Has Toll) +81 120-255-390 (Toll Free) Japan +81 45-330-9005 (Local) http://www.preciseautomation.com China +86 21-5131-7066 +886 080-003-5556 (Toll Free) Taiwan +886 3-5525258 (Local) Korea 1800-5116 (Toll Free) +65 1-800-4-276657 (Toll Free) Singapore +65 6309 0701 (Local) Copyright © 2022, Brooks Automation, Inc.
Page 4 2. PAC file and GPL update changed for Windows 10. 3. Added unpacking instructions. Working draft Rev 1.4 Dec. 28, 2021 1. Environmental spec updated. 2. Minor edits Rev 5.0.0 April 9, 2022 Working draft. first version as Brooks Copyright © 2022, Brooks Automation, Inc.
Page 5 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 Copyright © 2022, Brooks Automation, Inc.
Page 6: Table Of Contents
Verification of PFDD Collision Force Robot Workcell Design Appendix A: Example Performance Level Evaluation for PFDDR, Update for PFDD example 31 Appendix B: Table A2 from ISO/TS 15066: 2016 Appendix C: Safety Circuits for PFDD Robots Copyright © 2022, Brooks Automation, Inc.
Page 7 Loading a Project (Program) or Updating PAC Files Updating GPL (System Software and Firmware) Recovering from Corrupted PAC Files Gripper Support _____________________________________________________________ 82 Gripper Introduction Controlling the Precise Servo Grippers Servo Gripper Controller Digital Inputs and Outputs Copyright © 2022, Brooks Automation, Inc.
Page 8 Replacing the J4 slave controller in the PFDD6 Replacing the J4 to J5 Controller Harness, the J5 to J6 Controller Harness, OR the J5 OR J6 slave controller in the PFDD6 Replacing the J6 Motor Pigtail Harness Copyright © 2022, Brooks Automation, Inc.
Page 9 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 Copyright © 2022, Brooks Automation, Inc.
Page 10: Introduction To The Hardware
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. Copyright © 2022, Brooks Automation, Inc.
Page 11: Release History
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 Copyright © 2022, Brooks Automation, Inc.
Page 12: System Diagram And Coordinate Systems
“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. Copyright © 2022, Brooks Automation, Inc.
Page 13 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. Copyright © 2022, Brooks Automation, Inc.
Page 14: System Diagram
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. Copyright © 2022, Brooks Automation, Inc.
Page 15: Power Supplies And Power Considerations
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 Copyright © 2022, Brooks Automation, Inc.
Page 16: Energy Dump Circuit
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. Copyright © 2022, Brooks Automation, Inc.
Page 17: Remote Io Module (Ethernet Version)
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. Copyright © 2022, Brooks Automation, Inc.
Page 18: Machine Safety
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. Copyright © 2022, Brooks Automation, Inc.
Page 19: Mechanical And Software Limit Stops
1.0 sec allows the servos to decelerate the robot. The servos are set to decelerate the robot at 0.015G, or 150mm/sec . If the robot is moving at a joint speed of 100 Copyright © 2022, Brooks Automation, Inc.
Page 20: Releasing A Trapped Operator: Brake Release Switch
Note the J4 and J5 brakes on the PFDD6 are not released by the brake release switch to prevent unexpected sagging of the payload. Copyright © 2022, Brooks Automation, Inc.
Page 21: Collaborative Robot Safety
2016 by ISO/TS 15066 “Robots and Robotic Devices – Collaborative Robots”. “Collaborative Operation” is defined in section 3.4 of 10218:1:2011 as “a state in which purposely designed robots work in direct cooperation with a human within a defined workspace”. Copyright © 2022, Brooks Automation, Inc.
Page 22 An example of determining PL for a PFDDR workcell is given in Appendix A of this section, where it is shown that a PL of “b” is sufficient for the workcell. UPPDATE with DDR example. Figure 1 Copyright © 2022, Brooks Automation, Inc.
Page 23 35N, the neck must be compressed 3.5mm to reach this force, while in the case of the hand, which has an impact force pain threshold of 180N, the compression distance is less, at 2.4mm even though the force is much higher. Copyright © 2022, Brooks Automation, Inc.
Page 24 1. Clamping/squeezing force. This is the quasi-static case of the robot pressing a compliant part of the human body against a surface. This force should be considered when the robot is under manual control and for low speed collisions. Copyright © 2022, Brooks Automation, Inc.
Page 25: Robot Testing And Safety Circuits
Impact force against a rigid surface (trapping) is measured by moving the robot at speeds up to its maximum permitted speed and payload with the compliance plate impacting the force sensor when the Copyright © 2022, Brooks Automation, Inc.
Page 26 For all axes except the Z axis, the maximum forces that can be applied by the motors, multiplied by the transmission are well under 140N as can be seen in the manual control and low speed collision table entries. Copyright © 2022, Brooks Automation, Inc.
Page 27 This can be demonstrated by dropping the CPU into debug mode via the serial debug port which simulates a software crash. This will disable motor power. TUV has verified this fail- safe operation. Copyright © 2022, Brooks Automation, Inc.
Page 28: Test Procedure For The Pfdd Robots
Z direction at various speeds and crashes into the hand simulator attached to the force gage. For the Horizontal tests the robot is driven horizontally at various speeds into the hand Copyright © 2022, Brooks Automation, Inc.
Page 29: Verification Of Pfdd Collision Force
P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 simulator. For both vertical and horizontal tests, the force gage is fixed for rigid surface testing, and floating on a linear bearing rail for free space collision testing. Verification of PFDD Collision Force Copyright © 2022, Brooks Automation, Inc.
Page 31: Appendix A: Example Performance Level Evaluation For Pfddr, Update For Pfdd Example
S is S1, as possible operator collision forces will not injure operators. F is F1 as normal operation does not involve collisions with robot. P is P1 as the robot does not make unexpected motions Copyright © 2022, Brooks Automation, Inc.
Page 32 P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 So PL is “a”, and even a Category B controller is sufficient, given the low speeds and small possible collisions forces involved which cannot injure an operator. (See 5.2.3 under EN/ISO 10218-1:2011). Copyright © 2022, Brooks Automation, Inc.
Page 33: Appendix B: Table A2 From Iso/Ts 15066: 2016
Brooks Automation Collaborative Robot Safety P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 Appendix B: Table A2 from ISO/TS 15066: 2016 Copyright © 2022, Brooks Automation, Inc.
Page 35: Appendix C: Safety Circuits For Pfdd Robots
Brooks Automation Collaborative Robot Safety P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 Appendix C: Safety Circuits for PFDD Robots Copyright © 2022, Brooks Automation, Inc.
Page 37: Installation Information
System AC input power receptacle 90 to 265VAC • Lighted AC on/off power switch • Connectors for controller input and output signals • Two air fittings for 1/8in OD air hoses 70 psi max Copyright © 2022, Brooks Automation, Inc.
Page 38: System Dimensions
Installation Information PreciseFlex™ DDR Collaborative Robots P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 System Dimensions All dimensions are in millimeters. Copyright © 2022, Brooks Automation, Inc.
Page 44: Mounting Instructions
J4 housing, which is covered by the J4 foam cover. The J5 and J6 controllers are located inside the J5 housing. Details on accessing these controllers can be found in the service section. Copyright © 2022, Brooks Automation, Inc.
Page 45: Power Requirements
IEC electrical socket that accepts country specific electrical cords. Power requirements vary with the robot duty cycle, but do not exceed 700 watts RMS. Typical operating power is 150 to 300 watts RMS. Copyright © 2022, Brooks Automation, Inc.
Page 46: Hardware Reference
24VDC is turned on. Care should be taken to support the links of the robot when this button is pushed as the links weigh 14kg and will drop under gravity when this button is pushed. Copyright © 2022, Brooks Automation, Inc.
Page 63 Brooks Automation Hardware Reference P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 Wiring for J5, J6 motors, 6-axis PFD0 (Note J6 motor is 50WT, no brake Copyright © 2022, Brooks Automation, Inc.
Page 65: Facilities Panel
System AC input power receptacle 90 to 265VAC • Lighted AC on/off power switch • Connectors for controller input and output signals • Two air fittings for 1/8in OD air hoses 75 psi max Copyright © 2022, Brooks Automation, Inc.
Page 66: E-Stop Connector
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 Copyright © 2022, Brooks Automation, Inc.
Page 67: Mcp / E-Stop Interface
FORCE ESTOP_L2 (Toggles ESTOP Low at Start Up, Then High) RS232 (Com2) Interface Panel DB9 Female Connector AMP 5747150-7 Connector Part No User Plug Part No DB9 Male Plug Amp 1658655-1 (crimp) Pins 22-26AWG 745254-6 15 Pin D-Sub Signals Description 24VDC 48VDC Copyright © 2022, Brooks Automation, Inc.
Page 68: Digital Input And Output Signals
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”. Copyright © 2022, Brooks Automation, Inc.
Page 69 (See above.) As shipped from the factory, the output signals are configured as "sourcing", i.e. the external equipment must pull down an output pin to ground and the controller pulls this pin to 24VDC when the signal is asserted as true. Copyright © 2022, Brooks Automation, Inc.
Page 70 24VDC when the signal is asserted as true. The pin out for the PFDD Digital Input and Output Connector and the corresponding GPL signal numbers are described in the following table. Copyright © 2022, Brooks Automation, Inc.
Page 71: 25 Pin D-Sub Signals
The digital inputs are each connected directly to Analog to Digital Converter inputs in the CPU, so they can be set by SW for 0-10VDC analog inputs (future feature) or 24VDC digital inputs (current release). Copyright © 2022, Brooks Automation, Inc.
Page 72: Ethernet Interface
If a camera is mounted in the workcell, an external Ethernet switch must be added to connect these cameras and the robot to a PC. See the Setup and Operation Quick Start Guide for instructions on setting the IP address for the controller. Copyright © 2022, Brooks Automation, Inc.
Page 73: Rs-232 Serial Interface
3 to a line that goes back to a CPU serial input where it is multiplexed onto RS485 to connect back the main controller COM1 input. Serial data rate is limited to 9600 baud. (Not available in beta units) J4 and J7 on GSB Board Copyright © 2022, Brooks Automation, Inc.
Page 74 1. Keyence SR750, 1D and 2D, 24VDC supply, 200ma, 60mm distance. 2. Cognex DM50, DM60, DM70, 24VDC supply, 500ma, 45 to 110mm distance 3. Omron/Microscan MiniHawk, 1D and 2D, 5VDC supply, need converter from 24VDC Copyright © 2022, Brooks Automation, Inc.
Page 75: Software Reference
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. Copyright © 2022, Brooks Automation, Inc.
Page 76 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”. This will stop the application from running. You Copyright © 2022, Brooks Automation, Inc.
Page 77: Loading A Project (Program) Or Updating Pac Files
PAC files into the “Config” folder. These files will all have a .pac extension. Wait at least 15 seconds after the copy is complete before turning off the controller. The robot must be re-booted after new PAC files are installed for them to take effect. Copyright © 2022, Brooks Automation, Inc.
Page 78: Updating Gpl (System Software And Firmware)
Obtain the appropriate upgrade software from Precise, in the form of a .gz file. 2. Use the Windows 10 File Explorer (NOT the Web Explorer) to access the ROMDISK GPL storage area directly. Type "ftp://192.168.0.1/ROMDISK/bin" in the File Explorer address line. Copyright © 2022, Brooks Automation, Inc.
Page 79: Recovering From Corrupted Pac Files
The Flash RAM requires some time for a complete write cycle. During the write cycle, the console will display a flashing warning not to turn off robot power. If robot power is turned off during Copyright © 2022, Brooks Automation, Inc.
Page 80 3. Move Jumper J9 (System Reset) so that it connects the two jumper posts. This will cause the factory default configuration files to be loaded at controller boot up. 4. Cycle robot power to reboot the controller. 5. Follow the procedure above for updating PAC files. Copyright © 2022, Brooks Automation, Inc.
Page 83 GPL program using the Controller.PDbNum instruction. For the 23N gripper the formula for determining the approximate gripper squeeze is 7N +( Rated Current/1.26Amps)X18N for squeeze and ( Rated Current/1.26Amps)X18N –9N for gripper opening force. Copyright © 2022, Brooks Automation, Inc.
Page 84 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 Copyright © 2022, Brooks Automation, Inc.
Page 85: Servo Gripper Controller Digital Inputs And Outputs
RXD input. For J7 connect pins 2 and 3 to connect Digital Output 3 to pin 3 and connect pins 1 and 2 to connect pin 3 to a line that goes back to the controller RS232 TXD input. Copyright © 2022, Brooks Automation, Inc.
Page 86 Digital Output 3 (LED Output or TXD, select with J7) 24 VDC output Digital Input 1 (Pushbutton on some Electric Grippers 410001 or RXD, select with J4) 410002 Digital Input 2 (End of travel sensor option) 410003 Digital Input 3 Copyright © 2022, Brooks Automation, Inc.
Page 87: Optional Pneumatic Or Vacuum Gripper
400013. It can be toggled manually from the operator interface as shown below by clicking on the radio button, which will bring up the IO control panel shown below. In GPL it may be controlled with the Signal.DIO command. See the schematics section for solenoid wiring. Copyright © 2022, Brooks Automation, Inc.
Page 88 600013, as the valve is controlled from the J6 controller. In a similar manner to the 4-axis robot, simple electric grippers can be attached to the output flange of the 6-axis robot, by plugging into the DIO connector. Copyright © 2022, Brooks Automation, Inc.
Page 89 PFDD4, a special flange adapter with a notch to route the gripper cable back inside the J4 output pulley is required in order to route the cable up to the J4 controller in the PFDD4 outer link. Copyright © 2022, Brooks Automation, Inc.
Page 90 Signal.DIO(OpenSignal) = True Thread.Sleep(500) End Sub Public Sub SchunkClose Move.WaitForEOM() Signal.DIO(OpenSignal) = False Thread.Sleep(80) Signal.DIO(CloseSignal) = True Thread.Sleep(500) End Sub Public Sub SchunkReset Signal.DIO(OpenSignal) = True Thread.Sleep(80) Signal.DIO(CloseSignal) = True Thread.Sleep(2000) Signal.DIO(OpenSignal) = False Thread.Sleep(80) Copyright © 2022, Brooks Automation, Inc.
Page 91: Ethernet Connector In The Outer Links
100BaseT Ethernet from the main control board in the base of the robot to the outer link. Users may wish to connect a standard Ethernet connector to the Ethernet Pigtail. Connection details are given below for the mating connector. Copyright © 2022, Brooks Automation, Inc.
Page 92: Service Procedures
Joint rotated too quickly with power off. See Procedure below. Encoder cable may be damaged and encoder is getting “Encoder Data, Accel/decel Limit intermittent communication, causing apparent jumps in Error” position. Check encoder connectors. Replace motor/encoder or encoder only on DD axes. Copyright © 2022, Brooks Automation, Inc.
Page 93: Encoder Operation Error
J1 and J3 axes have single turn absolute encoders and do not require standby batteries. In standby mode, there is a limit on how quickly the motor can turn and still have the standby counter Copyright © 2022, Brooks Automation, Inc.
Page 94 4. For cases where the encoder operation error was triggered by shipping vibration, IN MOST CASES the encoder will not have lost any position data. However, after homing the robot it is a good idea to move the robot to the calibration position (using Copyright © 2022, Brooks Automation, Inc.
Page 95: Replacing The Encoder Batteries
“Encoder Battery Low” or Encoder Battery Down” message will be generated. However, in this case the encoder battery does not need to be replaced. It is only necessary to re-calibrate the robot, see below. Copyright © 2022, Brooks Automation, Inc.
Page 96 To replace the Encoder Battery in the 4-axis outer link the user must: 1. Remove the outer link foam cover from the sides of the outer link. It is attached with Velcro. 2. Remove the outer link top foam cover. It is attached with Velcro. Copyright © 2022, Brooks Automation, Inc.
Page 97: Calibrating The Robot: Setting The Encoder Zero Positions
CALPP_RevXX. When you are ready to execute the Project, press "Start". If CALPP is not loaded in the robot, first Load Cal_PP into the controller’s memory from a PC, using the web Operator Control Panel, as described above in the Software Reference Section. Copyright © 2022, Brooks Automation, Inc.
Page 98 6. Rotate J3 CCW when viewed looking down until its hard stop. 7. Start CAL_PP_XX 8. For the PFDD4 Rotate J4 CCW when viewed looking down until its hard stop. 9. For the PFDD6 position the robot following the steps below. Copyright © 2022, Brooks Automation, Inc.
Page 100 Service Procedures PreciseFlex™ DDR Collaborative Robots P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 CALPP Position PFDD6 Step Two CALPP Position PFDD6 Step Three Copyright © 2022, Brooks Automation, Inc.
Page 101 P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 CALPP Position PFDD6 With Gripper 10. With the CALPP application loaded, press “Start”. a. Application should start and prompt user to confirm correct robot position for calibration Copyright © 2022, Brooks Automation, Inc.
Page 102: Replacing Belts And Motors
In most cases, if a belt or a motor needs to be replaced, the robot should be returned to the factory. While there are procedures in this manual for replacing belts and motors, only experienced service technicians should attempt these procedures. Copyright © 2022, Brooks Automation, Inc.
Page 103: General Belt Tensioning
4. Measure the tension with the belt tension meter as described in Appendix E. Adjust the M5 Tension Screw. 6. After adjusting the Tension Screw, the M5 locking screws should be tightened to lock the assembly in place and the Rear Cover should be replaced. Copyright © 2022, Brooks Automation, Inc.
Page 104: Tensioning The 2Nd Stage Belt
AC power should be disconnected. Removing the rear cover allows access to the AC power terminals. Tools Required: 1. Gates Sonic Belt Tension Meter, Model 508C 2. 2.0mm hex driver or hex L wrench 3. 3.0mm hex driver 4. 4.0mm ball end hex Copyright © 2022, Brooks Automation, Inc.
Page 105: Replacing The Z Column Stage One Timing Belt
500mm, in order to get a higher frequency on the belt, which can be easier to measure with the tension meter. Use the 500mm span in this case. Replacing the Z column Stage One Timing Belt DANGER: Before replacing the power supplies, the AC power should be removed. Copyright © 2022, Brooks Automation, Inc.
Page 106 4. If present, remove the tape seal brackets. It may be necessary to release the tension on the tape seals first. In this case, slide the top plate laterally after removing screws from the top plate and front cover to release the tension on the tape seals Copyright © 2022, Brooks Automation, Inc.
Page 107: Replacing The Z Column Stage Two Timing Belt
1. Move the Z carriage to 640mm height for the 1000mm and 1420mm Z travel robots, or 380mm height for the 500mm Z travel robot. 2. Turn off the robot power and remove the AC power cord. 3. Remove the curved rear cover from the Z column. Copyright © 2022, Brooks Automation, Inc.
Page 108: Tensioning Or Replacing The Belts In The Pfdd4
Tensioning or Replacing the Belts in the PFDD4 Tensioning the Belts in the PFDD4 Outer Link DANGER: Before tensioning the timing belts, the AC power should be disconnected. Removing the front cover allows access to the AC power terminals. Copyright © 2022, Brooks Automation, Inc.
Page 109: Replacing The Belts In The Pfdd4 Outer Link
7. Replace the covers. Replacing the Belts in the PFDD4 Outer Link DANGER: Before replacing the timing belts, the AC power should be disconnected. Removing the front cover allows access to the AC power terminals. Copyright © 2022, Brooks Automation, Inc.
Page 110 5. Pulley the Stage Two Belt up over the idler pully shaft, then remove by pulling out thru the top of the outer link over the output pulley. 6. Replace parts, re-tension the belts, replace covers. 7. Recalibrate the robot. Copyright © 2022, Brooks Automation, Inc.
Page 111: Replacing The Outer Link Motors Or Harmonic Drives In The Pfdd6
J5 housing. 4. Remove the J5/J6 axes from J4 by removing 8 M4 X 8 SHCS. 5. At this point the J5/J6 assembly may be returned to the factory and a new assembly attached. Copyright © 2022, Brooks Automation, Inc.
Page 112: Replacing The Robot Main Controller
PAC files (config directory), any project files (projects directory), and the “Sys” files (sys directory), to a PC. These files can be copied using ftp://192.168.0.1/flash or the IP address of the controller. To replace the Robot Controller the user must: Copyright © 2022, Brooks Automation, Inc.
Page 113 6. Reload the robot PAC files (config directory), any project files (projects directory), and the “Sys” files (sys directory), from a PC. These files can be copied using ftp://192.168.0.1/flash or the IP address of the controller. Copyright © 2022, Brooks Automation, Inc.
Page 114: Replacing The Z Axis Slave Controller
3. Remove the Gripper Controller by removing 4 M3 X 10mm SHCS and unplugging the cables. 4. Replace the Slave Controller and re-attach the harness. 5. Set the jumpers correctly for the address and termination. 6. Replace the curved rear cover. 7. Recalibrate the robot. Copyright © 2022, Brooks Automation, Inc.
Page 116: Replacing The J3 Axis Slave Controller
4. Replace the Slave Controller and re-attach the harness. 5. Set the jumpers correctly for the address and termination. 6. Replace the LED light tower parts. 7. It is not necessary to recalibrate the robot if only this controller is replaced. Copyright © 2022, Brooks Automation, Inc.
Page 117: Replacing The J4 Or Gripper Slave Controller In Pfdd4
2. Remove the foam side cover from the outer link. It is attached with Velcro. 3. Remove the foam top cover from the outer link. It is attached with Velcro. 4. Remove the sheet metal cover from the outer link. 5. Replace the slave controller (GSBP). Copyright © 2022, Brooks Automation, Inc.
Page 118 PreciseFlex™ DDR Collaborative Robots P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 6. Set the jumpers correctly for the address and termination. 7. Recalibrate the robot. 8. Replace the covers. GSBP for J4 Axis, PFDD4 Copyright © 2022, Brooks Automation, Inc.
Page 119: Replacing The Gripper And Slip Ring In Pfdd4
Spare Part Required: 23N Servo Gripper with Spring Return PF0S-MA-00001 2. Slip Ring for 23N Servo Gripper with Spring Return PF04-MA.00010 To replace the 23N Servo Gripper or Slip Ring in the PFDD4 the user must: Copyright © 2022, Brooks Automation, Inc.
Page 120 7. At this point you may replace the gripper or the slip ring. 8. Reassemble parts, be careful not to pinch the slip ring cable, it fits in notch in flange. The robot does not need to be recalibrated after changing the slip ring or gripper. Copyright © 2022, Brooks Automation, Inc.
Page 121: Replacing The Gripper Spring Or Cable
1. Remove the Gripper Cover by removing 4 or 6 M2 X 6mm FHCS (depends on model). 2. Remove the spring cab le assembly by removing the M3 screws shown below. 3. Replace the spring cable assembly and replace the cover. Copyright © 2022, Brooks Automation, Inc.
Page 122: Adjusting The Gripper Backlash Or Centering Fingers
3. Move the racks back and forth to determine which rack has backlash and where it is located on the rack. 4. Loosen the 2 M3 X 8 SHCS clamping the rack to the finger mount. Copyright © 2022, Brooks Automation, Inc.
Page 124: Replacing The Main Harness
2. 2.5mm hex driver Spare Parts Required: J3 Clock Spring Harness PN PFD0H-MA-00021 To replace the harness the user must: 1. Remove the LED light tower and J3 Slave Controller per instructions for these assemblies. Copyright © 2022, Brooks Automation, Inc.
Page 125 5. For the PFDD6, simply remove the J4 foam end cover, and unplug the J4 end of the clockspring harness from the J4 slave amp (GSBP). 6. Remove the air hose clamp plate and thru hole bushing, and pull air hose up thru J3. Copyright © 2022, Brooks Automation, Inc.
Page 127: Replacing The J4 To Gripper Controller Harness In The Pfdd4
J3 slave amp does not require an external battery. Replacing the J4 to Gripper Controller Harness in the PFDD4 Tools Required: 1. 2.0mm hex driver 2. 2.5mm hex driver Spare Parts Required: Harness PN PFD0H-MA-00017 Copyright © 2022, Brooks Automation, Inc.
Page 128: Replacing The J4 Slave Controller In The Pfdd6
2. Remove the J4 controller mount plate from the bottom of J4. 3. Unplug the J3 to J4 harness and the J4 to J5 harness and the motor connectors. 4. Replace the J4 slave controller (GSBP). 5. Replace the parts. 6. Recalibrate the robot. Copyright © 2022, Brooks Automation, Inc.
Page 129 2. Slave controller PN G6X0-EA-00202 for J4 axis (20A, differential encoder) To replace these items the user must: Remove the foam side cover from J5, the foam end cover from J4 and the J5 cover plate. Copyright © 2022, Brooks Automation, Inc.
Page 132 Service Procedures PreciseFlex™ DDR Collaborative Robots P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 J5 Slave Controller (GSBP) Jumpers J6 Slave Controller (GSBP) Jumpers Copyright © 2022, Brooks Automation, Inc.
Page 133: Replacing The J6 Motor Pigtail Harness
1. Remove the foam side cover from J5, the IO harness bracket, and the J5 cover plate, threading the J6 motor pigtail harness thru the 25mm bearing. 2. Remove the J6 cover plate, replace the harness, tie wrap per below, replace parts. 3. Recalibrate the robot. Copyright © 2022, Brooks Automation, Inc.
Page 135: Appendix A: Product Specifications
The PFDD robots power supplies have an input range of 100 to 240 VAC, Required Power +/- 10%, 50/60 Hz. 700 watts peak maximum, 150-200 watts rms typical 43 kg for 500mm travel version, 53 kg for 1000mm version, 63 kg for Weight 1420mm version Copyright © 2022, Brooks Automation, Inc.
Page 136 The PFDD robots power supplies have an input range of 100 to 240 VAC, Required Power +/- 10%, 50/60 Hz, 700 watts peak maximum, 150-200 watts rms typical 45 kg for 500mm travel version, 55 kg for 1000mm version, 65 kg for Weight 1420mm version Copyright © 2022, Brooks Automation, Inc.
Page 137: Appendix B: Environmental Specifications
16AWG, 3 conductor, 10 Amps min Pollution Degree Approved Cleaning Agents IPA, 70% Ethanol/30% water, H2O2 Vapor up to 1000ppm IP Rating with Tape Seal Option IP Rating without Tape Seal Option IK Impact Rating IK08: 5 joule Copyright © 2022, Brooks Automation, Inc.
Page 138: Appendix C: Spare Parts List
24 VDC Supply PS10-EP-24150 48 VDC Motor Supply PS10-EP-481000 Slip Ring Harness Assembly, 23N Spring Gripper PF04-MA-00010 18Wire Solenoid Valve PF05-MC-X0001 Energy Dump Resistor Assembly PFD0-MA-00024 O-Rings for Front Cover dowel pins (2) 0000-HC-X0051 Copyright © 2022, Brooks Automation, Inc.
Page 140: Appendix D: Preventative Maintenance
Replace slip ring in DD4 if For units with 23N electric replace the slip ring every third inspection present test, or 20,000 hours of operation. Copyright © 2022, Brooks Automation, Inc.
Page 141: Appendix E: Belt Tensions, Gates Tension Meter
The tension meter will calculate the belt tension from the acoustic vibrations and display the tension in Newtons. Compare the tension to the table below. Adjust the belt tension preload screws if necessary. Copyright © 2022, Brooks Automation, Inc.
Page 143: Appendix F: Unpacking The Robot
Brooks Automation Appendix F: Unpacking the Robot P/N: PFD0-DI-00010, Rev 5.0.0, April 9, 2022 Appendix F: Unpacking the Robot Copyright © 2022, Brooks Automation, Inc.

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