Brooks PreciseFlex 100 User Manual

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PreciseFlex

100 Robot

User Manual

Part Number 603988, Revision A

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Page 1 PreciseFlex 100 Robot User Manual Part Number 603988, Revision A...
Page 2 © 2023 Brooks Automation. All rights reserved. The information included in this manual is proprietary information of Brooks Automation, and is provided for the use of Brooks customers only and cannot be used for distribution, reproduction, or sale without the express written permission of Brooks Automation.
Page 3 Europe support_preciseflex@brooksautomation.com +81 120-255-390 (Toll Free) Japan +81 45-330-9005 (Local) http://www.brooks.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 © 2023 Brooks Automation, Inc.
Page 4 PreciseFlex 100 Robot Part Number: 603988 Rev. A Revision History Revision Date Action Author Released manual at Rev. A to follow EC144813 07/24/2023 standard Brooks technical publication M. Ashenfelder styles. Copyright © 2023 Brooks Automation, Inc.
Page 5: Table Of Contents
Voltage and Power Considerations 3. Installation Information Environmental Specifications Facilities Connections Specifications and System Dimensions Unpacking and Handling Instructions Mounting Instructions Tool Mounting Accessing the Robot Controller Power Requirements Emergency Stop 4. Hardware Reference Copyright © 2023 Brooks Automation, Inc.
Page 6 Tensioning the Z-axis Output Belt Tensioning or Replacing the Z-axis Motor and Timing Belt Replacing the Theta Axis Motor Replacing the Power Supplies or Controller Replacing the Main Harness Replacing the Servo Gripper Controller Wiring for Pneumatic Gripper Copyright © 2023 Brooks Automation, Inc.
Page 7 Replacing the Gripper Installing the Optional GIO Board Appendices Appendix A: Product Specifications Appendix B: Environmental Specifications Appendix C: Spare Parts List Appendix D: Preventive Maintenance Appendix E: Belt Tensions, Gates Tension Meter Appendix F: Facilities Panel Copyright © 2023 Brooks Automation, Inc.
Page 8: Safety
1. Safety Safety Setup Brooks uses caution, warning, and danger labels to convey critical information required for the safe and proper operation of the hardware and software. Read and comply with all labels to prevent personal injury and damage to the equipment.
Page 9: Explanation Of Hazards And Alerts
Notice indicates a situation or unsafe practice which, if not avoided, may result in equipment damage. The Notice signal word is white on blue background with no icon. Copyright © 2023 Brooks Automation, Inc.
Page 10: Alert Example
Part Number: 603988 Rev. A Alert Example The following is an example of a Warning hazard alert. Number Description How to Avoid the Hazard Source of Hazard and Severity General Alert Icon Signal Word Type of Hazard Hazard Symbol(s) Copyright © 2023 Brooks Automation, Inc.
Page 11: General Safety Considerations
Using parts with different inertial properties with the same robot application can cause the robot’s performance to decrease and potentially cause unplanned robot motion that could result in serious personal injury. Do not use unauthorized parts. Confirm that the correct robot application is being used. Copyright © 2023 Brooks Automation, Inc.
Page 12 Use of this product in a manner or for purposes other than for what it is intended may cause equipment damage or personal injury. Only use the product for its intended application. Do not modify this product beyond its original design. Always operate this product with the covers in place. Copyright © 2023 Brooks Automation, Inc.
Page 13: Mechanical Hazards
Do not operate the product without its protective covers in place. While the collaborative robotics system is designed to be safe around personnel, gravity and other factors may present hazards and should be considered. Copyright © 2023 Brooks Automation, Inc.
Page 14: Electrical Hazards
Improper electrical connection or connection to an improper electrical supply can result in electrical burns resulting in equipment damage, serious injury, or death. Always provide the robot with the proper power supply connectors and ground that are compliant with appropriate electrical codes. Copyright © 2023 Brooks Automation, Inc.
Page 15: Ergonomic Hazards
This product has a high center of gravity which may cause the product to tip over and cause serious injury. Always properly restrain the product when moving it. Never operate the robot unless it is rigidly mounted. Copyright © 2023 Brooks Automation, Inc.
Page 16 Part Number: 603988 Rev. A Trip Hazard Cables for power and communication and facilities create trip hazards which may cause serious injury. Always route the cables where they are not in the way of traffic. Copyright © 2023 Brooks Automation, Inc.
Page 17: Emergency Stop Circuit (E-Stop)
Do not override or bypass the emergency stop circuit. Recycling and Hazardous Materials Brooks Automation complies with the EU Directive 2002/96/EU Waste Electrical and Electronic Equipment (WEEE). The end user must responsibly dispose the product and its components when disposal is required.
Page 18: Introduction To The Hardware
It is also possible to use a wireless tablet or computer to access the web browser, if the controller is connected to a wireless router. Copyright © 2023 Brooks Automation, Inc.
Page 19 Ethernet or in an embedded PC inside the robot. 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. Copyright © 2023 Brooks Automation, Inc.
Page 20: System Diagram And Coordinate Systems
Table 2-1: Axis & Description of Motion Axis Description of Motion Varies with model 0 or 350 mm 229 mm XZ, or 260 mm XYZ Theta +/- 270 degrees Gripper 76 to 136 mm Copyright © 2023 Brooks Automation, Inc.
Page 22: System Components
RS 485 serial communication and an optional PreciseFlex Remote IO module. It contains two Ethernet ports. The controller and power supplies are shown in Figure 2-2. Figure 2-2: System Diagram For detailed information on the controller including interfacing information, see the Guidance 1000A/B Controllers Manual (P/N: G1X0-DI-A0010). Copyright © 2023 Brooks Automation, Inc.
Page 23: Low Voltage Power Supplies
System Components Low Voltage Power Supplies The PreciseFlex 100 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. Electrical Shock Hazard Contact with electrical power can cause death or serious personal injury.
Page 24: Remote Front Panel, E-Stop Box And Manual Control Pendant
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. Figure 2-3: E-Stop Button Figure 2-4: Manual Control Pendant Copyright © 2023 Brooks Automation, Inc.
Page 25: Optional Rs485 Io Module (Gio)
2-5) can be added at the base of the robot. This module provides 12 digital inputs and 8 digital outputs in a 25-pin Dsub connector at the robot rear panel and is connected via RS485 to the robot controller. Figure 2-5: Optional Digital IO Module (GIO) Copyright © 2023 Brooks Automation, Inc.
Page 26: 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. Brooks offers an Arm-Mounted Camera Option for certain robots. Contact sales_ preciseflex@brooksautomation.com for details.
Page 27: Machine Safety
Manual Control Mode to a maximum of 250 mm per second for safety. While the PreciseFlex 100 is a light-duty robot that can only apply approximately 120 Newtons of force (or less in collaborative mode), it is very important for operators to keep their hands, arms and especially their head out of the robot’s operating volume, when the robot is running under computer...
Page 28: Safety Zones
“uncertified zones” and the “speed restrict zones” are referred to as “certified zones”. The supported zone shapes are rectangular volumes, cylinders and spheres. To define a safety zone, the type of safety zone must be specified along with its origin and dimensions. Copyright © 2023 Brooks Automation, Inc.
Page 29 Brooks Automation 2. Introduction to the Hardware Part Number: 603988 Rev. A Machine Safety Figure 2-7: Rectangular Volume Figure 2-8: Cylinder Figure 2-9: Sphere Copyright © 2023 Brooks Automation, Inc.
Page 30 For both of these tests, in order to satisfy the computational redundancy requirement of the Category 3 safety regulations, the shapes of these safety zones are limited to non-rotated rectangular volumes. Copyright © 2023 Brooks Automation, Inc.
Page 31 Non-rotated rectangular volume, XY speed restrict zone Table 2-3 describes the safety zone DataIDs. When any of these DataIDs are modified, the controller must be rebooted for the change to be put in effect. Copyright © 2023 Brooks Automation, Inc.
Page 32 Z/XY spd mm/sec it should be a negative value and defaults to -200. The second value is the maximum permitted speed in the horizontal XY plane (when within the safety zone), and defaults to 200 mm/sec. Copyright © 2023 Brooks Automation, Inc.
Page 33: Voltage And Power Considerations
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 Copyright © 2023 Brooks Automation, Inc.
Page 34 To release the Z brake, press the brake release switch (Figure 2-10) at the rear of the Z- axis motor cover, as long as 24VDC is present. It is not necessary for motor power to be on for the brake release to work. Copyright © 2023 Brooks Automation, Inc.
Page 36: Installation Information
500 mm standard, 1090 mm option available in XYZ version 685 mm standard, 1270 mm option available in XZ version Y-axis 350 mm standard Z-axis 260 mm standard in XYZ version 229 mm standard in XZ version Theta Axis +/- 270 degrees Copyright © 2023 Brooks Automation, Inc.
Page 37 (including end effectors, operation methods, objects being handled and obstacles in the workcell) must be evaluated for safety. For more information on the evaluation of applications and workcells without safety shields, please contact Brooks. Interfaces General...
Page 38 3. Installation Information PreciseFlex 100 Robot Specifications and System Dimensions Part Number: 603988 Rev. A Figure 3-2: XYZ Robot with Gripper, Front View Copyright © 2023 Brooks Automation, Inc.
Page 39 Brooks Automation 3. Installation Information Specifications and System Part Number: 603988 Rev. A Dimensions Figure 3-3: XYZ Robot with Gripper, Side View Copyright © 2023 Brooks Automation, Inc.
Page 40 3. Installation Information PreciseFlex 100 Robot Specifications and System Dimensions Part Number: 603988 Rev. A Figure 3-4: XYZ Robot without Gripper, Front View Copyright © 2023 Brooks Automation, Inc.
Page 41 Brooks Automation 3. Installation Information Specifications and System Part Number: 603988 Rev. A Dimensions Figure 3-5: XYZ Robot without Gripper, Side View Copyright © 2023 Brooks Automation, Inc.
Page 42 3. Installation Information PreciseFlex 100 Robot Specifications and System Dimensions Part Number: 603988 Rev. A Figure 3-6: XZ Robot with Gripper Front View Copyright © 2023 Brooks Automation, Inc.
Page 43 Brooks Automation 3. Installation Information Specifications and System Part Number: 603988 Rev. A Dimensions Figure 3-7: XZ Robot with Gripper, Side View Copyright © 2023 Brooks Automation, Inc.
Page 46: Unpacking And Handling Instructions
PreciseFlex robots must be attached to a rigid surface that can withstand lateral forces of 200 Newtons without moving or vibrating. The robot X-axis has T-Slots to accommodate M4 Economy T-Nuts for mounting screws located as shown above. M4 Economy T-Nuts, PN NDM04022 are available from Buckeye Fasteners. Copyright © 2023 Brooks Automation, Inc.
Page 47: Tool Mounting
The robot’s power supplies have an input range of 100 to 240 VAC, +/- 10%, 50/60 Hz. 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. Copyright © 2023 Brooks Automation, Inc.
Page 48: Emergency Stop
The E-stop signals are available in the Manual Control Pendant 9-pin DSub connector that is mounted on the left end cap of the X-axis. See "Hardware Reference" for detailed information on the E-Stop signals. Copyright © 2023 Brooks Automation, Inc.
Page 49: Hardware Reference
The cable from the brake release button at the rear of the Z motor housing plugs into the GSB controller located near the Z motor. This button provides a ground return from the Z-axis brake to Copyright © 2023 Brooks Automation, Inc.
Page 50 Part Number: 603988 Rev. A ground bypassing the transistor that performs this function under computer power so that the brake can be released manually without motor power being enabled. Figure 4-1: PP100 Robot Electrical System Diagram Copyright © 2023 Brooks Automation, Inc.
Page 51 Brooks Automation 4. Hardware Reference System Schematics, Diagram, Part Number: 603988 Rev. A and Power Supplies Figure 4-2: Controller Power Amplifier Connectors Figure 4-3: Control Board Connectors Copyright © 2023 Brooks Automation, Inc.
Page 52 4. Hardware Reference PreciseFlex 100 Robot System Schematics, Diagram, and Power Supplies Part Number: 603988 Rev. A Figure 4-4: GSB Controller Connectors Figure 4-5: Encoder Patch Board (Discontinued when GSBs Added for Z and T axes) Copyright © 2023 Brooks Automation, Inc.
Page 56 4. Hardware Reference PreciseFlex 100 Robot System Schematics, Diagram, and Power Supplies Part Number: 603988 Rev. A Figure 4-9: AC & 24V Harness PF400 Copyright © 2023 Brooks Automation, Inc.
Page 58 4. Hardware Reference PreciseFlex 100 Robot System Schematics, Diagram, and Power Supplies Part Number: 603988 Rev. A Figure 4-11: Harness, Z-axis Motor Encoder Connector, PP100 Copyright © 2023 Brooks Automation, Inc.
Page 59 Brooks Automation 4. Hardware Reference System Schematics, Diagram, Part Number: 603988 Rev. A and Power Supplies Figure 4-12: Theta Motor Assembly, X, Y, PF400 J3 Motor Copyright © 2023 Brooks Automation, Inc.
Page 60 4. Hardware Reference PreciseFlex 100 Robot System Schematics, Diagram, and Power Supplies Part Number: 603988 Rev. A Figure 4-13: Assembly, Gripper Motor with Pigtail Copyright © 2023 Brooks Automation, Inc.
Page 61: Robot Inputs And Outputs
The maximum air pressure that can be conveyed by the air lines through the robot is 75 PSI. Applying a pressure exceeding this level may disconnect interior connections or damage fittings or hoses. If a higher pressure is required, utilize an external air line should be utilized. Copyright © 2023 Brooks Automation, Inc.
Page 62: Mcp/E-Stop Interface
Remote IO option. As such it has a dedicated protocol and is not available for general use. Figure 4-14: DB9 Female Connector Table 4-1: Pinout Description 24VDC RS232 TXD RS232 RXD RS485- E-Stop1 E-Stop Daisy Chain 48VDC RS485+ Interface Panel Connector Part No DB9 Female Connector AMP 5747150-7 Copyright © 2023 Brooks Automation, Inc.
Page 63: Digital Input Signals
DB9 Male Plug Amp 1658655-1 (crimp) Pins 22-26AWG 745254-6 Digital Input Signals The standard PreciseFlex 100 robot provides four general purpose optically isolated digital input and output signals at the X-axis end cap (in addition to those signals that are available at the Gripper Control Board). ...
Page 64: Digital Output Signals
Output 4 is configured as “sinking” i.e. the external equipment must provide a 5VDC to 24VDC pull up voltage on an output pin and the controller pulls this pin to ground when the signal is asserted as true. Copyright © 2023 Brooks Automation, Inc.
Page 65 Guidance Controller, Hardware Introduction and Reference Manual. The pinout for the fifteen Pin Dsub Digital Input and Output Connector (Figure 4-19) and the corresponding GPL signal numbers are described in Table 4-2. Copyright © 2023 Brooks Automation, Inc.
Page 66: Gripper Controller Digital Inputs And Outputs
See Table 4-3. Table 4-3: Pinout & GPL Signal Number GPL Signal Number Description 200013 Digital Output 1/LED driver 200014 Digital Output 2 200015 Digital Output 3 24VDC output Copyright © 2023 Brooks Automation, Inc.
Page 67: Rs485 Remote Io Module (Gio)
RS485 network controllers for the gripper and optional linear axis. See “"Installing the Optional GIO Board"” under "Service Procedures" for details on installing this module. The software addresses will then be as follows. Figure 4-20: DB25 Female Copyright © 2023 Brooks Automation, Inc.
Page 68 Digital Input 12 24VDC 800014 Digital Output 2 800016 Digital Output 4 800018 Digital Output 6 800020 Digital Output 8 Interface Panel Connector Part No DB25 Female Connector User Plug Part No DB25 Male Plug Copyright © 2023 Brooks Automation, Inc.
Page 69: Ethernet Interface
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. Copyright © 2023 Brooks Automation, Inc.
Page 70: Software Reference
It may be necessary to enter a password if a company has protected access to the Web Interface. Once the password has been entered, click Admin to access all the features to perform system upgrades. The window in Figure 5-2 will display. Copyright © 2023 Brooks Automation, Inc.
Page 71 Click the Disable Power button to be sure motor power is off. To load a new project (for example CAL_PP), click Unload→Perform Operation before loading the new project into RAM. Copyright © 2023 Brooks Automation, Inc.
Page 72: Loading A Project (Program) Or Updating Pac Files
See the section below on "Calibrating the Robot: Setting the Encoder Zero Positions" for an example on how to load and execute the CAL_PP program. Copyright © 2023 Brooks Automation, Inc.
Page 73: Updating Gpl (System Software) Or Fpga (Firmware)
Both GPL (the system software) and the FPGA firmware may be upgraded in the field. To perform an upgrade, follow this procedure: Step Action Get the appropriate upgrade software from Brooks in the form of a .bin file. Email support_pre- ciseflex@brooksautomation.com. In the Operator Interface, go to the Utilities/System Upgrade menu.
Page 74: Recovering From Corrupted Pac Files
Brooks 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 backup copy from Brooks. 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 75 An ftp directory screen will display. In the Page menu in Windows Internet Explorer, select Open ftp site in Windows Explorer. Another window will open showing several folders, including “Config” and “Projects.” Copyright © 2023 Brooks Automation, Inc.
Page 76: Controller Software Extensions
This section discusses extensions to the standard Guidance Controller software that are specific to the PreciseFlex 100 Robot. Brooks offers a Command Server software package that allows a PC to send high level commands to the PP100 robot. This package is available upon request.
Page 77: Controlling The Preciseflex Servo Gripper
PrecisePlace130S 140901 or later. Controlling the Gripper Brooks 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. Brooks makes this routine available to customers upon request; email support_ preciseflex@brooksautomation.com.
Page 78: Gripper Squeeze (Simple Method)
PID loop in the controller in the negative direction only. Parameter 10351 can similarly be set to limit tcnts from the PID loop in the positive direction. Since the spring compensation in the gripper is treated as a feedforward torque, these parameters do not affect the spring compensation torque. Copyright © 2023 Brooks Automation, Inc.
Page 79: Grip Test And Squeeze Check
-4300 tcnts, or about 18 N. The exact spring compensation value is stored in field 5 of Parameter 12331. For the best accuracy in determining effective squeeze force at any gripper opening, subtract this value from the value in 12304. Copyright © 2023 Brooks Automation, Inc.
Page 80: Servo Gripper Controller Digital Inputs And Outputs
GPL Signal Number Description 200013 Digital Output 1 200014 Digital Output 2 200015 Digital Output 3 (LED on Theta Cover) 24VDC output 210001 Digital Input 1 210002 Digital Input 2 210003 Digital Input 3 Copyright © 2023 Brooks Automation, Inc.
Page 81: Optional Pneumatic Or Vacuum Gripper
GPL SIGNAL.DIO instruction. This is controlled by DOUT signal 200015. If direct control of this signal is desired, DataID 235 should be set to 0 and signal number 200015 should be controlled by program control. Copyright © 2023 Brooks Automation, Inc.
Page 82: Service Procedures
If the encoder cable has been disconnected, recalibrate the robot. If the battery voltage has Down” dropped below 2.5V, replace the encoder battery and recalibrate the robot. “Encoder Joint rotated too quickly with power off. See "Encoder Operation Error" on page Operation Error” Copyright © 2023 Brooks Automation, Inc.
Page 83 20,000 hours of run time. Grease is Alvania Grease EP2 from Shell. Mechanical noise Check the joint bearings for failure. Re-tension the belt. from any joint Loud buzzing or vibration from Re-tension the timing belts. any joint Copyright © 2023 Brooks Automation, Inc.
Page 84: Encoder Operation Error
Assuming the robot has not been damaged by the shipping process, this error can be reset by the following procedure: Step Procedure Access the Web Operator Interface to the robot with either “Maintenance” or “Administrator” privileges. From the Setup menu, select System Setup→Hardware Tuning and Diagnostics→Absolute Encoder. Copyright © 2023 Brooks Automation, Inc.
Page 85: Replacing The Encoder Battery
“Absolute Encoder Down” is generated. At this point, the absolute encoder backup function will not work. Note that if any motor/encoder is disconnected from the encoder battery by disconnecting the encoder cable, the “Encoder Battery Low” or Encoder Battery Down” message will be generated. Copyright © 2023 Brooks Automation, Inc.
Page 86 Attach the new Encoder Battery to the hold down with one tie wrap and replace the second tie wrap securing the motor cables to the encoder battery. Replace the rear cover. If the error message “Encoder Battery Down” was generated, the robot must be re-calibrated after this procedure. Copyright © 2023 Brooks Automation, Inc.
Page 87: Calibrating The Robot: Setting The Encoder Zero Positions
When ready to execute the project, select Start application and click Perform Operation. 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 in "Software Reference". Copyright © 2023 Brooks Automation, Inc.
Page 88 Rotate the Theta axis back in the negative direction until the gripper housing presses against the dowel pin. If the axis springs away from the pin due to the wire harness clock spring wind up, use masking tape to hold the gripper housing against the pin. Copyright © 2023 Brooks Automation, Inc.
Page 89 Encoder Zero Positions Step Action With the CALPP application loaded, select Start Application, and then press Perform Operation. The application should start and prompt for a confirmation of the correct robot position for calibration. Copyright © 2023 Brooks Automation, Inc.
Page 90: Replacing Belts And Motors
While there are procedures at the end of this manual for replacing belts and motors, only experienced service technicians should attempt these procedures. General Belt Tensioning The PreciseFlex 100 has been designed to make belt tensioning very simple. See "Appendix E: Belt Tensions, Gates Tension Meter" on page 123 for belt tension specifications.
Page 91: Tensioning The X-Axis Belt
Run the X carriage back and forth a few times to check the belt tracking. Adjust the set screws if necessary to make sure that the yoke is parallel to the X-axis and that the belt is tracking in the pulley and not pressing against the pulley flange. Copyright © 2023 Brooks Automation, Inc.
Page 92 6. Service Procedures PreciseFlex 100 Robot Tensioning the X-axis Belt Part Number: 603988 Rev. A Step Action Tighten the M4 screws to lock down the yoke and replace the end cap and tape seals. Copyright © 2023 Brooks Automation, Inc.
Page 93: Replacing The X-Axis Motor Assembly
Install the new motor and re-assemble components using Loctite 243 to attach the motor to the motor bracket and the motor bracket to the X extrusion. Plug the motor into the controller. Re-tension the X-axis belt per instructions above. Copyright © 2023 Brooks Automation, Inc.
Page 94: Replacing The X-Axis Timing Belt
To replace the X-axis timing belt, perform the following procedure: Step Action It is not necessary to remove the Z-axis for this procedure. The Z-axis has been removed in the picture below for clarity. Copyright © 2023 Brooks Automation, Inc.
Page 95 Remove the (4) M3 X 12 mm SHCS and lock washers retain the belt clamp. Thread the new belt through the tension yoke and pulley and clamp with the belt clamp. Make sure that the belt is centered under the belt clamp. Copyright © 2023 Brooks Automation, Inc.
Page 96 Then pull the cables in the E-chain tight, mark the cables with a pen at the bracket, and then push the cables 5 mm back into the E-chain so that the cables are floating in the Echain and not stretched tight. Secure the harness with (2) tie wraps around the E-chain bracket fingers. Copyright © 2023 Brooks Automation, Inc.
Page 97: Replacing The Y-Axis Motor Or Belt Assembly
Move the Y carriage down to the X-axis. Remove the Y-axis end cap by removing the (4) M4 X 16 mm SHCS. Remove the Y-axis top cover by removing the (3) M3 X 8 mm BHCS. Copyright © 2023 Brooks Automation, Inc.
Page 98 Action Release the Y-axis belt tension and replace the motor. Re-tension the Y-axis belt per the tension table in "Appendix E: Belt Tensions, Gates Tension Meter" on page 123. Replace the cover and end cap. Copyright © 2023 Brooks Automation, Inc.
Page 99: Replacing The Y-Axis Belt Assembly (For Xy Robots Only)
Remove the AC power before replacing the Y-axis Motor or Belt. To replace the Y-axis belt, loosen the belt clamp screws on the Y-axis carriage (see Figure 6-2). Figure 6-2: Y-axis Carriage and Belt Copyright © 2023 Brooks Automation, Inc.
Page 100: Tensioning The Z-Axis Output Belt
L key. Adjust the belt tension by turning the Tension Adjustment Screw. After adjusting the tension, run the Z-axis up and down a few times using the brake release switch, then check the tension again. Copyright © 2023 Brooks Automation, Inc.
Page 101: Tensioning Or Replacing The Z-Axis Motor And Timing Belt
After adjusting the tension and tightening the screws, run the Z-axis up and down a few times using the brake release switch, and then check the tension again. Replace the Z drive plastic cover. If the motor or belt has been replaced, the robot must be re-calibrated. Copyright © 2023 Brooks Automation, Inc.
Page 102: Replacing The Theta Axis Motor
Plug in the motor connectors. Secure the motor cables in a loop around the left side of the motor where the connectors are using tie wraps so the cables are clamped tightly to the motor as shown below. Copyright © 2023 Brooks Automation, Inc.
Page 103 Brooks Automation 6. Service Procedures Part Number: 603988 Rev. A Replacing the Theta Axis Motor Step Action Replace the cover. Recalibrate the robot. Copyright © 2023 Brooks Automation, Inc.
Page 104: Replacing The Power Supplies Or Controller
If replacing the 48 Volt power supply, it is important to swap the power enable jumper from the old power supply to the replacement power supply. There is no power enable jumper on the 24 Volt supply. Copyright © 2023 Brooks Automation, Inc.
Page 105 Head Screws that attach the CPU board to the amplifier board standoffs and unplug the CPU board from the amplifier board connector. Remove the amplifier board standoffs which attach the amplifier board to the X-axis controller sheet metal standoffs. Copyright © 2023 Brooks Automation, Inc.
Page 106: Replacing The Main Harness
Recalibrate the robot. Replacing the Main Harness Replacement of the Main Robot Harness is typically only performed at the factory. The Main Robot Harness is intended to last for the life of the robot. Copyright © 2023 Brooks Automation, Inc.
Page 107: Replacing The Servo Gripper Controller
Remove the Gripper Controller by removing the (4) M3 X 8 mm SHCS and unplugging the cables. Replace the Gripper Controller and re-attach the harness. Replace the Theta Link Cover. It is not necessary to recalibrate the robot after replacing the Gripper Controller. Copyright © 2023 Brooks Automation, Inc.
Page 108 Starting January of 2013 gripper controllers are a new rev (GSB3), which replaces the address DIP switch with jumpers. To make the SW in the GSB3 work in a compatible mode with the standard PAC files, Jumper J11 must be removed. Copyright © 2023 Brooks Automation, Inc.
Page 109: Wiring For Pneumatic Gripper
Also, two air lines are connected from the X-axis end cap to the two outer Legris fittings on the bottom of the Z-axis cover, as shown in Figure 6-3 Figure 6-4. Figure 6-3: Air Line Connection Figure 6-4: Air Line Connection Copyright © 2023 Brooks Automation, Inc.
Page 110 See jumpers in Figure 6-5. Inputs and outputs are 24VDC with outputs limited to 100 mA. For pin assignments on the 25-pin Dsub, see "RS485 Remote IO Module (GIO)". Figure 6-5: GIO Jumpers, GIO_6 Copyright © 2023 Brooks Automation, Inc.
Page 111: Replacing The Gripper Spring Or Cable
Remove the Gripper Cover by removing the (4) M3 X 6 mm FHCS. Remove the spring cable assembly by unhooking it as shown in Step 3. Replace the spring cable assembly and replace the cover. Do not use Loctite on the screws. Copyright © 2023 Brooks Automation, Inc.
Page 112: Adjusting The Gripper Backlash
Loosen the (2) M3 X 8 mm LHCS clamping the rack to the finger mount. Adjust the M2 SHCS and M3 set screws to adjust the rack backlash. Remove the (2) M3 X 8 mm SHCS one at a time, apply Loctite 243 screwlock, reinstall and tighten. Copyright © 2023 Brooks Automation, Inc.
Page 113: Replacing The Gripper Harness
Replace the gripper harness clamp plate on the theta housing. Rotate theta clockwise when looking down from top of the theta until it hits hard stop. Coil gripper harness five turns around theta housing when theta is against hard stop. Copyright © 2023 Brooks Automation, Inc.
Page 114: Replacing The Gripper
The gripper is tightly integrated into the theta housing to conserve space. Therefore replacing the gripper only is not a recommended field service procedure. If the gripper motor fails for any reason, the entire gripper theta assembly should be replaced. To replace the gripper, perform the following procedure: Copyright © 2023 Brooks Automation, Inc.
Page 115 Remove the entire Theta/Gripper assembly by loosening the (4) M3 X 10 mm SHCS 2 turns and sliding the assembly up and out of the T slots in the Z-axis extrusion. Install a new assembly and re-assemble. Recalibrate the robot. Copyright © 2023 Brooks Automation, Inc.
Page 116: Installing The Optional Gio Board
Part Number: 603988 Rev. A Installing the Optional GIO Board Brooks sells a digital IO board that provides 12 inputs and 8 outputs as an option; email sales_ preciseflex@brooksautomation.com. This board may be installed on the rear cover of the X-axis if desired.
Page 117 Inputs and outputs are 24VDC with outputs limited to 100mA. For pin assignments on the 25 pin Dsub, see “RS485 Remote IO Module (GIO”. Figure 6-6: GIO Option Installed Figure 6-7: GIO Board Installed Copyright © 2023 Brooks Automation, Inc.
Page 118: Appendices
Four optically isolated 5-24V inputs, four optically isolated 24V outputs at 100ma available on facilities panel at end cap. Digital I/O Channels Additional 12 isolated inputs and 8 isolated outputs available as option at back panel. Remote I/O is also available. Copyright © 2023 Brooks Automation, Inc.
Page 119 The robot’s power supplies have an input range of 100 to 240 Required Power VAC, +/- 10%, 50/60 Hz. 200 Watts typical 400 watts maximum Weight, XZTG version 22 kg for 635 mm travel version, 32 kg for 1270 mm version Copyright © 2023 Brooks Automation, Inc.
Page 120: Appendix B: Environmental Specifications
100-240 VAC +/- 10%, 50/60 Hz Mains cord rating, min 18AWG, 3 conductor, 5 Amps min Pollution Degree Approved Cleaning Agents IPA, 70% Ethanol/30% water, H2O2 Vapor up to 1000 ppm IP rating IK impact rating IK08: 5 Joule Copyright © 2023 Brooks Automation, Inc.
Page 121: Appendix C: Spare Parts List
G1100T Slave Controller SE (“GSB3”) G1X0-EA-T1101 G1100T Slave Controller Diff (“GSB3”) G1X0-EA-T1101-4D GIO Digital IO Board with pigtails GIO1-EA-01104 24VDC Supply PS10-EP-00125 48VDC Motor Supply PS10-EP-48365 Estop Box PP10-EA-00022 Pendant PP10-EA-00013 Harness, Gripper PP0H-MA-00001 Encoder Wiring PCA PP1C-EA-00001 Copyright © 2023 Brooks Automation, Inc.
Page 122: Appendix D: Preventive Maintenance
Every year Check belt tension all belts, re-tension if necessary Every year Check all joints in “free mode” for low bearing friction Every three years Replace all timing belts for high duty cycle applications Copyright © 2023 Brooks Automation, Inc.
Page 123: Appendix E: Belt Tensions, Gates Tension Meter
Figure 7-1: Gates Sonic Tension Meter, Model 507 C To use the tension meter, follow this procedure: Step Action Turn on the power. Click the Mass button. Enter the belt mass from the table below. Copyright © 2023 Brooks Automation, Inc.
Page 124 Gently pluck the belt so that it vibrates. 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 © 2023 Brooks Automation, Inc.
Page 125: Appendix F: Facilities Panel
Appendix F: Facilities Panel Appendix F: Facilities Panel The Facilities Panel on the left end cap includes: System AC input power receptacle Lighted AC on/off power switch Connectors for controller input and output signals Copyright © 2023 Brooks Automation, Inc.

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