Brooks PreciseFlex c10 Service Manual

Collaborative robots

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PreciseFlex

c10

PreciseFlex

c8A

PreciseFlex

c10 and c8A Collaborative Robots

Service Manual

Part Number 629016, Revision A

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Page 1 PreciseFlex PreciseFlex PreciseFlex c10 and c8A Collaborative Robots Service Manual Part Number 629016, Revision A...
Page 2 © 2024 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 Japan +81 45-330-9005 (Local) https://www.brooks.com/contact-us/ 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) Contact Technical Publications directly: Technical.Publications@brooks.com Accelerating Innovation Copyright © 2024, Brooks Automation...
Page 4: Revision History
PreciseFlex c10-c8A Service Manual Part Number: 629016 Rev. A Brooks Automation 15 Elizabeth Drive Chelmsford, MA 01824-2400 Tel: +1 978-262-2400 Fax: +1 978-262-2500 www.brooks.com Brooks Locations Worldwide: Brooks Japan K.K. KUMAMOTO SERVICE OFFICE 202 Mirai Office II Brooks Automation 312-1 Tatsudamachi Yuge...
Page 5 Brooks Automation Part Number: 629016 Rev. A Revision Date Action Author Released manual at Rev. A EC154168 April 24, 2024 to follow standard Brooks M. Ashenfelder technical publication styles. Copyright © 2024, Brooks Automation...
Page 6: Table Of Contents
PreciseFlex c10-c8A Service Manual Part Number: 629016 Rev. A Table of Contents 1. Safety Safety Setup Authorized Personnel Only Explanation of Hazards and Alerts Safety Text Safety Icons Signal Words and Color Alert Example General Safety Considerations Mechanical Hazards Electrical Hazards...
Page 7 Appendix I: Belt Tensions, Gates Tension Meter Appendix J: Example Performance Level Evaluation Normal Operator Interaction with Robot: Possible Low Frequency (rare) Interaction with Robot: Appendix K: Table A2 from ISO/TS 15066: 2016 Biomechanical Force and Pressure Limits Copyright © 2024, Brooks Automation...
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 © 2024, Brooks Automation...
Page 10: Alert Example
1. Safety PreciseFlex c10-c8A Service Manual Explanation of Hazards and Alerts Part Number: 629016 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...
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 © 2024, Brooks Automation...
Page 12 1. Safety PreciseFlex c10-c8A Service Manual General Safety Considerations Part Number: 629016 Rev. A Magnetic Field Hazard This product contains magnetic motors that can be hazardous to implanted medical devices, such as pacemakers, and cause personal harm, severe injury, or death.
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 © 2024, Brooks Automation...
Page 14: Electrical Hazards
1. Safety PreciseFlex c10-c8A Service Manual Electrical Hazards Part Number: 629016 Rev. A Vibration Hazard As with any servo-based device, the robot can enter a vibratory state resulting in mechanical and audible hazards. Vibration indicates a serious problem. Immediately remove power.
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 © 2024, Brooks Automation...
Page 16 1. Safety PreciseFlex c10-c8A Service Manual Ergonomic Hazards Part Number: 629016 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.
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 of the product and its components when disposal is required.
Page 18: Service Procedures
2. Service Procedures PreciseFlex c10-c8A Service Manual Recommended Tools Part Number: 629016 Rev. A 2. Service Procedures Recommended Tools The following tools are recommended for these service procedures: 1. Gates Sonic Belt Tension Meter, Model 507C for checking timing belt tension 2.
Page 19: Encoder Operation Error
AC power to the robot is disconnected. There are batteries in the back of the Z column of the robot and outer link that provides standby power to the encoders for the Z Copyright © 2024, Brooks Automation...
Page 20 2. Service Procedures PreciseFlex c10-c8A Service Manual Encoder Operation Error Part Number: 629016 Rev. A axis and outer link motors. J1, J3, and J4 on the c10 axes have single turn absolute encoders and do not require standby batteries. However, if a 60 N servo gripper is installed on the c10, the GSB4 associated with this gripper will be mounted in the outer link and will need a battery installed.
Page 21: Replacing The Encoder Batteries
However, in this case the encoder battery does not need to be replaced. It is only necessary to re- calibrate the robot (see Calibrating the Robot: Setting the Encoder Zero Positions. See the battery locations below. Copyright © 2024, Brooks Automation...
Page 22 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the Encoder Batteries Part Number: 629016 Rev. A Location of the Z Axis Encoder Battery Location of the Four-Axis Encoder Batteries Location of the Six-Axis Encoder Batteries Copyright © 2024, Brooks Automation...
Page 23 Remove the outer link top sheet metal cover. Replace the battery. Replace the covers. To replace the Encoder Battery in the 6-axis outer link, perform the following procedure. Step Action Remove the outer link covers. Replace the two batteries. Replace the cover. Copyright © 2024, Brooks Automation...
Page 24: Calibrating The Robot: Setting The Encoder Zero Positions
Cal_PP is supplied on the flash drive of the robot and is available in the Support area of the Brooks website. To run Cal_PP, the controller must be configured to run GPL programs and Cal_PP must...
Page 25 Install an M6 X 40 mm Calibration Pin in the base platter. Rotate J3 counter-clockwise, when viewed looking down, until its hard stop. Start CAL_PP_XX. For the c10, rotate J4 counter-clockwise, when viewed looking down, until its hard stop. Copyright © 2024, Brooks Automation...
Page 26 2. Service Procedures PreciseFlex c10-c8A Service Manual Calibrating the Robot: Setting the Part Number: 629016 Rev. A Encoder Zero Positions Step Action CALPP Position c10 Letter Description Insert M6 X 40 pin here to center J1 (0 degrees). Lower Z to hard stop (-2mm).
Page 27 Rotate J3 CCW to hard stop (350 degrees). Rotate J4 CCW to hard stop. Rotate J5 to press against calibration bar. Rotate J6 CCW to hard stop. Install J5 calibration bar with 2 M3 x 12 SHCS. Copyright © 2024, Brooks Automation...
Page 28 2. Service Procedures PreciseFlex c10-c8A Service Manual Calibrating the Robot: Setting the Part Number: 629016 Rev. A Encoder Zero Positions Step Action With the CALPP application loaded, click Start. An application should start and prompt the user to confirm the correct robot position for calibration.
Page 29: Replacing Belts And Motors
Removing the rear cover allows access to the AC power terminals. Tools Required Gates Sonic Belt Tension Meter, Model 508 C 2.0 mm hex driver or hex L wrench 4.0 mm hex ball end driver To tension the 1st stage belt, perform the following procedure. Copyright © 2024, Brooks Automation...
Page 30: Tensioning The 2Nd Stage Belt
2. Service Procedures PreciseFlex c10-c8A Service Manual Tensioning or Replacing the J2 (Z Part Number: 629016 Rev. A Column) Belts Step Action Turn off robot power and remove the AC power cord. Remove the curved rear cover of the robot.
Page 31: Replacing The Z Column Stage One Timing Belt
Replacing the Z column Stage One Timing Belt Electrical Shock Before replacing the power supplies, the AC power should be removed. Tools Required 2.0 mm hex driver 4.0 mm ball end hex driver Copyright © 2024, Brooks Automation...
Page 32: Replacing The Z Column Stage Two Timing Belt
2. Service Procedures PreciseFlex c10-c8A Service Manual Tensioning or Replacing the J2 (Z Part Number: 629016 Rev. A Column) Belts 2.5 mm hex driver or hex L wrench Spare Parts Required J2 Stage One Belt, PN PFD0-MC-X0006. To replace the Z column stage one timing belt, perform the following procedure.
Page 33 Remove the Z belt clamp which should be accessible through the access cutout in the Z extrusion, change the Z belt, and replace the clamp. Tension the Z belt per above. Replace the parts. Recalibrate the robot. Copyright © 2024, Brooks Automation...
Page 34: 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. Email support_ preciseflex@brooksautomation.com...
Page 35: Replacing The Outer Link Motors Or Harmonic Drives In The C8A
Unplug the J4 to J5 harness from the J4 slave amplifier, and pull the harness through J4 into the J5 housing. Remove the J5/J6 axes from J4 by removing the (8) M4 X 8 SHCS. Copyright © 2024, Brooks Automation...
Page 36 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the Outer Link Motors or Har- Part Number: 629016 Rev. A monic Drives in the c8A Step Action At this point the J5/J6 assembly may be returned to the factory and a new assembly attached.
Page 37: Replacing The Robot Main Controller
(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, follow this procedure. Step Action On the Facilities Panel, turn off the robot power and remove the AC power cord. Copyright © 2024, Brooks Automation...
Page 38 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the Robot Main Controller Part Number: 629016 Rev. A Step Action Remove the connector panel from the base of the robot by removing M3 X 6 mm flat head screws. Remove the main robot controller -- PreciseFlex PFD0 Controller PNPFD0-EA-00001-3 -- by removing the (3) M3 X 8 mm SHCS and the D-Sub standoffs from the connector side of the panel. ...
Page 39: Replacing The Z-Axis Slave Controller
Remove the GSB4X slave amp by removing the (4) M3 X 10 mm SHCS and unplugging the cables. Replace the slave controller and re-attach the harness. Set the jumpers correctly for the address and termination. Replace the curved rear cover. Copyright © 2024, Brooks Automation...
Page 40 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the Z-axis Slave Controller Part Number: 629016 Rev. A Step Action Recalibrate the robot. Copyright © 2024, Brooks Automation...
Page 41: Replacing The J3 Axis Slave Controller
Replace the slave controller and re-attach the harness. Set the jumpers correctly for the address and termination. Replace the LED light tower parts. It is not necessary to recalibrate the robot if only this controller is replaced. Copyright © 2024, Brooks Automation...
Page 43: Replacing The J4 Or Gripper Slave Controller In C10
Turn off the robot power and remove the AC power cord. Remove the covers from the outer link. Remove the sheet metal cover from the outer link. Replace the slave controller (GSB4X). Set the jumpers correctly for the address and termination. Recalibrate the robot. Copyright © 2024, Brooks Automation...
Page 44 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the J4 or Gripper Slave Con- Part Number: 629016 Rev. A troller in c10 Step Action Replace the covers. GSB4 for J4 Axis, c10 Copyright © 2024, Brooks Automation...
Page 45: Replacing The Gripper And Slip Ring In The C10
2.5 mm hex driver Spare Parts Required: 60 N standard gripper slip ring - P/N 627540 23 N standard gripper slip ring - P/N 627487 To replace the gripper or slip ring, perform the following procedure. Copyright © 2024, Brooks Automation...
Page 46 2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the Gripper and Slip Ring in Part Number: 629016 Rev. A the c10 Step Action Turn off the robot power and remove the AC power cord. Remove the covers from the outer link.
Page 47 Remove the gripper cover. Remove 6 M2 X 10 SHCS to remove the gripper, then unplug the slip ring connectors in the gripper to free the gripper. Unplug the slip ring connectors. Remove the M4 x 10 SHCS mounting gripper to gripper adaptor flange to free the gripper. Copyright © 2024, Brooks Automation...
Page 48: Adjusting The Gripper Backlash Or Centering Fingers
2. Service Procedures PreciseFlex c10-c8A Service Manual Adjusting the Gripper Backlash or Cen- Part Number: 629016 Rev. A tering Fingers Adjusting the Gripper Backlash or Centering Fingers Tools Required 1.3 mm “stubby” hex L wrench 1.5 mm “stubby” hex L wrench...
Page 49: Replacing The Main Harness
Gripper racks centered in fully open position 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 © 2024, Brooks Automation...
Page 50: Replacing The J3 Clock Spring Harness To The J4 Motor
2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the J3 Clock Spring Harness Part Number: 629016 Rev. A to the J4 Motor Replacing the J3 Clock Spring Harness to the J4 Motor Tools Required 2.0 mm hex driver 2.5 mm hex driver...
Page 51 Part Number: 629016 Rev. A Replacing the J3 Clock Spring Harness to the J4 Motor Step Action Remove the air hose clamp plate and thru hole bushing and pull the air hose up through J3. Copyright © 2024, Brooks Automation...
Page 52: Replacing The J4 To Gripper Controller Harness In The C10
2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the J4 to Gripper Controller Part Number: 629016 Rev. A Harness in the c10 Step Action Remove the clockspring harness as shown in the previous step, and install the new harness. For the 10c it is important to ensure that the harness is clamped in the notch in the J3 output flange as shown, or the J4 motor will interfere with the harness.
Page 53: Replacing The J4 Slave Controller In The C8A
Remove the J4 controller mount plate from the bottom of J4. Unplug the J3 to J4 harness and the J4 to J5 harness and the motor connectors. Replace the J4 slave controller (GSB4X). Replace the parts. Recalibrate the robot. Copyright © 2024, Brooks Automation...
Page 54: Replacing The J6 Motor Pigtail Harness
2. Service Procedures PreciseFlex c10-c8A Service Manual Replacing the J6 Motor Pigtail Harness Part Number: 629016 Rev. A Replacing the J6 Motor Pigtail Harness Tools Required 2.0 mm hex driver 2.5 mm hex driver Spare Parts Required J6 Motor and Encoder Pigtail - P/N 389633 To replace the J6 motor pigtail harness, perform the following procedure.
Page 57: Appendix A: C10 Product Specifications
4.9 bar max (71 PSI) E-Stop Dual channel Controller Mounting Embedded into robot base 44 kg (500 mm Z-axis) Weight 53 kg (1000 mm Z-axis) 63 kg (1420 mm Z-axis) Noise Level < 50 dB(A) Copyright © 2024, Brooks Automation...
Page 58 Appendices PreciseFlex c10-c8A Service Manual Appendix A: c10 Product Specifications Part Number: 629016 Rev. A General Specification Range SOFTWARE Programming via Guidance Development Studio (GDS) Programming Guidance Programming Language (GPL) TCS API Hand-guided teaching Enhanced Functions XY compliance (optional) Z-Height detection (optional)
Page 59: Appendix B: C8A Product Specifications
Power 70-175 watts typical operation DC Power Option Available Two 3.2 mm OD (1.7 mm ID) airlines provided for end-of-arm-tooling Pneumatics 4.9 bar max (71 PSI) E-Stop Dual Channel Controller Mounting Embedded into robot base Copyright © 2024, Brooks Automation...
Page 60 Appendices PreciseFlex c10-c8A Service Manual Appendix B: c8A Product Specifications Part Number: 629016 Rev. A General Specification Range Air Lines Two, 3.2 mm OD, 1.6 mm ID, max pressure 500 kpa (75 psi) 46 kg (500 mm Z-axis) Weight 55 kg (1000 mm Z-axis)
Page 61: Appendix C: Environmental Specifications
16AWG, 3 conductor, 10 Amps min Pollution Degree Approved Cleaning Agents IPA, 70% Ethanol/30% water, H2O2 Vapor up to 1000 ppm IP Rating with Tape Seal Option IP Rating without Tape Seal Option IK Impact Rating IK08: 5 Joule Copyright © 2024, Brooks Automation...
Page 62: Appendix D: Spare Parts List
Appendices PreciseFlex c10-c8A Service Manual Appendix D: Spare Parts List Part Number: 629016 Rev. A Appendix D: Spare Parts List NOTE: For help replacing spare parts, email support_preciseflex@brooksautomation.com Reference - the serial number format is: FD0-yymm-XY-zzzzz Yy – year Mm – month X –...
Page 63: Appendix E: Preventative Maintenance
Replace slip ring in c10 if For units with 23 N electric replace the slip ring every third inspection test, or present. 20,000 hours of operation. Copyright © 2024, Brooks Automation...
Page 64: Appendix F: Safety Circuits For The C8A And C10 Robots
Appendices PreciseFlex c10-c8A Service Manual Appendix F: Safety Circuits for the c8A Part Number: 629016 Rev. A and c10 Robots Appendix F: Safety Circuits for the c8A and c10 Robots NOTE: Note: (2 kg robot has redundant E-stop and 48 V power supply enabled)
Page 65 Current saturation triggers separate fault, turns off power at amp and 48 V. Monitor function with WD turns off power at amp and 48 V. Monitor and CPU WD tested at startup turning off 48 V. Asymmetric current limits limit Z force even with gravity load. Copyright © 2024, Brooks Automation...
Page 66: Appendix G: System Diagram And Power Supplies
Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Appendix G: System Diagram and Power Supplies The robot has a 24 VDC and 48 VDC power supply located in the Z column. The power supplies have both over-current and over-voltage protection and are CSA, UL, and CE certified.
Page 67 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies PFD0X - Block Diagram - P/N 890242 Joint Axis Controller Connectors - P/N 890242-000X Copyright © 2024, Brooks Automation...
Page 68 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Base Controller Connectors Gripper and Joint Axis Controller Connectors Copyright © 2024, Brooks Automation...
Page 69 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies Slip Ring for 23 N Gripper, Ass., Harness with Sensor, Vision PFC - P/N 627468 Copyright © 2024, Brooks Automation...
Page 70 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Slip Ring Dual and Single for 23 N Gripper, Ass., PFC Copyright © 2024, Brooks Automation...
Page 72 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Slip Ring for 60 N Gripper, Ass., Vision, PFC - P/N 627235 Copyright © 2024, Brooks Automation...
Page 73 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies Assy, Cable, Dual Battery Assy, Cable, Single Battery Copyright © 2024, Brooks Automation...
Page 74 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Assy, Cable, Battery Jumper J1 Timken Encoder, PFD0X - P/N 621306 Copyright © 2024, Brooks Automation...
Page 75 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies Motor and Encoder Pigtails, J6 PFDO - P/N 621472 Harness, Signal and DC Power, Base, PFDO - P/N 621475 Copyright © 2024, Brooks Automation...
Page 76 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Harness, AC Power, PFDO - 00030 Harness, AC Power, PFDO - 00031 Harness, AC Power, PFDO - 00032 Copyright © 2024, Brooks Automation...
Page 77 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies Harness, AC Power, PFDO - 00041 Harness, AC Power, PFDO - 00042 Harness, AC Power, PFDO Copyright © 2024, Brooks Automation...
Page 78 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Harness, Column and Inner Link, PFDO P/N 621476 J3 Timken Encoder, PFDOX - P/N 621306-0001 Copyright © 2024, Brooks Automation...
Page 80 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Harness, DC Interconnect, PFDO - P/N 622725 Copyright © 2024, Brooks Automation...
Page 81 Brooks Automation Appendices Part Number: 629016 Rev. A Appendix G: System Diagram and Power Supplies Harness, J3 Clockspring, PFDO - P/N 622726 Harness, Brake Release Cable Extension, PFDO - P/N 389630 Copyright © 2024, Brooks Automation...
Page 82 Appendices PreciseFlex c10-c8A Service Manual Appendix G: System Diagram and Power Part Number: 629016 Rev. A Supplies Harness, Single and Dual Valve, PFDO Harness, Dump Resistor with Pigtail, PFDO Copyright © 2024, Brooks Automation...
Page 84: Appendix H: Control System Overview
Part Number: 629016 Rev. A Appendix H: Control System Overview The PreciseFlex c8A and PreciseFlex c10 Robots are controlled by a distributed control system (see examples below). The main control board (PFD0) is located in the base casting behind the connector panel.
Page 86: Appendix I: Belt Tensions, Gates Tension Meter
Appendices PreciseFlex c10-c8A Service Manual Appendix I: Belt Tensions, Gates Tension Part Number: 629016 Rev. A Meter Appendix I: 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. If it appears a belt tension is not correct, the tension can be checked with a Gates Sonic Tension Meter, Model 507C or 508C.
Page 88: Appendix J: Example Performance Level Evaluation
Appendices PreciseFlex c10-c8A Service Manual Appendix J: Example Performance Level Part Number: 629016 Rev. A Evaluation Appendix J: Example Performance Level Evaluation Example Workcell description: A c10 moves 100-gram plastic trays from storage racks to an instrument and back to the storage racks. The gripper is an electric parallel jaw gripper with maximum 23 N of gripping force for plastic trays and is spring loaded so it will not drop trays if power fails.
Page 89: Appendix K: Table A2 From Iso/Ts 15066: 2016
Appendix K: Table A2 from ISO/TS 15066: 2016 Appendix K: Table A2 from ISO/TS 15066: 2016 NOTE: All results in this appendix are from testing on the PreciseFlex DD4 robot. Biomechanical Force and Pressure Limits Copyright © 2024, Brooks Automation...

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