Robot Manual R8.3

R8.
3 USER MANUAL Page 1
R8.3
USER MANUAL
Original User Manual
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
R8.3 USER MANUAL Page 2
This manual provides the information necessary to properly install, operate and service
Wittmann Robot Systems, and ensure correct and safe operation of our equipment.
Our robots must be installed and operated in accordance with these instructions by
authorized and qualified personnel only.
Improper installation startup and operation may result in injury to personnel and/or
damaged equipment.
Before installation, please read this manual completely, paying special attention to the
Safety Warnings marked .
To ensure optimal use of our equipment, we recommend that you attend the training
courses regularly offered at our Service Centers.
Proper function of the equipment can be ensured only if maintenance is performed

according to the instructions given in this manual.
The descriptions in this manual refer to the robot and equipment according to the
specification sheet. These specifications are subject to change without notice.
This manual is for the sole use of the user of the robot and may not be distributed to
unauthorized persons. No part of this manual may be copied or reproduced without our
written consent.
Use original Wittmann USB-sticks only. The function with USB-sticks of third party
suppliers is explicitly not guaranteed.
Do not use hard or pointed objects to operate the touch screen of the Teachbox. This
could damage the touch screen.
The noise emission of this device does not exceed 70 dB(A).
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Before starting up the robot for the first time, please review this manual thoroughly and
familiarize yourself with the operation of the robot. Improper use may injure personnel
and/or damage the robot, mold or molding machine.
Table of Contents
1 SAFETY ................................................................................................ 11
1.1 SAFETY REGULATIONS .........................................................................11
1.2 SAFETY FEATURES ................................................................................11
1.2.1 Safeguarding ......................................................................................11
1.2.2 Emergency STOP Buttons .................................................................11
1.2.3 Permit Key on Teachbox ....................................................................11
1.3 LIMITATIONS ...........................................................................................12
1.4 CAPABILITY OF THE SAFETY CONTROL ..............................................12
1.5 CONTROL OF HAZARDOUS ENERGY – (LOCKOUT / TAGOUT) ..........13
1.5.1 Glossary .............................................................................................13
1.5.2 Lockout/Tagout Kit .............................................................................14
1.5.3 Lockout/Tagout Procedure .................................................................14
1.5.4 Removal of LOTO ..............................................................................15
2 INSTALLATION .................................................................................... 16
2.1 MECHANICAL INSTALLATION ................................................................16
2.1.1 Dimensional Drawing – Adapter Unit ..................................................16
2.1.2 Mounting of the Robot ........................................................................16
2.1.3 Demounting of the Robot....................................................................17
2.2 PNEUMATICS ..........................................................................................18
2.2.1 Compressed Air Connection ...............................................................18
2.3 ELECTRICAL CONNECTIONS.................................................................19
2.3.1 Mains Power Supply ...........................................................................19
2.3.1.1 Fault Current Safety Switches ......................................................19
2.3.2 Interface with the Injection Molding Machine ......................................20
2.3.3 Mold Monitoring S5/S6 .......................................................................21
2.3.3.1 Settings for Virtual Roller Switches (Mold Safety Switches) .........22
2.3.3.2 Initialize Roller Switch Monitoring .................................................23
2.3.3.3 Test Procedure for Mold Safety S5 / S6 .......................................24
2.4 SAFETY PACKAGE/SAFEGUARDING ....................................................25
2.4.1 Safety Package ..................................................................................25
2.4.2 EXTERNAL Safety Package for Safety Door or Access Hatch .........26
2.4.3 Safety Guarding .................................................................................28
2.5 ELECTRICAL INTERFACE.......................................................................29
2.5.1 Euromap 67 interface .........................................................................29
2.5.1.1 Injection Molding Machine (IMM) Signals .....................................30
2.5.1.2 Robot Signals ..............................................................................31
2.5.2 Euromap 12 Interface .........................................................................33
2.5.2.1 Injection Molding Machine (IMM) Signals .....................................34
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2.5.2.2 Robot Signals ..............................................................................35

3 OPERATING INSTRUCTIONS FOR R8.3 CONTROL ......................... 36
3.1 BASIC OPERATION .................................................................................36
3.1.1 Introduction ........................................................................................36
3.1.2 Robot Axes.........................................................................................37
3.1.3 Emergency Stop Block .......................................................................38
3.1.4 Numerical Input ..................................................................................39
3.1.5 Text Input ...........................................................................................40
3.1.6 Operating Modes ................................................................................41
3.1.7 Operating Mode Reference ................................................................42
3.1.7.1 Reference travel in the operating mode Reference Missing .........42
3.1.7.2 Reference travel in the operating mode Manual ...........................43
3.1.8 Override .............................................................................................44
3.1.9 ECO-Mode .........................................................................................46
3.1.10 Safety System ..................................................................................47
3.1.10.1 Startup with Safety System ........................................................47
3.1.10.1.1 Manual Setup Mode ...................................................................................................... 47
3.1.10.1.2 Automatic Mode, Step Mode, Reference Travel ............................................................ 47
3.1.10.2 Selection of Operating Modes ....................................................47
3.1.10.2.1 Manual Setup Mode ...................................................................................................... 47
3.1.10.2.2 Automatic Mode, Step Mode, Reference....................................................................... 47
3.1.10.3 Monitoring of the Safety Gate.....................................................48
3.1.10.4 Error Effect Analysis ..................................................................48
3.1.11 User Administration and Passwords .................................................49
3.1.11.1 Administrator..............................................................................49
3.1.11.2 Users .........................................................................................50
3.1.11.2.1 User (create, change) ................................................................................................... 51
3.1.11.3 Profiles .......................................................................................52
3.1.11.4 Login ..........................................................................................53
3.1.11.5 Logout........................................................................................54
3.1.11.6 Forgot Password ........................................................................54
3.1.12 Manual Functions .............................................................................55
3.1.12.1 Numerical Axes ..........................................................................55
3.1.12.2 Axis Release in Manual Mode (optional) ....................................57
3.1.12.3 Pneumatic Axes .........................................................................58
3.1.12.4 Digital (B-) Axes .........................................................................59
3.1.12.5 Counters ....................................................................................60
3.1.12.6 Placing Counters........................................................................61
3.1.12.7 Conveyors..................................................................................62
3.1.12.8 Peripheral Outputs .....................................................................63
3.1.12.9 Vacuums ....................................................................................64
3.1.12.10 Grippers ...................................................................................65
3.1.12.11 Cylinders ..................................................................................66
3.1.13 FILE Menu of the main screen..........................................................67
3.1.13.1 Properties ..................................................................................67
3.1.13.2 Backup stored Teachprograms ..................................................68
3.1.14 INIT Menu ........................................................................................69
3.1.14.1 Stroke Limits ..............................................................................69
3.1.14.2 Roller Switches ..........................................................................70
3.1.14.3 Absolute Encoders (Admin only) ................................................70
3.1.14.4 Deactivate Monitoring ................................................................71
3.1.14.5 Maintenance - Lubrication Interval .............................................72
3.1.14.6 Setup: Robot Settings ................................................................73
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3.1.14.7 Setup: Date / Time .....................................................................75

3.1.14.8 Setup: Language........................................................................75
3.1.14.9 Setup: Network Settings (Admin only) ........................................76
3.1.14.10 Setup: Remote Users Settings (Admin only) ............................77
3.1.14.10.1 Create / Edit Remote Users (Admin only).................................................................... 78
3.1.14.11 Licenses (Admin only) ..............................................................78
3.1.14.12 Setup: Email Settings ...............................................................79
3.1.14.12.1 Tab Basic.................................................................................................................... 79
3.1.14.12.2 Tab Content ................................................................................................................ 79
3.1.14.12.3 Tab Timeouts .............................................................................................................. 80
3.1.14.12.4 Tab Recipients ............................................................................................................ 80
3.1.14.12.5 Tab Events ................................................................................................................. 81
3.1.14.13 Setup: Screensaver Properties ................................................82
3.1.14.14 Setup: Calibrate Touch ............................................................83
3.1.15 View Menu .......................................................................................84
3.1.15.1 Operating Systems ....................................................................84
3.1.15.2 Operating Data ..........................................................................85
3.1.15.3 Axes positions ............................................................................86
3.1.15.4 I / O ............................................................................................87
3.1.15.5 Safety Areas ..............................................................................88
3.1.15.6 Counters ....................................................................................89
3.1.15.7 Placing Counters........................................................................90
3.1.15.8 Conveyors..................................................................................91
3.1.15.9 Cylinders ....................................................................................91
3.1.15.10 POs - Peripheral Outputs .........................................................92
3.1.15.11 PIs - Peripheral Inputs..............................................................92
3.1.15.12 IMM I / O ..................................................................................93
3.1.15.13 AutoSwitches ...........................................................................94
3.1.15.14 Stopwatches ............................................................................94
3.1.15.15 Vacuums ..................................................................................95
3.1.15.16 Default Vacuum Level ..............................................................95
3.1.15.17 Grippers ...................................................................................96
3.1.15.18 Alarms .....................................................................................97
3.1.15.19 Error Buffer ..............................................................................98
3.1.15.19.1 Export the Error Buffer ................................................................................................ 99
3.1.15.20 Command Buffer ....................................................................101
3.1.15.20.1 Export the Command Buffer...................................................................................... 102
3.1.15.21 Virtual Subpendant (Emergency Stop Block) .........................104
3.1.15.21.1 Tab Standard ............................................................................................................ 104
3.1.15.21.2 Tab Easy .................................................................................................................. 105
3.1.15.22 Memory State.........................................................................106
3.1.16 System Report................................................................................107
3.1.17 Email Functions ..............................................................................108
3.1.17.1 Manual Email Function.............................................................108
3.1.17.2 Automatic Email Function ........................................................109
3.1.18 RFID / Digital EOAT (optional)........................................................110
3.1.18.1 Link a Teach Program with an EOAT .......................................110
3.1.18.2 EOAT Change .........................................................................110
3.2 TEACH-MODE USING THE TEXT EDITOR ...........................................111
3.2.1 Operation of the Texteditors .............................................................111
3.2.1.1 Entering the Text Editor .............................................................111
3.2.1.2 Exit the Texteditor and transfer the program to the CPU ............ 111
3.2.1.3 Editing Functions .......................................................................112
3.2.1.4 Online Editor ..............................................................................113
3.2.1.5 Offline Editor ..............................................................................113
3.2.1.6 Online Conversion .....................................................................113
3.2.2 Step Operation .................................................................................114
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3.2.2.1 Procedure Step ..........................................................................114

3.2.3 Part Programs, PROGRAM Menu ....................................................115
3.2.3.1 Part Programs............................................................................115
3.2.3.1.1 Robot Program (ROBOT-PRG) ..................................................................................... 115
3.2.3.1.2 Peripheral Program (PERI-PRG) .................................................................................. 115
3.2.3.1.3 Robot Reference Program (ROBOT-REF) .................................................................... 116
3.2.3.1.4 Peripheral Reference Program (PERI-REF) .................................................................. 116
3.2.3.1.5 115 additional Part Programs........................................................................................ 116
3.2.3.1.6 All Modes Program (ALLMODE PRG)........................................................................... 116
3.2.3.1.7 Sub-Allmodes Part Programs........................................................................................ 117
3.2.3.1.8 EOAT Change Program ................................................................................................ 117
3.2.3.2 Manage Part Programs ..............................................................118
3.2.3.2.1 Edit a Part Program ...................................................................................................... 119
3.2.4 FILE Menu of the text editor .............................................................120
3.2.4.1 New ...........................................................................................120
3.2.4.2 Open ..........................................................................................121
3.2.4.3 Import Macro..............................................................................122
3.2.4.4 Load Program from CPU............................................................124
3.2.4.5 Save (NAME.ZIP) ......................................................................124
3.2.4.6 Save As .....................................................................................125
3.2.4.7 Export Selection .........................................................................126
3.2.4.8 Transfer program to CPU ...........................................................128
3.2.4.9 Properties ..................................................................................129
3.2.4.10 Print .........................................................................................130
3.2.4.11 Exit to Main ..............................................................................132
3.2.4.12 Properties Window of the File Dialogue ...................................133
3.2.4.13 Picture Viewer ..........................................................................134
3.2.4.13.1 Associate a picture with a Teach program................................................................... 134
3.2.5 EDIT Menu .......................................................................................136
3.2.5.1 Selection Mode ..........................................................................136
3.2.5.2 Copy, Cut, Paste ........................................................................137
3.2.5.3 Search-Toolbar ..........................................................................139
3.2.5.4 Show Prefixes ............................................................................140
3.2.5.5 Show Default Names .................................................................141
3.2.5.6 Show Internal IDs.......................................................................141
3.2.5.7 Show Line Numbers...................................................................141
3.2.5.8 Show Execution Times ..............................................................142
3.2.6 Teach program Settings in the SETUP Menu ...................................143
3.2.6.1 Online / Offline Editor .................................................................143
3.2.6.2 Axes Definition ...........................................................................143
3.2.6.3 Safety Areas ..............................................................................144
3.2.6.3.1 Create / Edit Safety Areas............................................................................................. 146
3.2.6.3.2 Properties of the Working Area ..................................................................................... 147
3.2.6.3.3 Graphical Display of the Safety Areas ........................................................................... 148
3.2.6.4 Cylinder Definition ......................................................................150
3.2.6.4.1 Create / Edit Cylinders .................................................................................................. 151
3.2.6.5 Auto Switch Definition ................................................................152
3.2.6.6 Counter Names ..........................................................................154
3.2.6.7 Conveyor Names .......................................................................155
3.2.6.8 Peripheral Output Names...........................................................156
3.2.6.9 Peripheral Input Names .............................................................157
3.2.6.10 Stacking Sensor Names...........................................................158
3.2.6.11 Stopwatch Names ....................................................................159
3.2.6.12 Vacuum Names .......................................................................160
3.2.6.13 Gripper Names.........................................................................161
3.2.6.14 Vacuum Reference States .......................................................162
3.2.6.15 Gripper Reference States ........................................................163
3.2.6.16 Setup Standard Vacuum Pressure ...........................................164
3.2.7 Part program Settings in the PART PRG SETUP menu ...................166
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3.2.7.1 Positions ....................................................................................166

3.2.7.1.1 Create / Edit Positions .................................................................................................. 166
3.2.7.2 Labels and Subroutines .............................................................168
3.2.7.3 Placing Program ........................................................................168
3.3 TEACH COMMANDS OF THE TEXTEDITOR ........................................169
3.3.1 Axes .................................................................................................169
3.3.1.1 Axes Selection ...........................................................................169
3.3.1.2 Terminology ...............................................................................169
3.3.1.2.1 Pneumatical Axes ......................................................................................................... 169
3.3.1.2.2 Numerical Axes ............................................................................................................ 169
3.3.1.2.3 Path Axes ..................................................................................................................... 169
3.3.1.3 Move ..........................................................................................170
3.3.1.3.1 Absolute Movement ...................................................................................................... 171
3.3.1.3.2 Relative Motion ............................................................................................................. 171
3.3.1.3.3 Parallel Movements ...................................................................................................... 172
3.3.1.3.4 Curve ............................................................................................................................ 174
3.3.1.3.5 Stop .............................................................................................................................. 175
3.3.1.3.6 Soft Torque Push .......................................................................................................... 175
3.3.1.3.7 Release (optional)......................................................................................................... 177
3.3.1.3.8 Stack Sensor (optional)................................................................................................. 178
3.3.1.3.9 Find ń´ Pick ................................................................................................................. 179
3.3.1.3.10 Follow Conveyor (optional) ......................................................................................... 180
3.3.1.3.11 Mold Opening Synchronization (optional) .................................................................... 183
3.3.1.4 3D Motions.................................................................................185
3.3.1.4.1 3D Absolute Motion ...................................................................................................... 187
3.3.1.4.2 3D Relative Motion ....................................................................................................... 187
3.3.1.4.3 3D Curve ...................................................................................................................... 187
3.3.1.5 Speed ........................................................................................188
3.3.1.5.1 VMAX ........................................................................................................................... 188
3.3.1.5.2 VABS ............................................................................................................................ 188
3.3.1.5.3 AABS ............................................................................................................................ 189
3.3.1.5.4 R3D .............................................................................................................................. 190
3.3.1.5.5 V3D .............................................................................................................................. 190
3.3.1.6 Wait Sync...................................................................................191
3.3.1.6.1 Wait Path Sync ............................................................................................................. 191
3.3.1.7 Movements and Parameters for Scara Robots...........................192
3.3.1.7.1 Pathmode ..................................................................................................................... 192
3.3.1.7.2 Angular Motions - „in degrees“ ...................................................................................... 193
3.3.2 Placing Programs .............................................................................194
3.3.2.1 Create/Edit Placing Programs ....................................................195
3.3.2.1.1 Dialogue for Axes Selection .......................................................................................... 196
3.3.2.1.2 Tab 1. - 1st Position, Name........................................................................................... 197
3.3.2.1.3 Tab 2. - Stacking Pattern .............................................................................................. 198
3.3.2.1.4 Tab Options .................................................................................................................. 199
3.3.2.1.5 Tab STS - Stacking Sensor........................................................................................... 200
3.3.2.1.6 Tab Displacement ......................................................................................................... 201
3.3.2.2 Add Placing Program Commands to the Teach Program ........... 202
3.3.3 Injection Molding Machine IMM ........................................................203
3.3.3.1 Injection Molding Machine IMM - Standard Functions ................ 203
3.3.3.1.1 MOLD CLOSE and FULLY MOLD OPEN ..................................................................... 204
3.3.3.1.2 EJECTORS FORWARD/BACK and COREPULLERS PULL/SET ................................. 205
3.3.3.2 Injection Molding Machine IMM - Automatic Functions ............... 206
3.3.3.2.1 MOLD CLOSE! WAIT ................................................................................................... 207
3.3.3.2.2 EJECTORS FORWARD/BACK (WAIT) and CORE PULLERS PULL/SET (WAIT) ....... 207
3.3.3.3 Injection Molding Machine IMM - Logical Functions – Mold Was Closed
..................................................................................................208
3.3.4 Smart Removal.................................................................................209
3.3.4.1 Smart Removal: In .....................................................................209
3.3.4.2 Smart Removal: Out ..................................................................212
3.3.5 Peripherals .......................................................................................215
3.3.5.1 Conveyor ...................................................................................215
3.3.5.2 Peripheral Outputs PO ...............................................................216
3.3.5.3 Cylinder function ........................................................................217
3.3.5.3.1 Applying cylinders in a teach program........................................................................... 218
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3.3.5.4 Vacuums ....................................................................................219

3.3.5.5 Vacuum Level ............................................................................220
3.3.5.6 Grippers .....................................................................................221
3.3.5.7 Monitoring of Vacuum Circuits, Grippers and Peripheral Outputs222
3.3.6 Counters...........................................................................................225
3.3.6.1 64 freely usable Counters ..........................................................225
3.3.6.2 Reset / Manipulate Placing Counters .........................................227
3.3.7 Program branching ...........................................................................229
3.3.7.1 Jump ..........................................................................................229
3.3.7.2 Label ..........................................................................................230
3.3.7.3 If - Elseif - Else - Endif ...............................................................230
3.3.7.3.1 Variant 1: ...................................................................................................................... 231
3.3.7.3.2 Variant 2: ...................................................................................................................... 231
3.3.7.3.3 Variant 3: ...................................................................................................................... 232
3.3.7.4 Call - Subr – Ret ........................................................................233
3.3.7.5 And ............................................................................................235
3.3.7.6 Or ..............................................................................................235
3.3.7.7 End ............................................................................................236
3.3.7.8 Jump Conditions ........................................................................237
3.3.7.8.1 Jump condition: Counter ............................................................................................... 237
3.3.7.8.2 Jump Condition: Placing Program ................................................................................. 238
3.3.7.8.3 Jump Condition: PI-Peripheral Input ............................................................................. 238
3.3.7.8.4 Jump Condition: IMM - Injection Molding Machine ........................................................ 239
3.3.7.8.5 Jump Condition: Vacuum .............................................................................................. 240
3.3.7.8.6 Jump Condition: AutoSwitch ......................................................................................... 240
3.3.7.8.7 Jump Condition: Part program ...................................................................................... 240
3.3.7.8.8 Jump Condition: Area ................................................................................................... 241
3.3.7.8.9 Jump condition: Position ............................................................................................... 241
3.3.7.8.10 Jump Condition: Mode ................................................................................................ 242
3.3.7.8.11 Jump Condition: Stacking sensor ................................................................................ 243
3.3.7.8.12 Jump Condition: Start ................................................................................................. 243
3.3.7.8.13 Jump Condition: Production End Active ...................................................................... 243
3.3.7.8.14 Jump Condition: Input ................................................................................................. 243
3.3.7.8.15 Jump Condition: Output .............................................................................................. 244
3.3.7.9 Start/Stop Part Program .............................................................245
3.3.8 Wait functions ...................................................................................246
3.3.8.1 Wait ...........................................................................................246
3.3.8.2 Wait Timer .................................................................................246
3.3.8.3 Time...........................................................................................247
3.3.9 More Commands ..............................................................................248
3.3.9.1 More ..........................................................................................248
3.3.9.2 Remark (REM) ...........................................................................248
3.3.9.3 Production End ..........................................................................249
3.3.9.4 Blockstop lock/unlock .................................................................250
3.3.9.5 Stopwatch ..................................................................................251
3.3.9.6 Operating Mode .........................................................................253
3.3.9.7 Eco Mode ..................................................................................254
3.3.9.8 Area Switch................................................................................255
3.3.10 AutoSwitches .................................................................................256
3.3.10.1 The Teach command AutoSwitch ............................................257
3.3.11 User Defined Error Messages ........................................................259
3.3.11.1 Introduction ..............................................................................259
3.3.11.2 Creating and Storing the File UserErr.txt ..................................259
3.3.11.3 The Teach Command ALARM .................................................261
3.4 QUICK EDITOR ......................................................................................262
3.4.1 Introduction ......................................................................................262
3.4.2 Operation of the Quick Edit ..............................................................262
3.4.2.1 Entering the Quick Edit ..............................................................262
3.4.2.2 Display and Editing Functions ....................................................262
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3.4.2.3 Exit the Quick Edit......................................................................263

3.4.3 FILE Menu of the Quick Edit .............................................................264
3.4.3.1 Open ..........................................................................................264
3.4.3.2 Open Template ..........................................................................265
3.4.3.3 Save (NAME.ZIP) ......................................................................266
3.4.3.4 Save As .....................................................................................266
3.4.3.5 Properties ..................................................................................268
3.4.3.6 Print ...........................................................................................269
3.4.3.7 Exit to Main ................................................................................270
3.4.4 Parameters for the Quick Edit...........................................................271
3.4.4.1 Create Parameters.....................................................................271
3.4.4.2 Apply Parameters ......................................................................273
4 HOW TO TEACH A PROGRAM ......................................................... 274
4.1 USING THE QUICK NEW WIZARD AND THE QUICK EDIT .................. 274
4.2 PROGRAMMING THE ROBOT IN THE TEXT EDITOR .........................279
4.2.1 Creating a New Program in the Text Editor ......................................279
4.2.2 Verifying Your Program Using STEP Mode ......................................280
4.2.3 Storing Your Program on a storage medium.....................................280
4.3 PROGRAM EXAMPLE ...........................................................................281
4.3.1 Function of Program .........................................................................281
4.3.2 Sequence .........................................................................................281
4.3.3 Sketch of Sequence .........................................................................282
4.3.4 Sketch of Depositing Program ..........................................................282
4.3.5 Reference Travel of Robot ...............................................................282
4.3.6 Robot Teach Program (Robot Prg.) ..................................................283
4.3.6.1 Placing Program Placingp-001 ...................................................284
4.3.7 Reference Program for the Robot (Robot Ref.) ................................284
5 TROUBLESHOOTING ........................................................................ 285
5.1 OPERATING ERRORS ..........................................................................285
5.1.1 Operating Errors in Plain Text Messages .........................................286
5.1.1.1 Axis Errors .................................................................................286
5.1.1.2 Vacuum Errors ...........................................................................289
5.1.1.3 Gripper Errors ............................................................................289
5.1.1.4 Peripheral Equipment Output Messages ....................................290
5.1.1.5 Cylinder Messages ....................................................................290
5.1.1.6 Conveyor Belt Messages ...........................................................290
5.1.1.7 General Hardware Error Messages ............................................291
5.1.1.8 System Error Messages .............................................................293
5.1.1.9 CAN Device Messages ..............................................................293
5.1.1.10 Teach program Compiler Messages ........................................294
5.1.1.11 Teach program Interpreter Messages ......................................295
5.1.1.12 Configuration Errors .................................................................296
6 MAINTENANCE .................................................................................. 297
6.1 GENERAL ..............................................................................................297
6.2 LUBRICATION INSTRUCTIONS FOR LINEAR GUIDES AND GEAR RACKS
.....................................................................................................................298
6.2.1 Lubrication Intervals for Standard Robots .........................................298
6.2.2 Lubrication Procedures.....................................................................298
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6.2.3 Grease Specification ........................................................................298

6.3 DRIVE BELTS ........................................................................................299
6.4 MOTOR BRAKES ...................................................................................299
6.5 BATTERY REPLACEMENT ....................................................................300
6.5.1 IPC ...................................................................................................300
6.5.2 Sanyo R Inverters at Axes with Absolute Encoders ..........................301
6.6 MOLD SAFETY RELAYS........................................................................303
6.7 MAINTENANCE SCHEDULE .................................................................304
6.8 AUTOMATIC LUBRICATION ..................................................................305
6.8.1 Description .......................................................................................305
6.8.2 System Maintenance ........................................................................306
6.8.2.1 Lubrication System Maintenance Procedure: .............................306
6.8.2.2 Suitable greases ........................................................................306
7 KEY TERMS ....................................................................................... 307
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1 Safety
Wittmann Robots can be operated at high speeds so as to allow short removal and
cycle times. In order to minimize the risk of injury to personnel, the robot and
automation equipment must always be operated with the proper safeguards, in
accordance with legal regulations.
1.1 Safety Regulations
In many countries the obligation of robot vendors to supply systems meeting applicable
safety regulations and the responsibility of the operator of these devices are governed
by law or by safety standards of professional associations. Always comply to the
regulations applicable for you.
1.2 Safety Features
1.2.1 Safeguarding
The safeguarding required for operation of the robot is not included in our standard
scope of supply, since adaptation to specific site conditions is required. If such
safeguarding is provided by you, please note that it must be installed prior to startup of
the equipment in order to be included in the safety circuit of the system upon startup.
See Chapter 2.4 Safety Package/Safeguarding.
The user bears the legal responsibility for following safety regulations.
1.2.2 Emergency STOP Buttons

One emergency stop button is located on the Teachbox.
When an emergency stop button is pressed, the power is turned off. The gripper and
vacuum valves and the vacuum pump are not disconnected, to avoid dropping parts
from the gripper. In addition, the controls and the Teachbox will remain under power to
allow indication of error messages.
The emergency stop button can be released by pulling it.
The emergency stop circuits of the robot and of the injection molding machine are
connected by the robot-machine interface. Therefore when the emergency stop button
on the molding machine is pressed the robot will also go into emergency stop and vice
versa.
1.2.3 Permit Key on Teachbox

This key must be depressed for setting up for manual operation in order to be able to
carry out travel motions with the robot. For more precise operation, see Chapter 3.1.10.
Should this permit key be released during setup, the safety functions will interrupt all
travel motion of the robot.
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1.3 Limitations
Limitations of use
Specified use This appliance is to be used to handle (plastic-) parts within
the production process of an injection molding machine. The
robot may only be used after safeguarding according to EN
ISO 10218 has been established, and the safety concept
described in this user manual has been realized.
Reasonably Installation and operation without consideration of EN ISO
foreseeable misuse 10218
Field of application
Commerce Yes
Industry Yes
Categories of users Task Qualifications / Impairments

Qualified personnel Installation / commissioning / Professional training
decommissioning / repairs /
Maintenance / removal
Apprentices Guided operation semiskilled
Operators Operation skilled / semiskilled
Spatial limitations
Description of the system The robot consists of the z-axis part, which contains the
electrical system and the CPU of the control system;
furthermore id guides the x-axis. The x-axis part also holds
the y-axis that executes the vertical movements of the
robot. The y-axis additionally holds a rotary device.
Time limitations
Specified time of use 10 to 20 years
Recommended maintenance intervals See chapter 6 Maintenance
Other limitations
Ambient temperature +5 to +40 °C
Relative humidity 15 to 85 %
Required degree of cleanliness No special requirements
Height above sea level 0 to 1000 m
Electrical supply Depending on version, see type plate
Required pressure for compressed air 4 – 7 bar
Hazardous areas (EX) Do not use in hazardous areas (EX)
1.4 Capability of the Safety Control

The capability of the safety control of the robot conforms with PLr = d of
EN ISO 13849-1.
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1.5 Control of Hazardous Energy – (Lockout / Tagout)

Lockout / Tagout (LOTO) refer to specific practices and procedures to safeguard
employees from the unexpected energy, startup of machinery/equipment, or the
release of hazardous energy during service or maintenance activities.
This requires that a designated individual turn off and disconnect the
machinery/equipment from its energy source(s) before performing service or
maintenance and that the authorized employee(s) lock and tag the energy-isolating
device(s) to prevent the release of hazardous energy and take steps to verify that the
energy has been isolated effectively.
The following is a glossary and general description of the LOTO procedure.
Always refer to applicable local codes in performing Lockout/Tagout procedures
1.5.1 Glossary
Affected Employee An employee whose job requires them to operate a machine or piece of
equipment on which service or maintenance is being performed.
Authorized Employee A person who locks or implements a tagout system procedure on
machines or equipment to perform service or maintenance on that
machine or equipment. An authorized employee and an affected
employee may be the same person when the affected employee's duties
also include performing service or maintenance.
Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal, or other energy.
Lockout The placement of a lockout device (such as a lock) on an energy-
isolating device, in accordance with an established procedure that
ensures the device and the equipment cannot be operated until the
lockout device is removed.
Servicing and / Workplace activities such as constructing, installing, setting up,
or Maintenance adjusting, inspecting, modifying, maintaining or servicing machines or
equipment. These activities include lubrication, cleaning or un-jamming
of machines or equipment, and making adjustments or tool changes
where the employee may be exposed to the unexpected energy, start-up
of equipment or release of hazardous energy.
Tagout The placement of a tagout device (such as a tag) on an energy-isolating
device, in accordance with an established procedure that ensures the
device and the equipment may not be operated until the tagout device is
removed.
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1.5.2 Lockout/Tagout Kit

Use of an approved LOTO kit is required. It is the customer’s responsibility to provide
this kit.
Fig.: Examples of LOTO devices
Customers are also responsible for ensuring that all employees are properly trained
and utilize the LOTO procedures.
1.5.3 Lockout/Tagout Procedure

Before service/maintenance activities begin, the following procedures must be
implemented in the order listed below when locking or tagging out equipment:
1. Prepare for shutdown
The Authorized Employee shall evaluate the equipment to be serviced and identify
all sources of hazardous energies and the methods necessary to control them.
2. Notify all Affected Employees
The Authorized Employee turning off the power shall notify Affected Employees in
the work area that power will be shut off, the reason for the shut-down, and that the
equipment will be locked/tagged out.
3. Shut down equipment
The equipment/machine shall be shut down by the normal stopping procedure.
When appropriate, a "DO NOT OPERATE" tag shall be affixed to the power switch.
4. Isolate equipment
The equipment/machine shall be de-energized, secured and isolated from
hazardous energy sources. An orderly shutdown must be utilized to avoid any
increased or additional hazard(s) to employees.
5. Lockout/Tagout
The Authorized Employee shall place locks and/or tags in the appropriate energy
isolating locations.
6. Release stored energy
After lockout devices have been placed on the equipment, all stored electrical,
pneumatic, gravitational, mechanical and/or thermal energy must be disconnected
and drained to a zero-energy state or otherwise made safe.
7. Verify isolation
Before performing maintenance on the machine, the Authorized Employee verifies
the system is isolated. This is generally accomplished by first establishing that no
personnel are exposed and then turning the machine switch to the ON position
using the normal operating controls
8. Perform the service/maintenance activity
LOTO devices should be removed promptly following completion of
Service/maintenance activities.
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1.5.4 Removal of LOTO

Once the specific maintenance or service work has been completed, the person who
attached the lock or tag is responsible for promptly removing that device.
Removal of LOTO devices will be accomplished by following the steps listed below:
1. Inspect the work area.
Ensure that the equipment/machine is fully assembled and operational, all tools and
nonessential items are removed, and all safety guards are reinstalled.
2. Ensure that all employees are clear of the equipment/machine.
3. Remove the LOTO device.
Each device must be removed by the person who put it on.
4. Reenergize the equipment/machine.
5. Notify Affected Employees that servicing has been completed and the
machine is ready for use.
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2 Installation
Installation and startup shall be performed by authorized personnel only, in order to

avoid injury to personnel or damage to equipment.
Our trained service engineers are available to assist you.
2.1 Mechanical Installation
2.1.1 Dimensional Drawing – Adapter Unit
Please see the accompanying drawing for the dimensions of the robot with the
dimensions for attachment of the gripper.
The robot is normally mounted on the fixed platen of the injection molding machine by
means of an adapter unit in accordance with VDMA 24466 or FHK-85-12-22.
If the adapter is supplied by us, a drawing for installation on the machine is enclosed.
2.1.2 Mounting of the Robot

The weight of the robot is shown on the robot identification plate on the Z beam.
Depending on the version the robots are equipped with one or more of the following
devices for lifting:
• lifting eyes on the main beam (Z axis).
• machined slots for lifting with a fork lift (e.g., in low bays) or with belts.
• Additional holes for the use of lifting rods.
Before lifting the transport pallet, you have to make sure, that the main carriage
(Z axis) and kick stroke (X axis) are in their balanced position.
The axes are in a balanced position, when the respective

arrow marks are aligned.
The picture on the left shows the red arrow marks of the
correctly aligned z-axis of a W811 as an example.
The main carriage and kick stroke can only be moved by applying voltage from an
external power supply in the X and Y axes. Because of the high accelerations of servo
drives, this operation is hazardous and therefore should be performed only by our
trained service engineers.
Before lifting the robot, the vertical axis must be secured against tipping.
When lifting with a fork lift, secure the robot against slipping.
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2.1.3 Demounting of the Robot

The weight of the robot is shown on the robot identification plate on the Z beam.
Depending on the version the robots are equipped with one or more of the following
devices for lifting:
• lifting eyes on the main beam (Z axis).
• machined slots for lifting with a fork lift (e.g., in low bays) or with belts.
• Additional holes for the use of lifting rods.
Before dismantling and lifting away from the console, you have to make sure,
that the main carriage (Z axis) and kick stroke (X axis) are in their balanced
position.
The axes are in a balanced position, when the respective

arrow marks are aligned.
The picture on the left shows the red arrow marks of the
correctly aligned z-axis of a W811 as an example.
The easiest way to move the robot axes into balance, is to do it with the manual
functions provided by the Teachbox, before the robot is decommissioned.
Before dismounting, all electrical and pneumatical connections have to be

disconnected.
Before lifting the robot away, all cables and hoses hanging down from the robot have to
be secured properly, in order to avoid damages, locking the transport, and to avoid the
danger of personal injury.
Before lifting the robot, the vertical axis must be secured against tipping.
When lifting with a fork lift, secure the robot against slipping.
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2.2 Pneumatics
2.2.1 Compressed Air Connection

This connection is made on the service unit with a 1/2" hose. A shutoff valve (ball cock
or quick connection coupling) should be installed at the point of connection of the main
compressed air line.
Required air pressure: 60 - 100 psi (4 – 7 bar)
Air consumption per robot cycle:
The air consumption depends on the optional equipment installed on your robot.
Air consumption of the robot may be calculated from the following table:
Consumption per stroke * Cons. per sec. **

CNC Robots C axis A axis Vacuum per circuit
W811 0,3 0,4 0,4
W813, W823 0,2 0,2 0,4
W821, W831 1,3 0,4 0,4
W832, W833 1,1 1,3 0,4
W843 1,1 1,3 0,4
W853 6,4 8,3 0,4
W873 6,6 4,5 0,4
*: In ft³ at 90 psi (6 bar)

**: For venturi vacuum circuits only
Example of calculation of compressed air consumption:
W833CNC: with X , Y, Z axes motor driven

A and C axes pneumatic
2 vacuum circuits, operated 10 sec. each
1) A axis:
moved twice per cycle: 2 x 1.3 = 2,6 dm³
2) C axis:
moved twice per cycle: 2 x 1.1 = 2,2 dm³
3) 2 vacuum circuits:
each one operated for 10 sec./cycle: 2 x (10 x 0.4) = 8,0 dm³
4) Total consumption: 2,6 + 2,2 + 8 = 12,8 dm³
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2.3 Electrical Connections
2.3.1 Mains Power Supply
The required electrical voltage and power supply are indicated on the identification
plate of the robot. Power connection normally is made with cables and CEE plugs.
The power connection must be made by a qualified electrician in accordance with

federal, state and local regulations.
For personnel safety, proper installation of the earth ground must be verified.
After connection to the power supply, the direction of rotation must be checked (e.g.,
on the vacuum pump). The phasing must be clockwise.
2.3.1.1 Fault Current Safety Switches
Fault current (old: FI, new: RCD) safety switches may be used only under certain
conditions in conjunction with frequency converters:
• In frequency converters with 3-phase input voltage, in the event of a ground

leak a part of the fault current may prevent release of an
FI / RCD safety switch.
• Parasitic capacities in the converter can in principle cause leakage currents,

which may result in false tripping.
Alternative safety measures are for example grounding or protective isolation.
If a fault current safety switch is used in robots with 3-phase converters, it must be a
new RCD TYPE B or RCMA .
If a fault current safety switch is used in robots with single-phase converters, it must be
a new RCD TYPE B or RCD TYPE A .
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2.3.2 Interface with the Injection Molding Machine

The robot is equipped with an electrical interface (plug type HAN 32A) according to
Euromap E67 / E12. In robots supplied as integrated systems, molding machines are
equipped with CAN-BUS controls and safety signals are executed by an emergency
stop. See wiring diagram at the end of this chapter and pin description (Section 2.6).
Connection of the interface plug to the machine and testing of all signals must be done
by a specialist in injection molding machines and robots. Preferably, this should be
done by one of our service engineers together with a qualified service engineer for the
injection molding machine.
The interface signal functions must be carefully tested, as improper operation may
cause malfunction or damage to the robot and molding machine.
In particular, the functions of the safety circuits must be thoroughly checked:
• Emergency stop signals from and to the IMM

• Function of mold safety interlock switches S5/S6
• External safety circuits for access door to the protected area
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2.3.3 Mold Monitoring S5/S6
Proper adjustment of the switching points of the roller switches S5 and S6 is extremely
important, since they secure the closing and opening motions of the IMM. These roller
switch signals are independent from the permission signals of the robot program and
are directly wired through the electrical interface to the IMM (redundant safety).
The switches for S5 and S6 can be physical switches (proximity sensors or roller
switches) or virtual switches (software switching points).
Function and Adjustment of Roller Switch S5:

The roller switch S5 is mounted on the vertical axis and is operated by the cam on the
vertical axis. Only when S5 is actuated, the closing/opening motion is released.
Adjust the cam (the switching point) in a way that S5 is only actuated, when gripper
and part are at a position with sufficient safety distance above the mold.
Function and Adjustment of Roller Switch S6:

The S6 switch is mounted to the main traversing carriage and is operated by the cam
on the Z beam. S6 overrides the function of S5, so that the robot arm can move down
outside the machine without interrupting closing or opening of the IMM.
Adjust the cam (the switching point) in a way that S6 is actuated only while providing a
sufficient safety distance outside the protective guarding of the machine (with the
largest part on the gripper!).
After changing switching points for Mold Monitoring, the roller switch monitoring has to
be re-initialized.
After proper adjustment of the cams, double-check the function of the safety switches
S5 and S6. If neither switch is actuated (robot arm inside mold) ensure that even with a
closing signal present from the robot the closing and opening motion of the IMM is not
possible!
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2.3.3.1 Settings for Virtual Roller Switches (Mold Safety Switches)

Robots with absolute encoders use virtual mold safety switches instead of real
switches and cams.
Open the Init menu Roller Switches to set the switching points and behavior of those
virtual switches.
Fig.: Roller Switches Position
On the tab Position select the desired axes and press to input the position of the
switching point for the related virtual roller switch with the dialogue for numerical input.
Use the tab Init to define if the 0-positions of the axes are situated inside or outside the
mold area.
Fig.: Roller Switches Init
Once you finished all settings, press to exit the window.
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2.3.3.2 Initialize Roller Switch Monitoring

The software constantly monitors the switching points of the roller switches for mold
safety, in order to detect any malfunctions in time. This serves as an additional safety
for avoiding collisions with the mold of the IMM.
Open the Init menu Roller Switches.
The tab Position shows the positions of the switching points as determined by the
software for all mold safety switches present at the robot.
Fig.: Window for roller switches
Switching points that have not been detected since the last time the roller switch
monitoring was reset, will display ??????.? as their position.
If during a product change or during initial setup switching points have been changed
by altering the cams, the roller switch monitoring has to be reset by pressing . All
Positions will display ??????.? and will automatically be re-determined during
movements of the respective axes in operation modes manual and automatic.
Press to close the window.
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2.3.3.3 Test Procedure for Mold Safety S5 / S6
• Switch off Operation with Robot. The LED at the button is not lit.
• Slightly close the mold. The Signal Mold Open must be off.
• Now try to move the Y-axis into the mold area.
• The Y-axis must stop latest when leaving the S5. The error message "Mold
Monitoring" or "Mold Monitoring Braking Distance" must appear on the Teachbox.
• Confirm the message.
• Check if the robot has left the S5. Use the menu View – I/O to do so; the input 482
Roller Switch S5 must be off. If this is not the case, deactivate mold monitoring in
the menu Init – Deactivate monitoring and carefully move the Y-axis off the
switch.
• Now try to close and open the mold. Both movements must be impossible, and an
error message must appear at the IMM.
• Move the Y-axis up and out of the mold area.
• Activate mold monitoring in the menu Init – Deactivate monitoring, if you have
deactivated it previously.
In case of a negative test result, please contact our service center.
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2.4 Safety Package/Safeguarding

As outlined in Chapter 1, the work envelope of the robot must be properly safeguarded
in accordance with legal regulations.
2.4.1 Safety Package
Our robots with R8.3 controls are equipped as a standard with a safety package.
The safety package includes:

• Emergency Stop Disconnect Unit with two channels
• Safety contactor(s) for hardware shutoff of the axis drive when the safety door
(hatch) is opened. In addition, the software monitors these contactors for proper
operation (redundant safety).
• Remote control with 2 permit keys
• Software safety package (monitoring of inputs and outputs)
• Cable with plug for ease of connection of all necessary switching and display
elements for mounting on an access door or hatch
The robot can be operated only if all safety requirements have been met, i.e., all
protective devices have been properly installed prior to startup of the robot.
For a detailed description of the function of the safety package see Section 3.1.10.
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2.4.2 EXTERNAL Safety Package for Safety Door or Access Hatch
Lamp H302 red

Lamp H301 green
Control with
hard- and software for
the safety package
S301
Door switch1
S302 Control panel

Door switcht2 with permit keys
K309
Door interlock
switch
S303
Button for outside
acknowledgement
and Block Stop
S313
a) Step/Automatic/Reference
b) Manual/Setup
External safety package includes:
• Door monitoring switch „Safety Door Open“ (S301)

• Door interlock with contact for software monitoring of function
The door can be opened only when the robot motions have come to a complete stop (K309).
• Door opening contact with roller switch and cam for confirmation of position:
Door open/closed (S301/S302)
• Outside acknowledgment button (S304)
• Selector switch for manual/automatic operation (S313)
• Mounting panel with junction box, plug and 2 indicator lamps:
(H301): robot disabled (H302): robot enabled (automatic operation possible)
These parts are required in order to confirm the function of the safety door in the safety
circuit of the robot program and are obtainable, as an option, with or without safety
door.
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Before starting up the robot, check the safety circuits as follows:
1) Install the complete safety package.

2) Check K24V/X6 PIN7 (wiring board):
If you can measure 24V between X6/PIN 7 (wiring board) and X6/ PIN 8 (wiring
board) the emergency stop circuit is enabled.
3) Check of A24V on X3 PIN 2 (wiring board) (robot disabled):
If a measurement between terminals X3 PIN 2 (wiring board) and X6/ PIN 8
(wiring board) indicates 0V, the circuit is working properly.
4) Open the safety door.
5) Close the safety door.
6) Press the outside acknowledgment button (lamp H301 lights).
7) Turn the selector switch to „Auto“ setting (lamp H302 lights).
8) Check X3 PIN 2 (Verdrahtungsprint) (robot enabled):
If a measurement between terminals X3 PIN 2 (Verdrahtungsprint) and X6/ PIN
8 (wiring board) indicates 24V, the circuit is working properly.
9) Turn the selector switch to „Manual“ (lamp H301 lights).
10) Check of both permit keys for remote control:
When one of the two permit keys is held in its intermediate position, the lamp
H301 lights and operation of the robot with safety door open is possible.
If the permit key is pressed fully, operation of the robot is not possible
(panic).
11) Turn selector switch to „Auto“ position (lamp H302 lights).
12) Teach the robot a „blank“ program and start automatic cycle:
It must not be possible to open the safety door during automatic operation.
Function of Safety Package:
A) Interruption of cycle in automatic operation

The selector switch is in the AUTO/STEP/REFERENCE position.
1) Pressing the „Block Stop“ key on the Teachbox or the button at the safety door
allows the robot to complete the last motion, then the door interlock magnet is
released and the safety door can be opened.
The safety package immediately interrupts the motion in both the hardware and
software upon forcible opening of the safety door.
2) To resume operation:
- Close doors
- Press outside acknowledgment button
- Press automatic start key. Cycle will resume with the next instruction in
the teach program.
B) Manual or setup operation

1) Set selector switch to MANUAL/SETUP.
2) The door interlock magnet will be released, the door can be opened, and the
safety area can be entered.
3) All motions can be performed by remote control by simultaneously pressing the
permit keys and the function keys. Before every new motion, the permit key must
be released one time and then pressed again.
A maximum drive speed of 250 mm/sec is possible In Manual/Setup Operation.
4) To resume operation in automatic mode:
- Close doors
- Press outside acknowledgment button
- Set selector switch to automatic operation
- Press automatic start key; this ensures that the system cannot inadvertently be
started by a third party if an operator is still in the protected area.
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Note:
According to applicable safety regulations, slow motions of the robot axes (max.
of 250 mm/sec or 10 in/sec) are not sufficient to allow access to the work
envelope of the robot and to avoid accidents. Access is allowed only if the
automatic mode is completely interrupted and this condition is secured by
hardware contactors that prevent any motion.
2.4.3 Safety Guarding

This consists of safety door and safety guarding elements.
These safety guarding elements are available as an option in the following sizes (width
* height):
- 1000 mm * 2000 mm
- 500 mm * 2000 mm
These provide complete safety guarding of the work envelope of the robot and/or the
entire automated system.
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2.5 Electrical Interface

This section is not applicable to robots with an integrated system, since here the
signals are transmitted to the injection molding machine via a CAN-BUS interface.
Robots equipped with a R8.3 control unit are available with 2 different interface
versions to communicate with the injection molding machine:
• Euromap 67
• Euromap 12
Both versions are described in the following chapters.
2.5.1 Euromap 67 interface

The Euromap 67 interface defines the connection plug between the injection molding
machine and the robot:
socket
pin
Robot Plug Plug on Injection Molding machine
The robot-injection molding machine interface is designed according to the directives of

Euromap 67, which states:
Unless otherwise noted, the signals level signals, which are maintained during the
described function.
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2.5.1.1 Injection Molding Machine (IMM) Signals
Pin contact Function

no.
ZA1 Emergency Stop Channel 1
ZC1 The emergency stop switch of the injection molding machine is used to interrupt
the emergency stop circuit of the robot.
ZA2 Emergency Stop Channel 2
ZC2 The emergency stop switch of the injection molding machine is used to interrupt
ZA3 Safety system active Channel 1
ZC3 For protecting against hazardous motions of the robot. The switch is closed
when the safety system of the injection molding machine is active.
ZA4 Safety system active Channel 2
ZC4 For protecting against hazardous motions of the robot. The switch is closed
ZA5 Reject
The signal is HIGH when the molded piece is a reject. The switch must be
closed when the tool is open and must remain HIGH at least until “close tool
enabled“ (see pin contact No. A6).
ZA6 Mold closed
HIGH signal when tool closing has been completed; the signal “close tool
enabled“ is no longer necessary (see pin contact No. A6).
ZA7 Mold open
HIGH Signal if the mold opening position is equal or more than the required
position. Inadvertent alteration to mold opening stroke smaller than that required
for the robot to approach must be impossible.
ZA8 Mold at intermediate position
Optional HIGH signal when the mold opening has reached the specified intermediate
position and remains HIGH until the mold is completely open. The signal may be
used in two ways:
1.) The mold stops in the intermediate position, whereupon a signal is sent to the
robot. Complete opening of the IMM takes place through the signal “complete
mold opening enabled“ (see pin A7).
2.) The IMM transmits the signal, but does not remain in the intermediate
position.
Signal is LOW when the intermediate position is not used.
ZA9 Signal Voltage Robot 24V DC
ZB2 Fully automatic mode injection molding machine
HIGH signal, when operating the injection molding machine together with the
robot is possible.
ZB3 Ejector back position
HIGH signal when the ejector is back, regardless of the position of the movable
tool plate. The signal acknowledges “ejector back enabled“ (see pin contact
No.B3).
ZB4 Ejector forward position
HIGH signal when the ejector is forward. The signal acknowledges “ejector
forward enabled“ (see pin contact No. B4).
ZB5 Core pullers 1 free for robot to approach
HIGH signal when the core pullers, regardless of the position of the movable tool
plate, are in position for the robot to approach.
ZB6 Core pullers 1 in position to remove molding
HIGH signal when the core pullers are in position for removal of the injection
molding.
ZB7 Core pullers 2 free for robot to approach
Optional HIGH signal when the core pullers, regardless of the position of the movable tool
plate, are in position for the robot to approach.
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no.
ZB8 Core pullers 2 in position to remove molding
Optional HIGH signal when the core pullers are in position for removal of the injection
molding.
ZC5 reserved for future EUROMAP signal
ZC8 free
ZC9 Signal Ground Robot 0V
2.5.1.2 Robot Signals

no.
A1 Emergency stop of robot Channel 1
C1 Opening of the switch contacts of the robot must shut off the control system of
the molding machine.
A2 Emergency stop of robot Channel 2
C2 Opening of the switch contacts of the robot must shut off the control system of
A3 Mold area free
C3 Signaling is effected by the limit switch at the travel-in rail. The switch is opened
when the travel-in rail, in the region of the injection molding machine, leaves its
starting position before it is moved into the tool area. If the switch is open,
neither a closing nor opening motion of the tool may take place.
Even when the control system of the robot is shut off, the switch must work as
described.
A4 reserved for future EUROMAP signal
C4
A5 free
A6 Close mold enabled
HIGH Signal when the robot is far enough out of the tool that it can be closed
and when other robot control systems enable closing of the tool. The signal
remains HIGH for the duration of the tool-closing operation. In the event of a
LOW signal due to a disturbance, the tool-closing motion must be aborted.
Note: The signal “close tool enabled“ may not be linked with other OR signals in
any operating mode.
A7 Complete mold opening enabled
optional HIGH Signal when the robot has removed the piece from the mold and permits
further opening of the mold. The contact must remain closed until the IMM gives
the signal “mold open“.
A8 reserved for future EUROMAP signal
A9 Signal Ground IMM 24V DC
B2 Operation with robot
At operation with robot the signal is LOW.
B3 Ejector back enabled
HIGH signal when the removal operation has been performed far enough for the
motion “ejector back“ to be carried out. The signal is HIGH for the duration of the
motion “ejector back“. The signal must be maintained at least until the signal
“ejector back“ from the molding machine (see pin contact No. ZB3).
B4 Ejector forward enabled
HIGH signal, when the removal operation has been performed far enough for the
motion “ejector forward“ to be carried out. The signal is HIGH for the duration of
the motion “ejector forward.“ The signal must be maintained at least until the
signal “ejector forward“ from the molding machine (see pin contact No. ZB4).
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no.
B5 Enable movement of core pullers 1 to position for the robot to approach
freely. HIGH signal when the motion of the core pullers is to the position for the
robot to approach freely is enabled.
B6 Enable movement of core pullers 1 to position for removal of the molding
HIGH signal when the motion of the core pullers is to the position for removal of
the molding is enabled.
B7 Enable movement of core pullers 2 to position for the robot to approach
optional freely. HIGH signal when the motion of the core pullers is to the position for the
robot to approach freely is enabled.
B8 Enable movement of core pullers 2 to position for removal of the molding
optional HIGH signal when the motion of the core pullers is to the position for removal of
the molding is enabled.
C5 free
C6 reserved for future EUROMAP signal
C7 reserved for future EUROMAP signal
C8 free
C9 Signal Ground IMM 0V DC
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2.5.2 Euromap 12 Interface

The interface consists of the plug connection between the injection molding machine
and the robot :
1 25
9 2 17 26
Pin
10 3 18 27
11 19 28
4
12 20 29
5
Socket 13 21 30
6
14 22 31
7
15 23 32
8
16 24
The robot-injection molding machine interface is designed according to the directives of

VDMA 24465, and/or according to Euromap 12, which state:
Unless otherwise noted, the signals are maintained during the described function and
should not be shorter than 0.5 sec.
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2.5.2.1 Injection Molding Machine (IMM) Signals

No.
1, 9 Emergency Stop
The emergency stop switch of the injection molding machine is used to interrupt
2 Mold open
The signal is produced by closing the switch. Signal must be interlocked so that
it can be produced only when the minimum tool opening for insertion is reached.
3, 11 Safety system active
For protecting against hazardous motions of the robot. The switch is closed
4 Ejector back
Switch is closed when the ejector is back, regardless of the position of the
movable tool plate. The signal acknowledges “ejector back enabled“ (see pin
contact No. 21).
5 Ejector forward
Switch is closed when the ejector is forward. The signal acknowledges “ejector
forward enabled“ (see pin contact No. 22).
The signal may be an impulse.
6 Core pullers free for robot to travel in
Switch is closed when the core pullers, regardless of the position of the movable
tool plate, are in position for free travel-in of the robot.
7 Core pullers in position for removal of injection moldings
Switch is closed when the core pullers are in position for removal of the injection
molding.
The signal may be an impulse.
8 Reject
Switch is closed when the molded piece is a reject. The switch must be closed
when the tool is open and must remain closed at least until “close tool enabled“
(see pin contact No. 17).
10 Fully automatic mode injection molding machine
Switch is closed when the operating mode selector switch is on “fully automatic
mode.“
11 Reserved for SUVA Safety Package: IMM safety door closed +24V
12 Mold closed
Switch is closed when tool closing has been completed; the signal “close tool
enabled“ is no longer necessary (see pin contact No. 17).
13 Free
14 Mold at intermediate position
Switch is closed when the IMM has reached the specified intermediate position
and remains closed until the IMM is completely open. The signal may be used in
two ways:
1.) The mold stops in the intermediate position, whereupon a signal is sent to the
robot. Complete opening of the IMM takes place through the signal “complete
mold opening enabled“ (see pin 28).
2.) The IMM transmits the signal, but does not remain in the intermediate
position.
Switch is open when the intermediate position is not used.
(Option: Reserved for SUVA Safety Package: IMM safety door closed Channel
2)
15 No part available
16 Signal voltage of robot
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2.5.2.2 Robot Signals

No.
17 Close tool enabled
Switch closes when the robot is far enough out of the tool that it can be closed
and when other robot control systems enable closing of the tool. The switch is
closed for the duration of the tool-closing operation. In the event of contact
release due to a disturbance, the tool-closing motion must be aborted.
Note: The signal “close tool enabled“ may not be linked with other OR signals in
any operating mode.
18, 26 Tool area free
Signaling is effected by the limit switch at the travel-in rail. The switch is opened
when the travel-in rail, in the region of the injection molding machine, leaves its
starting position before it is moved into the tool area. If the switch is open,
neither a closing nor opening motion of the tool may take place.
Even when the control system of the robot is shut off, the switch must work as
described.
19, 27 Emergency stop of robot
Opening of the switch contacts of the robot must shut off the control system of
20 Operation with robot
With the robot in operation the switch is open.
21 Ejector back enabled
Switch closes when the removal operation has been performed far enough for
the motion “ejector back“ to be carried out. The switch is closed for the duration
of the motion “ejector back“. The signal must be maintained at least until the
signal “ejector back“ from the molding machine (see pin contact No. 5).
22 Ejector forward enabled
Switch closes when the removal operation has been performed far enough for
the motion “ejector forward“ to be carried out. The switch is closed for the
duration of the motion “ejector forward.“ The signal must be maintained at least
until the signal “ejector forward“ from the molding machine (see pin contact No.
5).
23 Enable motion of core pullers for removal of injection moldings
Switch is closed when the motion of the core pullers is enabled.
24 Enable motion for free travel-in of robot
25 Option: Reserved for SUVA Safety Package: Robot safety door acknowledged
outside 1st channel
28 Complete mold opening enabled
Switch is closed when the robot has removed the piece from the mold and
permits further opening of the mold. The contact must remain closed until the
IMM gives the signal “mold open.“ If the contact is not used, it must remain open.
(Option: Reserved for SUVA Safety Package: Robot safety door
acknowledged outside Channel 2)
29 reserved for future EUROMAP signal
30,31 free
32 Signal voltage of molding machine
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3 Operating Instructions for R8.3 Control

3.1 Basic Operation
3.1.1 Introduction
The R8.3 control unit is a high-performance control system with a teach programming
interface for the robot and peripheral equipment.
Before starting up the robot for the first time, please review the manual thoroughly and
familiarize yourself with the operation of the robot, to avoid improper use or
programming.
Improper use or programming may result in injury to personnel and damage to the
robot, gripper, mold or injection molding machine. Programming of the robot must be
carried out only by trained personnel who are fully familiar with the operation of the
robot.
We offer training sessions at our service centers. Please contact us.
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3.1.2 Robot Axes
Fig.: Standard Linear Robot
Fig.: Scara Robot
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3.1.3 Emergency Stop Block

The buttons on the Emergency Stop Block are used for basic operation of the robot.
This buttons work regardless whether the Teachbox is connected or disconnected.

Depending on the mode of operation the LED of the corresponding button is lit.
Fig.: Emergency Stop Block
Reference travel
Performing the reference travel. Possible in the mold area only when the
loaded teach program contains a reference travel.
IMM: Operation with robot

Enables operation of IMM with robot. In shut-off state the IMM can be
operated without robot. The LED will flash, when turned on while mold,
ejectors or core pullers are not in a defined position. In this case the
function will be turned on with a delay, in order to allow reaching such a
position.
Automatic-Start
Start of automatic operation. The robot must be in reference mode, the
IMM must be in automatic mode and operation with robot must be on.
Block Stop
Ends automatic operation after complete execution of the currently
processed instruction or group of instructions. Automatic operation may
be continued by pressing the Automatic Start button again.
Manual operation / Stop

Causes an immediate stop and switches to manual operation.
Control Voltage On
Press to switch on the control voltage after the mains switch has been
turned on, or after an emergency stop.
EMERGENCY STOP
Causes the robot to stop immediately. Relevant outputs are disabled
through hardware, the EMERGENCY STOP circuit to the IMM is
interrupted and the LED of the button is lit.
The error message EMERGENCY STOP appears on the display.
See also: 3.1.15.21 Virtual Sub Pendant
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3.1.4 Numerical Input

This window is used to input numbers when necessary.
Fig.: Numerical Input
The title bar displays the name of the parameter. The minimum and maximum values
for the parameter are shown left and right of the current value and on the status bar at
the bottom of the window.
Input the digits using the numeric keys.
discards the changes.
and move the Cursor to the desired direction.
deletes from the current cursor position to the right.
deletes from the current cursor position to the left.
discards the changes and closes the window.
confirms the value and closes the window.
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3.1.5 Text Input

This window is used to input text when necessary.
Fig.: Text Input
The name of the parameter is shown on the status bar at the bottom of the window.
Input is done using the alphanumeric keys that are positioned like on a typewriter.
discards the changes.
and move the Cursor to the desired direction.
deletes from the current cursor position to the right.
deletes from the current cursor position to the left.
confirms the value and closes the window.
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3.1.6 Operating Modes

Operation of the robot requires knowledge about the various operating modes of the
robot.
These divide to the following:
Reference Missing
Status of the control unit after activation. All manual functions are available,
but the numerical axis positions shown on the Teachbox display are invalid. In
order to be able to use all functions of the robot, a reference travel must be
performed.
Manual
All functions of the robot are available; the Teachbox displays valid position
values. In order to be able to start automatic operation, a reference travel must
be performed.
Reference
All axes, vacuum and gripper circuits are in their respective reference
positions. The teached reference programs have been executed. It is possible
to start automatic operation.
Automatic
The Teach program loaded to the robot is being executed.
Blockstop
End of automatic operation after complete performance of the currently
processed instruction or group of instructions. Automatic operation can be
resumed at the next program line by pressing the button .
Wait IMM
The robot is waiting for the injection molding machine.
The robot will switch from Automatic to Wait IMM:

• When the machine changes to Manual.
• When the machine is not in Automatic and the robot reaches a
command that waits for a signal of the machine.
• When the machine is not in Automatic or Operation With Robot is not
on when the robot executes the command
WAIT OP. WITH IMM = ON.
The robot will continue automatic operation automatically once the machine
changes to Automatic or when Operation With Robot is being switched on.
See also:
3.1.7 Operating Mode Reference
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3.1.7 Operating Mode Reference
The Reference travel brings the robot and any peripheral equipment present into a
defined home position in order to enable operating mode Automatic. The reference
positions of the gripper and vacuum circuits are selectable.
As long as no reference travel has been successfully executed after powering up the
unit, only the operating mode Reference Missing will be available.
Depending on the current operating mode of the robot, two different types of reference
travel are executed when the button is pressed:
• Reference travel in the operating mode Reference Missing

• Reference travel in the operating mode Manual
3.1.7.1 Reference travel in the operating mode Reference Missing
In the operating mode Reference Missing no reference travel can be executed in

the mold area. First, the axes have to be moved out of the mold area using manual
functions; furthermore the B-axis (if present) must be moved to its 0-position.
Press and hold the button to start the initial standard reference travel for the robot.
The axes will be traveled to their reference positions using the sequence Y-X-Z-C-A.
Pneumatic axes simply travel to their 0-position limit switch.
Also the numerical axes travel to their 0-position limit switch at first. Axes with an
incremental encoder then travel to the reference mark of the encoder. After that the
respective axis travels to its configured reference position. In standard configuration
this is 10.0 mm (0.04") in plus direction from the 0-position limit switch. After reaching
this reference position the numerical position of the axis is set to zero.
If the button is released before the reference position of the robot is reached, the
movement is stopped immediately.
When you press the button again, the sequence will continue.
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When all axes have reached their reference position, the robot switches to operating
mode Manual.
The Icon is shown at the status bar in the upper left corner of the display; the LED
of the button is lit.
If no corresponding reference travel (ROBOT-REF) has been programmed, now the

grippers have to be brought to their defined reference position. At last the reference
travel in the operating mode Manual has to be carried out, in order to enable automatic
operation.
3.1.7.2 Reference travel in the operating mode Manual
Press and hold the button to start the reference travel.
If reference teach programs for the robot (ROBOT-REF) and the peripheral equipment
(PERI-REF) are programmed, at first these sequences are carried out simultaneously
(!). This makes it possible to reference the robot from inside the mold area, and to bring
peripheral equipment to its home position at the same time. Furthermore the vacuum
and gripper circuits can be switched to their reference states by the reference teach
programs.
If no reference travel for the robot has been programmed, or if after carrying out the
reference teach programs individual axes have not yet reached their 0-position, these
axes are moved into their reference position in the sequence Y-X-Z-C-A.
When the button is released, the movement is stopped immediately. When the
button is pressed again, the reference travel will start from the beginning.
When the reference position is obtained, the robot switches to operating mode
Reference.
The Icon is shown at the status bar in the upper left corner of the display; the LED
of the button is lit.
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3.1.8 Override
This function is used to set the travel speeds of the motor axes in connection with the
maximum speed (VMAX) set in the teach program.
The key can be used in every operating mode to open the override window.
Here you can use the sliders to change the Overrides for the numerical axes of the
robot.
Fig.: Sliders
When the option locked is activated with a all sliders are moved together. When the
option locked is deactivated, the overrides of the axes can be altered individually.
The keys and are used to change the Overrides in steps of 1%.
The key can be used to set the Overrides of all axes to 30% simultaneously.
Use the option ECO-mode to turn the mode for economic travel on or off.
is used to exit the override window.
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Preferably the speeds of the numerical axes should be set in the Teach programm
using VMAX and VABS commands. This should happen in a way that the Overrides of
the axes can be set to 100% when the robot is executing the standard production
cycle.
Depending on the robot settings the Overrides are automatically reduced to 30%,
when:
- a new teach program is started.
- the robot is being powered up.
Example:
In the teach program a maximum speed of 80% of the maximum design speed (design
Vmax) was programmed for the Z axis (Vmax=80%).
The manual override is set at 50% (of Vmax).
Therefore the drive speed is 40% of the maximum design speed.
Fig.: VMAX and Override
Refer to: VMAX, VABS
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3.1.9 ECO-Mode
The function ECO-Mode adapts speed and acceleration of the numerical axes while
traveling outside the mold in a way that the robot arrives at its waiting position outside
the mold at ECO-Buffer time before the next mold opening starts. The movements
inside the mold remain unchanged by the ECO-Mode. This way - without changing the
overall cycle time - a more economic operation of the robot is achieved, compared to
running the robot with full speed and acceleration outside the machine.
You can turn the ECO-Mode on and off in the Override window, using the option ECO-
Mode.
With the ECO-Mode turned on, the robot is calculating the optimum setting during the
first few cycles after starting automatic mode. Only after this the robot will execute the
placing motion with constant low speed and acceleration. The settings made by the
ECO-Mode will be shown with the small sliders in the Override window.
Fig.: Override window with ECO-Mode active
Should the robot out of any reason be too late (mold opens before the robot arrives at
the waiting position), the rest of the cycle will be executed with full speed and
acceleration. During the next cycles the robot will then retry to find the correct settings.
For alternative routines executing special motions (that take significantly longer or
shorter to finish than the standard motion) the ECO-Mode can be deactivated for the
current cycle using the Teach command ECO MODE. The robot will then use the
settings done with VMAX, VABS, AABS and the Override for the current cycle. The
ECO-Mode will be automatically re-activated with the next cycle. Furthermore the ECO-
Mode can be turned on by the command automatically and can be reset.
For permanent irregular travel times, the ECO-Buffer time should be increased to
cover the time difference between the longest and shortest trip, and thus to achieve a
better control behavior.
In order for the ECO-Mode to work, please use a compatible sequence to wait for the
open mold or Smart Removal: In.
Refer to: 3.3.9.7 Teach command ECO MODE
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3.1.10 Safety System
3.1.10.1 Startup with Safety System
3.1.10.1.1 Manual Setup Mode

In order to be able to travel in the manual mode after the control unit has been
activated, the selector switch must be in the MANUAL SETUP position, and one of the
permit keys on the bottom of the teachbox must be actuated.
3.1.10.1.2 Automatic Mode, Step Mode, Reference Travel

After the control unit has been activated, safety must be ensured, since otherwise the
AUTOMATIC, STEP and REFERENCE TRAVEL modes cannot be used with the robot.
To ensure safety:
1.) Open safety door
2.) Close safety door
3.) Press outside acknowledgment key
4.) Set selector switch to position Auto-Step-Reference
The period between opening and acknowledgment outside may be as long as desired
(no time monitoring features are in place).
3.1.10.2 Selection of Operating Modes
3.1.10.2.1 Manual Setup Mode

If the selection switch is in the position MANUAL SET UP, each axis may be moved
while actuating on of the permit keys on the bottom of the teachbox. If you release the
key the selected function will be stopped immediately (software axis stop function;
power supply 24 V for outputs will be disconnected through hardware).
During each change of function (e.g., X axis to Y axis) the permit key must be released
and then pressed again. In order to enter the teach mode, you must first perform
referencing (ensure safety - set selector switch to position Auto - Stepping -
Reference). Then call up the teach mode and set the selector switch to position
MANUAL SET UP. Now the safety door can be opened and it will be possible to teach
the positions inside the protective guarding using the permit key.
3.1.10.2.2 Automatic Mode, Step Mode, Reference

In order to travel to the reference position, all doors must be checked for safety. The
selector switch must be set to AUTOMATIC - STEPPING - REFERENCE position. This
applies to the automatic and stepping modes as well. Should it be necessary to access
the machine during the automatic cycle, press the key first in order to unlock the
door. The door will be unlocked when all axes have completed their motions. If the door
is not opened, automatic operation can be continued with the key. However, if
the door is opened, safety must be ensured after the intervention and the removal cycle
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will be continued with the key. If Safety ensured is shown on the input, the
reference position may be approached and automatic operation started. Safety must
also be ensured for the STEP mode.
3.1.10.3 Monitoring of the Safety Gate

The safety gate monitoring system is active only when the selector switch is in the
AUTOMATIC - STEP - REFERENCE position.
Safety Gate:
The safety gates are electrically monitored by a safety module which ensures that the
robot can be used only in manual operation when someone is within the safeguarded
area, and that no one can accidentally enter the hazardous area of the plant while the
robot is used in the automatic mode. In addition, it is verified that no switches have
been bridged or other interventions made in the safety circuits.
3.1.10.4 Error Effect Analysis

- Safety gate is forced open during automatic operation
-> The safety contactor circuit disconnects all outputs from the power supply by
means of hardware. At the same time, the automatic cycle is interrupted by the
software and shift to manual operation is made.
- The safety gate is opened during the block stop mode

-> The safety contactor circuit disconnects all outputs from the power supply by
means of hardware. At the same time, the software does not permit start of a
new function. Hence a defective output or a faulty program will not lead to an
undesirable motion.
- In the MANUAL SETUP MODE (safety gate not monitored) an axis motion can
be executed only with the permit key. If this key is pressed for a longer period
(30 sec.) without a motion being performed, no new travel instruction may be
executed (by the software). The entire system will go into a failure state (time
monitoring permit key).
- In addition, in an unsafe state all motor axes will be disconnected

by means of hardware from the frequency converter/servo module
feeder line through contactor disconnects.
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3.1.11 User Administration and Passwords

User administration makes it possible to assign different rights of access to fifteen
different users for operation of the robot. For example, operators may be authorized
only for robot operation, shift supervisors for manual functions as well, while machine
programmers could also be allowed to load and change programs, and so forth.
User's rights may be freely specified in 8 different user profiles. Profile 7 defines what
can be accessed without entering a password. The eighth profile (profile 0) is
permanently defined and is reserved for the administrator (Admin) of the system. The
administrator is assigned all rights; as sole user authorized to do so, he may also
create profiles and change passwords. Each user receives a personal password and is
assigned one of the user profiles 1 to 6.
The user administration of the R8.3 control is always active, and cannot be
deactivated. In order to enable operation without a password, enable read/write access
for all functions in profile 7. Thus only the settings reserved for the Administrator will
require a login.
Write down the passwords, especially the administrator password and keep them in a
suitable safe place.
If you lose the administrator password the functions reserved for the administrator
(Changes in the password system and several other base settings) will be no longer
accessible! In this case please contact our nearest service center.
3.1.11.1 Administrator
In order to be able to manage users with their profiles and passwords, and for some
other base settings you will have to login as administrator.
The user name for the administrator is always ADMIN.

The password for the administrator is 1234 at delivery.
For real use of the user administration the password of the administrator must be
changed in order to avoid unauthorized access.
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3.1.11.2 Users
Creating, changing and deleting of users is only possible if you login as administrator.
In the menu Init select User Administration, and switch to the tab Users.
Here you can assign User Profiles to existing users by activating the desired option in
the line with the user by tapping the option.
is used to create a new user.
is used to delete the highlighted user.
is used to edit the highlighted user
discards the entries and closes the window.
confirms the new user data.
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3.1.11.2.1 User (create, change)

Here you can create a user or change the data of a user.
Fig.: Window to edit a user
After tapping the respective input field, the desired value can be entered using the
dialogue for text input.
confirms the new profile data.
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3.1.11.3 Profiles
You have to login as administrator to access the user profiles.
In the menu Init select User Administration and switch to the tab Profiles.
Here you can set up user profiles 1 to 7 to suit your needs.
is used to lock the highlighted function in the respective profile. This will be
indicated by an x in the table.
is used to give a "read only" permission for the highlighted function in the
respective profile. This will be indicated by an r in the table.
is used to give a "read and write" permission for the highlighted function in the
respective profile. This will be indicated by an r/w in the table.
confirms the new profile data.
Profile 7 is used to permit functions for use without password!
If a "read and write" permission is given for the Text Editor, automatically a "read and
write" permission is given for the Manual Functions.
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3.1.11.4 Login
With user administration activated in the logged out state (e.g. after powering up the
unit) only the buttons to change the mode of operation, the help function and the
functions activated in profile 7 are available. All other functions are deactivated.
The icon will be displayed in the status bar.
Each user has to login with name and password to access the functions attached to his
profile. Tap the menu Init and there Login to do so.
You then can login using the following window:
Enter your user name after tapping the input field Insert Username using the dialogue
for Text Input.
Enter your user password after tapping the input field Insert User Password using the
dialogue for Text Input.
will confirm the entries and log you in.
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3.1.11.5 Logout
With user administration activated, one should logout when leaving the Teachbox, in
order to avoid misuse of the appliance.
Tap the menu Init and Logout to do so.
The Icon will be displayed in the status bar.
Only the buttons to change the mode of operation, the help function and the functions
activated in profile 7 will be available. All other functions will be deactivated.
3.1.11.6 Forgot Password

In case you forgot the administrator password, you can press the button Forgot
Password in the Login window to get the passwords encrypted to a code:
With this code you can contact our local service center to help you.
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3.1.12 Manual Functions
3.1.12.1 Numerical Axes
This function is used to manually move the selected numerical axis in the operating
modes Manual, Reference and Reference Missing. Furthermore the

current position of the axis is displayed in all operating modes.
At robots with secondary axes press the axis button longer, if you want to display the
buttons for toggling between main axis and secondary axis.
Whether the numerical axes can be moved using variable or fixed manual speeds is
being set in the Init Menu Setup: Robot Settings.
Fig.: Numerical axis with variable manual speed
Fig.: Numerical axis with fixed manual speeds
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moves the axis into plus direction with variable speed.
moves the axis into plus direction with high manual speed.
moves the axis into plus direction with low manual speed.
moves the axis about 0,1mm into plus direction.
moves the axis about 0,1mm into minus direction.
moves the axis into minus direction with low manual speed.
moves the axis into minus direction with high manual speed.
moves the axis into minus direction with variable speed.
is used to close the window.
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3.1.12.2 Axis Release in Manual Mode (optional)
When horizontal, numerical axes are equipped with the optional feature of Axis
Release, it can also be activated in operating mode Manual. Releasing an axes in
manual mode will open the brakes of the respective axes, which results in the
possibility to shift those axes by hand.
Activation is done in the View Menu Axes Positions:
Fig.: View Menu Axes Positions with Release
With a at the option Release the respective axis will be released immediately.
The release can be switched off manually tapping the option Release again.
Additionally the release will be switched off automatically, if any other drive command
is sent to the axis.
is used to release all releasable axes.
is used to deactivate all releases.
See also: 3.3.1.3.7 Teach command Axis Release
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3.1.12.3 Pneumatic Axes
This function is used to manually move the selected pneumatic axis in the operating
modes Manual, Reference and Reference Missing. Furthermore the

current position of the axis is displayed in all operating modes.
Fig.: Window for pneumatic axes
moves the axis directly to the endposition in plus direction.
moves the axis to the next intermediate position in plus direction.
moves the axis to the next intermediate position in minus direction.
moves the axis directly to the endposition in minus direction.
The number of positions depends on the type and equipment of the selected axis.
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3.1.12.4 Digital (B-) Axes
This function is used to manually move the selected digital axis in the operating modes
Manual, Reference and Reference Missing. Furthermore the current

position of the axis is displayed in all operating modes.
Fig.: Window for digital axes
moves the axis 90° into plus direction.
moves the axis 15° into minus direction.
When traveling a digital axis, the respective button should be held until the control unit
has finished the selected movement. Otherwise the axis may stop between two
positions and cause an error message.

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3.1.12.5 Counters
This function is used to display, reset or set the 64 counters of the Teach program in
any mode of operation.
Fig.: Counter window
is used to set the selected counter to a desired value. The numeric value is
entered using the dialogue for numerical input.
is used to reset the selected counter to zero.
is used to reset all 64 counters to zero.
Depending upon the application of the counter in the teach program, modifying
counters (especially in automatic mode) can result in serious changes in execution of
the program, as well as in damage due to collisions! Therefore, counters should
(especially in automatic mode) be modified only with caution by persons who are
familiar with the effects of such modification on the teach program.
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3.1.12.6 Placing Counters
This function is used to display the current values of the counters of the 16 placing
programs of the teach program in all operating modes. In operating modes
Manual, Reference and Reference Missing it is furthermore possible

to reset the counters to zero.
Fig.: Window for placing counters
Name
Shows the name of the respective placing program.
Used Axes
This shows which axes are used in the respective placing program.
1. - 2. - 3.
This shows the current values of the placing counters of the respective placing
program.
Part Counter
This shows the current value of the part counter of the respective placing program.
is used to reset the counters of the selected placing program.
is used to reset the counters of all 16 placing programs.
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3.1.12.7 Conveyors
This function is used to manually switch the conveyors during operating modes

states of the conveyors are displayed in all operating modes.
Fig.: Window for conveyor belts
means the respective conveyor is OFF.

means the respective conveyor is ON.
is used to switch the selected conveyor on.
is used to switch the selected conveyor off.
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3.1.12.8 Peripheral Outputs
This function is used to manually switch the peripheral outputs during operating modes

states of the peripheral outputs are displayed in all operating modes.
Fig.: Window for peripheral outputs
means the respective peripheral output is OFF (LOW).

means the respective peripheral output is ON (HIGH).
is used to switch the selected peripheral output on.
is used to switch the selected peripheral output off.
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3.1.12.9 Vacuums
This function is used to manually switch the vacuum circuits during operating modes

states of the vacuum circuits are displayed in all operating modes.
Fig.: Window for vacuum circuits
means the respective vacuum is OFF.

means the respective vacuum is ON.
means the respective vacuum is blowing off (optional).
is used to switch the selected vacuum on.
is used to switch the selected vacuum off.
is used to switch the selected vacuum to blow off (optional).
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3.1.12.10 Grippers
This function is used to manually switch the grippers during operating modes
Manual, Reference and Reference Missing. Furthermore the current states

of the grippers are displayed in all operating modes.
Fig.: Window for grippers
means the respective gripper is OPEN.

means the respective gripper is CLOSED.
indicates that the gripper is RELEASED.
indicates that the state of the gripper is UNKOWN.
is used to switch the selected gripper on.
is used to switch the selected gripper off.
is used to release the selected gripper.
The state RELEASED is only available at gripper circuits equipped with the required
valves.
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3.1.12.11 Cylinders
This function is used to manually switch the Cylinders defined within the teach program
during operating modes Manual, Reference and Reference Missing.

Furthermore the current states of the cylinders are displayed in all operating modes.
Fig.: Window for cylinders
indicates that the cylinder is in OFF position.

indicates that the cylinder is in ON position.
indicates that the cylinder is RELEASED.
indicates that the state of the cylinder is UNKOWN.
is used to switch the selected cylinder to its ON position.
is used to switch the selected cylinder to its OFF position.
is used to release the selected cylinder.
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3.1.13 FILE Menu of the main screen
3.1.13.1 Properties
Here the properties of the Teach program of the robot are displayed. That is the
program which is executed when the robot is in automatic operation.
Fig.: Window for properties of the CPU program

Name of Teach program
Shows the name of the teach program of the robot. This name is not necessarily the
same as the file name of the program.
CPU = Teachbox or CPU <> Teachbox
Displays whether the teach programs in the robot (CPU) and the Teachbox are equal
or unequal.
Tooldata
Displays the Tooldata text of the teach program of the robot. The text for Tooldata can
only be edited in the properties window of the text editor.
Size
Displays the size of the teach program in the robot. The maximum size of a teach
program is limited to 32.768 bytes.
Number Part Programs
Shows the number of part programs of the teach program in the robot: ROBOT-PRG,
PERI-PRG, ROBOT-REF, PERI-REF, ALLMODE-PRG and up to 120 additional part
programs.
Number Placing Programs
Shows the number of placing programs used in the teach program in the robot. The
maximum number of placing programs available in a teach program is limited to 16.
If a picture has been associated with the selected teach program, can be used to
open the picture viewer.
can be used to email the Teach program as an email attachment (*.wip, *.htm and
*.txt file) using the manual email function of the robot.
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3.1.13.2 Backup stored Teachprograms

The R8.3 control gives you the possibility to store Teachprograms on the internal
storage medium of the robot control unit. Nevertheless you should regularly backup the
stored programs externally, in order to avoid data loss.
Everything you store on the internal storage medium of the robot will end up in the
folder C:\PUBLIC and its subfolders. Therefore use the backup function for the public
folder to backup your data on an USB stick.
Proceed like this:
1) Plug in your backup-USB-stick to the Teachbox.
2) Login as Administrator.
3) Open the menu File – System Backup/Restore and select the tab .
Fig.: Selection for backup of the Public folder
4) Activate only the option Public folder and press .
5) Answer the questions about overwriting. At the end of the backup process you will
have the possibility to display a report about the copied files.
6) Close the window with .
7) Logout as Administrator.
Storage location for the backed up files on the USB stick is the folder Backup. Each
robot will add its own subfolder inside that folder. The name of the subfolder will consist
of the respective robot type and serial number using the format Wxxx-xxxx. Thus you
can use one USB stick to backup data from several robots.
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3.1.14 INIT Menu

The INIT menu is used to adjust robot settings. Some settings can be accessed by the
logged-in administrator (Admin) only.
3.1.14.1 Stroke Limits

The stroke limits are software limit switches to limit the maximum travel range of an
axis.
In operating mode Reference Missing the stroke limits are not active, the axes
travel is limited by the hardware limit switches. If a stroke limit is reached in manual
mode, the robot will stop at the position value of the stroke limit without an error
message. In automatic mode the error message 004-007 STROKE LIMIT will be
shown.
Axes commands in a Teachprogram will be checked already during transfer to the

CPU. If an axis command targets a position outside the stroke limits, the error message
160-005 TARGET OUT OF STROKE LIMITS including the affected line number and
axis will be shown.
Fig.: Window for stroke limits
After tapping the respective input field, the desired axis value can be input using the
dialogue for numerical input. The title bar of the dialog box will show which axis value is
to be entered while doing so.
discards the entries and closes the windows.
changes the stroke limits to the entered values.
The respective stoke limit of a numerical axis will be set automatically, when a position
limit switch is approached while the robot is not in operating mode Reference
Missing.
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3.1.14.2 Roller Switches

The roller switches are used for mold monitoring.
Refer to chapter 2.3.3 Mold Monitoring S5/S6
3.1.14.3 Absolute Encoders (Admin only)

The menu Init – Absolute encoders serves for setting the zero points of axes with
absolute encoders.
Setting the zero points of axes with absolute encoders will be necessary at initial
startup in the factory; after installing a new drive belt, motor, gearbox, etc.; and after a
battery failure of the Sanyo R drive.
Caution! Changing the zero points will lead to severe danger of collisions,
because all positions in all Teachprograms of the robot will be invalid!
See also:
6.5.2 Battery replacement at Sanyo R inverters.
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3.1.14.4 Deactivate Monitoring

This function is only available for users with write permission for the text editor.
In the selection window Init / Deactivate monitoring you can disable various
monitoring functions temporarily. Thus you can manually move the robot out of
hazardous areas, after one or more of the monitoring functions were triggered.
Fig.: Selection window for Deactivate Monitoring
The following monitoring functions can be deactivated:

• Mold Monitoring
• Safety Areas (if present)
• Collision Monitoring (if present)
The selection window only shows monitoring functions which are currently present.
A deactivates the respective monitoring.
When monitoring functions are deactivated, the icon for the mode of operation changes
its color to yellow.
The monitoring functions remain deactivated until one of the following events:
• A reference travel is executed.
• The users logs out or is being logged out.
• The monitoring functions are re-activated manually.
Press to close the window.
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3.1.14.5 Maintenance - Lubrication Interval

This function was introduced in order to call the user's attention to regular lubrication of
the guides.
Fig.: Window for lubrication
In the line Configured Interval the configured lubrication interval in kilometers is

shown.
At the axes the distances traveled since the last lubrication are shown.
If the distance traveled by one axis exceeds the configured interval, the symbol will
be shown in the status bar, to remind that lubrication is needed.
After the robot has been lubricated, the traveled distances can be reset to zero using
the button .
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3.1.14.6 Setup: Robot Settings
Fig.: Window for robot settings
Set Service Signal when Lubrication Interval is reached

This is used to configure whether or not an output is to be switched on once the
lubricating interval has been exceeded. Any desired signal transmitter (horn, lamp, etc.)
may be connected to this output.
Switch POs in Editor On

This function is used to configure whether or not peripheral outputs and conveyors are
turned on or off during teaching when the corresponding function is programmed. I.e., if
this option is activated and the command to turn on peripheral output 2 is entered in the
editor, output 2 will in fact be turned on immediately. This will not happen if the option
Switch POs in Editor On is deactivated.
Step speed
Speed setting in percent of the configured maximum axis speed used for axes
movements in step mode and while executing programmed reference travels. After
tapping the input field the desired value can be entered using the dialogue for
numerical input. Value range is from 1 to 30%.
Clear Counters
This is to determine when the counters and placing programs of the teach programs
are to be cleared automatically. If the option Clear Counters with New Teach Program
is deactivated, the request Clear all Placing programs and Counters? is shown every
time a new or changed teach program is being transferred.
Override
The two options are to determine the automatic behavior of the Override. When none
of the options is activated, the Override is automatically reduced to 30% when a new
teach program is started or the robot is being powered up.
Axes Speeds
This is to determine if numerical axes use variable or fixed speeds for manual
movements.
Units
This is to determine if distances and positions are displayed in Millimeters or Inches.
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End-Of-Arm-Tooling by RF-Id
Use this option to determine the behavior when the optional RF-ID End-Of-Arm-Tooling
recognition loads teach programs automatically.
Show mouse cursor

Use this option to display a mouse pointer at the coordinates of the last registered
touch at the touch screen.
confirms the entries and closes the window.
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3.1.14.7 Setup: Date / Time

Here you can set date and time.
Fig.: Window for date and time settings
3.1.14.8 Setup: Language

This is to change the display language of the Teachbox.
Fig.: Window for language setting
First select the desired language from the list by tapping it.
Then press to load the selected language.
During the loading process a window with a progress bar is shown.
is used to close the window without changing the language.
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3.1.14.9 Setup: Network Settings (Admin only)

This is to do the settings for the network connection of a robot.
Fig.: Window for network settings
IP-Address
Distinct, static network address of the robot.
Subnet Mask
Mask for limiting the number of participants in the local network.
Default Gateway
Address for establishing connection with participants outside the own local network
segment.
DNS Server
Address of the server for name resolution.
Mailserver
Address of the server handling email traffic.
UDP Port
Local port for UDP traffic. Use the standard setting.
VNC Logout Time
Time of inactivity after which (remote-) users automatically release the Teachbox
access.
The values for IP-Address, Subnet Mask, Default Gateway, DNS Server and Mailserver
have to be assigned by the network administrator.
After tapping the respective input field use the dialogue for numerical input to enter the
desired value.
The current network settings can be viewed in View / Operating Systems also.
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3.1.14.10 Setup: Remote Users Settings (Admin only)

This is to do the settings necessary for VNC remote users access.
Using VNC (Virtual Network Computing) and a VNC viewer software the Teachbox can
be displayed on a remote PC via a network and the robot being remote controlled
respectively. At integrated solutions with injection molding machines VNC is used to
enable accessing the functionalities of the Teachbox also on the panel of the injection
molding machine.
For using this function it is required that the robot is attached to a network. Furthermore
the Network Settings must be correct and Licenses for VNC access must be
available.
Fig.: Window for remote users settings
Press to open the window for creating a new remote user.
Press to open the window for editing the selected remote user.
Press to delete the selected remote user.
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3.1.14.10.1 Create / Edit Remote Users (Admin only)
Type
A remote user of the type IMM can access all functions of the Teachbox, if his assigned
local user has the respective permissions. This is used for IMM integrations. Also a
remote user of the type Remote User can only access functions, his locally assigned
user has permissions for – additionally he can neither use manual functions nor
perform changes of the operating mode. The type IMM is only available at integrated
solutions.
Username
Here you choose a user from the local User Administration to be used for the remote
user. The remote user will always be automatically logged in with the user name of the
selected user, and will have the respective permissions.
IP-Address
The IP-Address oft the remote computer of the remote user. The remote user will be
identified with his IP-Address, and will be given access with that address only.
Online Users
This displays a list of IP-addresses of remote computers that are requesting VNC
access successfully or unsuccessfully.
3.1.14.11 Licenses (Admin only)

This window displays the number of available VNC licenses for remote users.
Furthermore this is where you activate additionally acquired licenses.
In case you should need additional licenses, please contact our service office
responsible for you.
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3.1.14.12 Setup: Email Settings

This is to do the settings for the manual and automatic email functions of a robot.
3.1.14.12.1 Tab Basic
Here you input the E-mail sender address for the robot and the contact email
address of our technical support facility responsible for you, using the dialogue for
text input.
After selecting the desired entries with a you can press to use the default
addresses.
3.1.14.12.2 Tab Content
Select the content to be included in automatically generated emails.
You can add description text for the work cell of the robot using the dialogue for text
input after tapping the input field.
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3.1.14.12.3 Tab Timeouts
Set the timeout for the automatic email function. In case of the robot stopping with an
error message (switching from automatic mode to manual mode) and nobody
confirming the error message(s) within this timeout, the robot will send emails with the
selected content to the selected recipients.
3.1.14.12.4 Tab Recipients
Create, change or delete possible recipients for the automatic email function.
Press to open the window for creating a new recipient.
Press to open the window for editing the selected recipient.
Press to delete the selected recipient.
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3.1.14.12.5 Tab Events
Select the recipients to sent an email to with the automatic email function. You can
create additional recipients on the tab Recipients.
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3.1.14.13 Setup: Screensaver Properties
Fig.: Window for the properties of the screensaver
Start screensaver after inserted time

This is used to activate or deactivate the screensaver.
Activation Timeout
This is the time to pass after the last touching of the touchscreen, before the
screensaver starts. After touching either the minutes or seconds field, values are input
using the dialogue for numerical input.
Switch Time
This is the time the screensaver uses to show each picture. After touching either the
minutes or seconds field, values are input using the dialogue for numerical input.
is used to start the screensaver immediately for testing purposes.
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3.1.14.14 Setup: Calibrate Touch

This function is used to calibrate the touchscreen of the Teachbox. This is necessary
for the Teachbox to correctly calculate digital X/Y coordinates from the two analogue
resistance values supplied by the touchscreen. Only then it is possible for the
Teachbox to react correctly when the touchscreen is tapped on.
Calibrating the touchscreen is only necessary when pressed buttons are not interpreted
correctly.
After calling the function please follow the instructions on the screen. Tap the center of
the displayed crosses as exactly as possible.
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3.1.15 View Menu

The VIEW menu is used to display information out of the robot control unit.
3.1.15.1 Operating Systems

This window displays the versions of software loaded to the robot and the network
settings.
Fig.: Window for Operating Systems
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3.1.15.2 Operating Data

This window displays operational data of the robot.
Fig.: Window for Operating Data
Cycletime
Displays the time between the last but one and the last positive slope of the signal
"Mold Open" from the IMM. This is the time needed to produce one part (round).
Cyclecounter
The cycle counter counts the positive slopes of the signal "Mold Open" from the IMM
during automatic operation of the robot. The cycle counter is only reset by using the
boot medium.
Withdrawaltime
Displays the time between the positive slope of the signal "Ejector is forward" of the
IMM and the moment when the robot is travelling onto the bar of the S5 rollerswitch of
the Y-arm. This is the time the robot needs to get out of the mold with the part on the
gripper.
Mold open time

Displays the time between the positive slope of the signal "Mold Open" of the IMM and
the positive slope of the permit signal "Close mold" of the robot to the IMM. This is the
time the IMM has to wait for the robot before it can mold the next part.
Operating Hours
Displays the overall time the robot worked in automatic mode. The operating hours are
only reset by using the boot medium.
Lubrication
In the first line the lubrication interval is displayed, in the following lines the kilometers
travelled by the linear axes since the last lubrication are shown.
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3.1.15.3 Axes positions

This window displays the current positions of the robot axes and their drive type.
Fig.: Window for axes positions
The number and type of the axes shown is depending on the configuration of the actual
robot.
The positions are shown in millimeters for linear axes and in degrees for rotary axes.
The resolution of the values displayed is always one tenth.
See also: 3.1.12.2 Axis Release in Manual Mode
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3.1.15.4 I / O
This window displays the current states of the inputs and outputs of the robot control
unit.
Fig.: Window for inputs and outputs
Tap one of the tabs Input or Output to select if either the inputs or the outputs are to
be shown.
All 512 theoretically possible inputs and outputs of a robot are shown. If any input or
output is displayed in this window, it does not indicate that this input or output is really
existent on the actual robot. If (NC) is displayed right next to the name, the respective
input or output is not configured on the current robot.
indicates that the input/output is OFF (LOW).

indicates that the input/output is ON (HIGH).
The four buttons on the right are shortcuts to certain function groups:
inputs and outputs of the IMM interface
peripheral inputs and peripheral outputs
inputs and outputs of the grippers
inputs and outputs of the vacuum circuits
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3.1.15.5 Safety Areas

Here you can view the settings of the current safety areas.
Fig.: View Menu safety areas with working area and example areas
The Working Area is always present. It is defined by the Stroke Limits of the robot.
is used to open a window showing the coordinates of the selected safety area.
When you press with the working area selected, the window for setting the
visibility of the working area in the graphical display will be opened.
is used to open the graphical display of the safety areas.
See also:
3.2.6.3 Setup Menu: Safety Areas
3.2.6.3.3 Graphical display of the safety areas
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3.1.15.6 Counters
This window displays the current values of the 64 counters of the teach program.
Fig.: Window for counters
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3.1.15.7 Placing Counters

This window displays the current counter values of the 16 placing programs of the
teach program.
Name
Shows the name of the respective placing program.
Used Axes
This shows which axes are used in the respective placing program.
1. - 2. - 3.
This shows the current values of the placing counters of the respective placing
program.
Part Counter
This shows the current value of the part counter of the respective placing program.
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3.1.15.8 Conveyors
This window shows the current state of operation of the conveyor belts.
Fig.: Window for conveyors
indicates that the respective Conveyor is OFF.

indicates that the respective Conveyor is ON.
3.1.15.9 Cylinders
This window shows the current state of the cylinders defined in the teach program.
Fig.: Window for cylinders
indicates that the cylinder is in OFF position.

indicates that the cylinder is in ON position.
indicates that the cylinder is RELEASED.
indicates that the state of the cylinder is UNKOWN.
valves.
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3.1.15.10 POs - Peripheral Outputs

This window displays the current states of the peripheral outputs of the robot control
unit.
Fig.: Window for peripheral outputs
indicates that the peripheral output is OFF (LOW).

indicates that the peripheral output is ON (HIGH).
3.1.15.11 PIs - Peripheral Inputs

This window displays the current states of the peripheral inputs of the robot control unit.
Fig.: Window for peripheral inputs
indicates that the peripheral input is OFF (LOW).

indicates that the peripheral input is ON (HIGH).
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3.1.15.12 IMM I / O
This window displays the current states of the signals of the IMM interfaces.
Fig.: Window for IMM interfaces
If the robot is equipped with 2 interfaces for injection molding machines, tap one of the
options IMM 1 or IMM 2 to select the interface to be displayed.
indicates that the interface signal is OFF (LOW).

indicates that the interface signal is ON (HIGH).
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3.1.15.13 AutoSwitches
This window displays the current states of the 32 AutoSwitches.
Fig.: Window for AutoSwitches
indicates that the AutoSwitch is OFF.

indicates that the AutoSwitch is ON.
3.1.15.14 Stopwatches
This window displays the values measured by the four stopwatches available in the
teach program.
Fig.: Window for stopwatches
The minimum value, maximum value and average value calculated from the
measurements done, as well as the current value are displayed for each stopwatch.
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3.1.15.15 Vacuums
This window shows the current state of operation of the vacuum circuits.
Fig.: Window for vacuum circuits
indicates that the vacuum circuit is OFF.

indicates that the vacuum circuit is ON.
indicates that the respective vacuum is blowing off (optional).
3.1.15.16 Default Vacuum Level

This window shows the current pressure values and states of the analogue vacuum
circuits.
Fig.: Window for vacuum pressure values
indicates that the vacuum circuit is OFF.

indicates that the vacuum circuit is ON.
The big bar and the field below the scale show the current under-pressure, the small
bar and the number right next to it display the set default vacuum level.

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3.1.15.17 Grippers
This window shows the current state of the grippers.
Fig.: Window for grippers
indicates that the gripper is OPEN.

indicates that the gripper is CLOSED.
indicates that the gripper is RELEASED.
indicates that the state of the gripper is UNKOWN.
valves.
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3.1.15.18 Alarms
This window displays all occurring operational error messages in plain text, each with a
specific error number.
Fig.: Error Window
The error messages are displayed in two colors:
Red
Error and cause currently exist. The error is active. The cause of the error has to be
eliminated, before the error can be confirmed. The icon will be displayed in the
status bar if one or more errors are active.
Gray
The error occurred, but the cause no longer exists. The error is inactive and can be
confirmed.
is used to confirm inactive errors.
Press to display a help text for each error message. Press to turn off the
help texts again.
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3.1.15.19 Error Buffer

This window displays the last 500 operational error messages in chronological order.
Fig.: Error Buffer
is used to refresh the list.
can be used to email the contents of the error buffer by means of the manual
email function of the robot. This requires the robot being connected to a network.
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3.1.15.19.1 Export the Error Buffer
The contents of the error buffer can be stored to a UNICODE text file *.TXT on the USB
stick. Path and name of the file are selectable. The default folder is
D:\ROBOT\LOG\ERRORS. The generated file can be opened, displayed and printed
with a PC, or can be forwarded to our service department if needed.
Press to open the dialogue for exporting the error buffer:
Fig.: Dialogue for exporting the error buffer
The display of the contents of the current folder uses the following icons:
for a sub-folder
for a text file *.TXT
After tapping the field Filename you can use the dialogue for text input to input the
desired filename. By tapping on it in the display of the current folder, you can also use
the name of an existing file.
is used to step up one folder.
opens the standard folder for this file operation.
could be used to create a new folder.
is used to delete the selected file or folder.
is used to rename the selected file or folder.
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is used to optimize the display of the contents of the current folder for either short
or long file names.
is used to open the selected folder.
is used to save the file to the current folder, applying the name from the field
Filename.
is used to abort the function and to close the window.
Before the file is actually stored, the Teachbox checks if a file with the same name is
already stored in the selected folder, and a check back message may appear.
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3.1.15.20 Command Buffer

This window displays the last actions (operating steps) executed in chronological order.
Fig.: Command Buffer
is used to refresh the list.
can be used to email the contents of the command buffer by means of the manual
email function of the robot. This requires the robot being connected to a network.
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3.1.15.20.1 Export the Command Buffer
The contents of the command buffer can be stored to an UNICODE text file *.TXT on
the USB stick. Path and name of the file are selectable. The default folder is
D:\ROBOT\LOG\COMMANDS. The generated file can be opened, displayed and
printed with a PC, or can be forwarded to our service department if needed.
Press to open the dialogue for exporting the command buffer:
Fig.: Dialogue for exporting the command buffer
for a sub-folder
for a text file *.TXT
After tapping the field Filename you can use the dialogue for text input to input the
desired filename. By tapping on it in the display of the current folder, you can also use
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is used to optimize the display of the contents of the current folder for either short
or long file names.
is used to save the file to the current folder, applying the name from the field
Filename.
Before the file is actually stored, the Teachbox checks if a file with the same name is
already stored in the selected folder, and a check back message may appear.
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3.1.15.21 Virtual Subpendant (Emergency Stop Block)
The buttons on the Emergency Stop Block are used for basic operation of the robot.
The virtual Subpendant displays these buttons on the touch screen of the Teachbox.
Touch the icon for the operating mode at the upper left corner of the touch screen to
access the virtual Subpendant directly.
3.1.15.21.1 Tab Standard
Fig.: Tab Standard of the virtual Subpendant (Emergency Stop Block)
Reference travel
Press and hold to execute the reference travel. In the mold area this is possible only
when a reference program has been programmed.
IMM: Operation with robot

This enables operation of IMM with robot. In shut-off state the IMM can be operated
without robot.
Automatic-Start
Start of automatic operation. The robot must be in reference position and operation
with robot must be activated.
Block Stop
Press to stop automatic operation after complete execution of the currently processed
instruction or group of instructions. Automatic operation can be continued by pressing
the Automatic Start button again.
Manual operation / Stop

Causes an immediate stop and switches to manual operation.
See also: 3.1.3 Emergency Stop Block

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3.1.15.21.2 Tab Easy
Fig.: Tab Easy of the virtual Subpendant (Emergency Stop Block)
Here, the buttons of the Subpendant and some additional functions for easy operation
of the robot are collected in the groups Prepare, Start and Stop.
Dry Cycle
Use this function to test a Teachprogram, without producing parts with the IMM. When
the Teachprogram runs on to decisions that would account for the IMM to run in full
automatic mode, a dialogue will be displayed, where the user can decide how the robot
shall continue.
One Cycle
Use this function to make the robot take out and place one shot only. The mold of the
IMM will remain open. The robot will travel back above the IMM and will switch to
Blockstop mode at the command that waits for the opening of the mold. Only after
or being pressed again, the mold of the IMM will be closed, and the next cycle will
start.
EOAT Change
Use this to execute the EOAT change program .
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3.1.15.22 Memory State

This window displays information about the memory load of the Teachbox. For service
purposes only.
Fig.: Window for Memory State
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3.1.16 System Report

The System Report is useful for simple and effective transmission of all data out of the
robot control unit that might be helpful for the service department to do a remote
diagnosis in case of a problem.
The following information will be stored in a file:
• Versions of software and operating systems

• Operating data
• Teach program out of the robot
• Contents of the error buffer
• Contents of the command buffer
• Configuration data
When creating a system report, plug a USB stick into the Teachbox first. Then open the
Help menu "?" and start the function System Report.
The dialogue for text input will appear, and a comment about the report can be entered.
After this the System Report will be stored on the USB stick using the following file
name and path: ..\ROBOT\LOG\SYSTEM\Wxxx-xxx_sys.zip
After a successful completion of the storage process, a window like this will appear:
can be used to email the system report file by means of the manual email function
of the robot. This requires the robot being connected to a network.
The System Report can now be loaded from the USB stick to a PC, and can be
forwarded via email, for example.
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3.1.17 Email Functions
3.1.17.1 Manual Email Function

By means of the manual email function the user can send the current Teach program,
the error buffer, command buffer or system report to any choice of recipients directly
from the robot.
For using this function it is required that the robot is attached to a network and has
access to a mail server. Furthermore the Network Settings and the Email Settings in
the menu Init/Setup must be correct.
After accessing the function with , the window for selecting email recipients will
appear:
Fig.: Window for selecting email recipients
Add recipient
Tap this field to enter a new recipient with the dialogue for text input.
Select recipient
Tap to select an existing recipient and press to add this recipient to the list of
recipients for the current email.
Recipients
This field displays the list of recipients chosen for the current email. Press if you
want to remove all entries from this list of recipients.
is used to send the email to the chosen recipients.
is used to cancel the function without sending an email.
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3.1.17.2 Automatic Email Function

By means of the automatic email function the user can receive automatically generated
emails from the robot in case it has stopped with an error message and nobody
confirmed the error within a set timeout.
For using this function it is required that the robot is attached to a network and has
access to a mail server. Furthermore the Network Settings and the Email Settings in
the menu Init/Setup must be correct.
The email generated by the robot will have the subject Alarms/Errors from
control cabinet .
With all possible content activated, the message text of the email will look somehow
like this example:
This E-mail was automatically created by the robot.
Control No.: 4711

Teachbox-Version: 8.02
Master-Version: 8.02
Operating Mode: Manual
Work cell: MY TEST ROBOT
Alarms/Errors from control cabinet

active: 0
inactive: 1
006-000-000 Vacuum-01 PART LOST inactive
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3.1.18 RFID / Digital EOAT (optional)

With the optional EOAT recognition systems RFID and Digital EOAT the robot can
(semi-) automatically load the correct teach program for the application at an EOAT
change.
3.1.18.1 Link a Teach Program with an EOAT

If a gripper is present on the EOAT recognition system, the dialogue for linking the
teach program with an EOAT-ID will be shown when storing the teach program using
the menu File – Save As.
Fig.: Dialogue for linking a teach program with an EOAT-ID
Press if you want to link the program with the EOAT.
3.1.18.2 EOAT Change

When the EOAT recognition system recognizes a newly attached gripper, the dialogue
for selecting one of the teach programs linked with the EOAT will appear.
Fig.: Dialogue for selecting a linked teach program
Highlight the desired program and press to load it.
You can use to unlink the highlighted teach program.
Press if you don't want to load a program.
With the corresponding setting made in the menu Init – Setup – Robot Settings the
program will be loaded automatically, if only one single program is linked with the
EOAT. In this case the selection dialogue will not be shown.
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3.2 Teach-Mode using the Text Editor

Teach-Mode is used to create a Teach program for the robot and the attached
peripheral equipment. This program contains all procedures and movements necessary
for automatic operation and reference travel. In general the text editor is used for this,
in order to be able to use the full functionality of the R8.3 control unit.
3.2.1 Operation of the Texteditors
3.2.1.1 Entering the Text Editor
The text editor can be called up in all operating modes using the button .
If the text editor is entered in the operating mode Reference Missing, the Offline
Editor will be activated automatically, because no valid positions are available for the
numerical axis in this operating mode.
If the text editor is entered in one of the operating modes Automatic or
Blockstop, only times, speeds and positions of numerical axes (+/- 10mm) can
be adapted. Adding or deleting of commands will not be possible, except the Offline
Editor is activated
Only if the text editor is entered in one of the operating modes Manual or
Reference, the full functionality of the Online Editor will be available.
See also:
3.2.3 Part Programs
3.2.1.2 Exit the Texteditor and transfer the program to the CPU
Exit the Text Editor by using the button or by using the option Exit to Main of
the File menu.
Refer to: 3.2.4.11 File Menu: Exit to Main.
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3.2.1.3 Editing Functions

The most common editing functions of the text editor can be accessed using the
buttons on the bottom of the editor window.:
takes you to the first line of the Teach program.
takes you to the last line of the Teach program.
deletes the highlighted line(s).
adds an empty line before the highlighted one.
opens a window to edit the highlighted command.
See also:
3.1.6 Selection Mode
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3.2.1.4 Online Editor

Teaching in the online editor is the most commonly used method to program a teach
program. The entire program is created by approaching the various axis positions. It
can be tested and optimized immediately.
3.2.1.5 Offline Editor

The offline editor can be turned on in the teach editor using the option OfflineEditor of
the Setup menu. This puts the teachbox offline, but the Emergency-Stop-Block with the
buttons for basic operation of the appliance remains active.
The teach program is created or edited without travelling the robot, while the robot
processes another program in the Master CPU. However, no axis positions can be
entered.
The turned-on offline editor is indicated by a flashing on the status bar at the upper
left of the display. If a numerical axis is selected, the characters "?????.?" are shown
instead of the current axis position. Upon acknowledgment with the axis
command is added to the teach program with the undefined position . Predefined
positions are taken over correctly.
For a program edited or created offline, all axis instructions created offline must be
converted online, before the program can be transferred to the master CPU and before
it can be executed.
3.2.1.6 Online Conversion

The Online Conversion is started by selecting the option OnlineEditor in the Setup
menu.
After a successful conversion the following notice will appear:
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3.2.2 Step Operation

To test a program or a program section, you can use Step Operation run through
individual instructions or the complete program. Step operation may be carried out in
various operating modes:
• Step operation in Block Stop mode

• Step operation in Reference and Manual modes
To do this, the one must be in the editor, and the program in the editor must be already
transferred to the CPU. The highlighted instruction is executed by holding down the
key. Execution of the instruction may be aborted at any time by releasing the
key.
Step Operation in Block Stop Mode

The program is stepped through chronologically according to the automatic sequence.
All travel instructions of the numerical axes are executed at the full speed of the
automatic sequence.
Step Operation in Reference and Manual Modes

The speeds of travel motions of the numerical axes can be set from 1 to 30% of the
maximum speed.
For safety reasons, a newly created program must be run through in Step operation
before the first automatic operation.
The branch to the alternative sequence when a monitoring triggers will not be executed
in step operation.
3.2.2.1 Procedure Step

By tapping the menu point Edit-Debug-Step is Procedure Step the user can activate
or deactivate Procedure Step.
Procedure Step means, that when a CALL command is being stepped, not only the
CALL command is executed, but the whole subroutine called up by the CALL
command.
In this case the cursor remains on the CALL command, until the execution of the
subroutine is finished.
A subroutine may only be tested using a procedure step, when it has already been
tested with "normal" step operation.
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3.2.3 Part Programs, PROGRAM Menu

3.2.3.1 Part Programs
Part Programs A complete standard teach program includes the following part
programs:
• Robot Program (ROBOT-PRG)

• Peripheral Program (PERI-PRG)
• Robot Reference Program (ROBOT-REF)
• Peripheral Reference Program (PERI-REF)
• All Modes Program (ALLMODE-PRG)
Up to 115 additional part programs can be added.
Each of these additional part programs can be a Sub-Allmodes Part Program.
One of the additional part programs can be used as EOAT Change Program.
After opening the editor the robot program ROBOT-PRG will be displayed for editing.
To switch the editor to a different part program, simply select the desired program from
the Menu Program. The status field on the bottom left corner of the editor window
indicates, which part program is currently shown in the editor.
Fig.: Indication of current part program
3.2.3.1.1 Robot Program (ROBOT-PRG)

This program is used to program all movements and procedures the robot has to
execute together with the IMM in Automatic mode.
The robot program is executed cyclically. After execution of the last command line of
the robot program or an END command within, the execution of the robot program will
continue at its first line.
3.2.3.1.2 Peripheral Program (PERI-PRG)

This program is used to control all sequences (in peripheral equipment) that have to be
executed independently from the movements of the robot.
The program must be started in the robot program or in one of the 115 additional part
programs. After that it will be executed in parallel to (at the same time as) the other part
programs running in Automatic mode.
The Peripheral Program will not be executed cyclically. After execution of the last
command line of a peripheral program or an END command within, the execution of the
peripheral program will be stopped. If the peripheral program should be executed
permanently (cyclically) this feature has to be programmed accordingly (using a Jump
command).
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3.2.3.1.3 Robot Reference Program (ROBOT-REF)

This program is used to control all movements and procedures executed by the robot
during the reference travel in operating mode Manual.
3.2.3.1.4 Peripheral Reference Program (PERI-REF)

This program is used to control all movements and procedures executed by peripheral
equipment during the reference travel in operating mode Manual. This program
will be executed in parallel to the robot reference program. The two reference programs
can perform coordinated sequences using handshakes with counters.
3.2.3.1.5 115 additional Part Programs

Like the peripheral program the additional part programs are used to control all
sequences (in peripheral equipment) that have to be executed independently from the
movements of the robot.
The programs must be started in the robot program or in one of the other additional
part programs. After that they will be executed in parallel to (at the same time as) the
other part programs running in Automatic mode.
Additional part programs will not be executed cyclically. After execution of the last
command line of an additional part program or an END command within, the execution
of the additional part program will be stopped. If the additional part program should be
executed permanently (cyclically) this feature has to be programmed accordingly (using
a Jump command).
3.2.3.1.6 All Modes Program (ALLMODE PRG)

The ALL MODES program (ALLMODE-PRG) is executed by the R8.3 control unit in the
background, regardless of the current mode of operation the robot is in. Meaning this
program is not only executed in the operating mode Automatic, but also in the
operating modes Manual, Reference and Blockstop.
The ALL MODES program cannot be executed in the operating mode
Reference Missing.
This program is used to control movements and procedures, that have to be executed
in every operating mode of the robot (except Reference Missing).
The ALL MODES program does not start automatically. Like the peripheral program, it
has to be started either from a different part program using the respective Teach
commands; or it is started manually using the function "START/STOP ALLMODE-
PRG." of the INIT menu.
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Once the ALL MODES program is activated, it is executed cyclically. After execution of
the last command line of the ALL MODES program or an END command within, the
execution of the ALL MODES program will continue at its first line.
The Icon is shown in the status bar of the Teachbox right next to the operating
mode, to indicate that the ALL MODES program is running. Changes of the mode of
operation will not interrupt the ALL MODES program. Only the respective STOP-
command, or an emergency stop or powering down the robot will stop the ALL MODES
program.
Even more flexibility can be added to ALL MODES programs using the event Mode.
This gives the possibility to react on the actual robot mode.
3.2.3.1.7 Sub-Allmodes Part Programs

Sub-Allmodes Part Programs are additional part programs which, like the ALL MODES
program are not only executed in operating mode Automatic, but also in the
operating modes Manual, Reference and Blockstop.
Sub-Allmodes Part Programs do not start automatically. They also do not start
automatically, when the ALL MODES program is started. Sub-Allmodes Part Programs
must be started from within the ALL MODES program or from within another Sub-
Allmodes Part Program using the respective start teach command.
Sub-Allmodes Part Programs will not be executed cyclically. After execution of the last
command line of a Sub-Allmodes Part Program or an END command within, the
execution of the Sub-Allmodes Part Program will be stopped. If a Sub-Allmodes Part
Program should be executed permanently (cyclically) this feature has to be
programmed accordingly (using a Jump command).
Once the ALL MODES program is stopped, all Sub-Allmodes Part Programs will be
stopped also.
3.2.3.1.8 EOAT Change Program

The EOAT Change Program is used for moving to an EOAT changing position, or to
change the EOAT automatically.
The EOAT Change Program has to be programmed in the text editor. All functions of
the robot can be used.
When the button on the virtual Subpendant is pressed and held during operating
modes Manual or Reference, first a reference travel (according to the reference
program) will be executed. After this the EOAT Change Program will run.
If the button should be released and pressed again during execution of the EOAT
Change Program, the EOAT Change Program will not start all over, but will continue
working at the current program line.
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3.2.3.2 Manage Part Programs

This function is used to manage the part programs of the teach program.
Fig.: Window to manage part programs
The Part Program Information Table shows information about the part program
selected in the list of Existing Part Programs.
is used to create a new part program.
is used to edit the settings of the part program selected in the list of Existing Part
Programs.
is used to delete an additional part program selected in the list of Existing Part
Programs. The standard programs ROBOT_PRG, PERI-PRG, ROBOT-REF, PERI-
REF and ALLMODE-PRG cannot be deleted.
is used to close the window, and to discard the entries.
is used to confirm the entries, and to close the window.
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3.2.3.2.1 Edit a Part Program

This function is used to create a new additional part program, or to edit the settings for
an existing part program.
Fig.: Window to edit part program settings
After tapping the field Part program name you can change the name of an additional
part program using the dialogue for text input. The names of the standard programs
ROBOT_PRG, PERI-PRG, ROBOT-REF, PERI-REF and ALLMODE-PRG cannot be
altered.
The button Teachable Axes is used to open the dialogue for axes definition. Her you
can assign axes to the part program.
Use one of the three options on the left bottom of the window to define the type of the
new part program:
Standard Program
Use this option to create a standard additional part program.
Allmode Program
Use this option to create a sub-allmodes part program.
Use part program as End-Of-Arm-Tooling change program

Use this option to create the EOAT change program. The standard name EOAT
Change is assigned to this program automatically.
is used to close the window, and to discard the entries.
is used to confirm the entries, and to close the window.
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3.2.4 FILE Menu of the text editor
3.2.4.1 New
This function is used to create a new empty teach program in the Teachbox.
Fig.: Options window for a new teach program
The window Options for new Teach program is used to select which elements from
the existing program are kept with the new teach program. This is possible for:
• Names
• Positions
• Axis Definitions
• Cylinders
• Reference settings for vacuum and gripper circuits
• AutoSwitches
• Safety areas
The different elements are selected or deselected by tapping the respective option. A
means, that the element is selected to be taken over to the new program.
is used to select all elements.
is used to deselect all elements.
is used to cancel the process.
is used to create a new empty teach program.
The program currently loaded in the Teachbox will be irretrievably deleted. The
program in the robot remains unchanged.
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3.2.4.2 Open
This function is used to load a teach program from a storage medium to the Teachbox.
Fig.: Window to open a file
The field Search in displays the path of the current folder. By touching the field you
can select one of the standard folders C:\PUBLIC (internal storage medium of the
Teachbox) or D:\ROBOT\TEACHPRG (USB-Stick).
for a sub-folder
for a teach program file *.WIP
for a teach program file *.ZIP
is used to open the properties window of the selected program.
can be used to optimize the display of the contents of the folder for either long or
short file names.
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is used to load the selected program to the Teachbox.
is used to abort the function and close the window.
The program stored in the teachbox will be irretrievably deleted by loading another
teach program.
Before the program can be executed, it has to be transferred to the robot.
Every newly loaded teach program must be run through at least once in step mode
before automatic operation.
The file name of a stored teach program is not necessarily the same as the teach
program name.
3.2.4.3 Import Macro

A macro is a file *.WIM which contains one or more program lines, that were exported
from a (different) teach program previously.
The function Import macro is used to insert a macro *.WIM from a storage medium to
the teach program before the current position of the cursor.
Abb.: Window to import a Macro
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for a sub-folder
for a macro file *.WIM
short file names.
is used to load the selected macro to the Teachbox, and to insert it to teach
program before the selected line.
If labels or subroutines whose names already exist in the teach program are loaded,
they are automatically renamed to LABEL_xxx or SUBR_xxx. "xxx" represents a 3 digit
number.
If an associated JUMP instruction is loaded together with an already existing label, the
JUMP instruction will also be changed to the new label name. The same applies to
CALL instructions that are loaded together with their subroutines.
If a placing program, which has the same name as an existing placing program in the
teach program but otherwise differs from the latter in some way, it will automatically be
renamed with the name of the first unused placing program.
If a macro that does not correspond to configured robot hardware (e.g., an axis not
present) is loaded, a flag will appear and the offline editor will be activated. The
corresponding instructions will now have to be changed or removed manually, after
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which the program can be switched back ONLINE again with the function ONLINE
EDITOR of the Setup menu.
If an axis instruction with a reference to a previously defined position, which has the
same name as a previously defined position existing in the teach program but
otherwise differs in some way from the latter, is loaded, it will be automatically renamed
to POSITION_xxx. "xxx" represents a 3 digit number.
When a macro is loaded, axis positions of configured axes will be transferred without
comment. However, this does not mean that they can be approached without risk.
Programs expanded by macros must therefore always be tested in STEP mode.
When a macro is loaded, instructions with configured peripheral input/outputs are

accepted without comment. However, this does not mean that these instruction
sequences are compatible with the attached peripheral, especially when the macro
comes from another control system.
3.2.4.4 Load Program from CPU

This function is used to load the teach program from the robot to the Teachbox.
The teach program loaded in the Teachbox including all names, cylinder definitions and
position definitions will be irreversibly deleted.
3.2.4.5 Save (NAME.ZIP)

This function is used to save the teach program from the Teachbox to a storage
medium as a *.ZIP file. Both name and path of the file will be the ones used before.
The name of the target file is shown in brackets right next to the menu entry Save. If no
name is displayed, Save will call the function Save as instead.
The previous version of the program stored on the storage medium with the same
name will be deleted irretrievably.
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3.2.4.6 Save As
medium as a *.ZIP file. Path and name of the file are selectable.
Fig.: Window to save a teach program
The field Save in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the
for a sub-folder
The field Filename suggests the last filename used or the teach program name as
filename. After tapping the field you can use the dialogue for text input to change the
filename as desired. The extension will always be ZIP. By tapping it in the display of
the current folder, you can also use the name of an existing file.
is used to create a new folder.
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short file names.
is used to save the teach program to the current folder, applying the name
from the field Filename.
Before storing is executed, a check is made to see whether a program of the same
name is already stored in the selected folder, and a check back message may appear.
If a coded gripper is present on the optional RFID / Digital-EOAT gripper recognition

system, you will be asked if you want to assign the program to that gripper.
3.2.4.7 Export Selection

This function is used to save previously selected lines from the teach program to a
storage medium as a macro *.WIM. Path and name of the file are selectable.
Fig.: Window to save a macro
for a sub-folder
for a macro file *.WIM
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After tapping the field Filename you can use the dialogue for text input to enter the
desired filename. The extension will always be WIM. By tapping it in the display of the
current folder, you can also use the name of an existing file.
short file names.
is used to save the macro to the current folder, applying the name from the
field Filename.
Before storing is executed, a check is made to see whether a macro of the same name
is already stored in the selected folder, and a checkback message may appear.
See also:
3.2.4.3 File Menu: Import Macro
3.2.5.1 Edit Menu: Selection Mode
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3.2.4.8 Transfer program to CPU

This is used to transfer the teach program from the Teachbox to the robot. This is
necessary to enable execution of the program.
A progress bar is shown during the process.
With the appropriate setting of the option Clear counters in the Init Menu
Setup: Robot Settings a request about resetting counters and placing programs will
pop up:
The program previously stored in the robot will be irretrievably overwritten.
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3.2.4.9 Properties
Here the properties of the teach program in the text editor of the Teachbox are
displayed. That is the program which can be edited. Before this program can be
executed in automatic operation, it has to be transferred to the robot.
Fig.: Window for properties of the program in the texteditor

Shows the name of the teach program in the text editor. This name is not necessarily
the same as the file name of the program. After tapping the input field, the name can
be edited using the dialogue for text input.

Displays whether the teach programs in the robot (CPU) and the Teachbox are equal
or unequal.
Tooldata
Displays the Tooldata text of the teach program in the text editor. After tapping the
input field, the Tooldata text can be edited using the dialogue for text input.
Size
Displays the size of the teach program in the text editor. The maximum size of a teach

Shows the number of part programs of the teach program in the text editor: ROBOT-
PRG, PERI-PRG, ROBOT-REF, PERI-REF, ALLMODE-PRG and up to 11 additional
part programs.

Shows the number of placing programs used in the teach program in the text editor.
The maximum number of placing programs available in a teach program is limited to
16.
can be used to open the picture viewer. There you can either associate a picture
with the teach program, or watch the picture associated with the teach program.
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can be used to email the teach program by means of the manual email function of
the robot as an email attachment (*.wip, *.htm and *.txt file).
is used to discard the entries and to close the window.
is used to confirm the entries and to close the window.
3.2.4.10 Print
This function is used to print the teach program loaded in the Teachbox to either a
UNICODE-textfile *.TXT or an HTML-file *.HTM on the USB stick. Path and name of
the file are selectable. The default folder is D:\ROBOT\PRINT. The generated file can
be opened, displayed and printed with a PC.
Fig.: Window to print a teach program to a file
The button right next to the field for the filename is used to select the type of file for
printing:
activates printing to a textfile
activates printing to an HTML-file
The field Save in displays the path of the current folder.
for a sub-folder
for a textfile *.TXT
for an HTML-file *.HTM
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Only files of the same type as selected for the printout will be displayed.
filename as desired. By tapping it in the display of the current folder, you can also use
short file names.
is used to save the printout to the current folder, applying the name from the
field Filename.
Before storing is executed, a check is made to see whether a file of the same name is
already stored in the selected folder, and a checkback message may appear.
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3.2.4.11 Exit to Main
This function can also be called with the button , and is used to exit the editor.
If the teach program in the editor is different than the one in the robot, then it is
possible to select whether or not the program shall be transferred from the Teachbox to
the robot:
This is necessary to enable execution of the program.
A progress bar will be shown during the process.
With the appropriate setting of the option Clear counters in the Init Menu
Setup: Robot Settings a request about resetting counters and placing programs will
pop up:
The program previously stored in the robot will be irretrievably overwritten, if the
program from the Teachbox is transferred to the robot.
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3.2.4.12 Properties Window of the File Dialogue

Here the properties of the teach program selected in the file dialogue are displayed.
Fig.: Window for properties of a stored program

Shows the name of the selected teach program. This name is not necessarily the same
as the file name of the program.
Displays whether the selected teach program and the one in the robot (CPU) are equal
or unequal.
Tooldata
Displays the Tooldata text of the selected teach program. The text for Tooldata can
Size
Displays the size of the selected teach program. The maximum size of a teach program
is limited to 32.768 bytes.
Shows the number of part programs of the selected teach program: ROBOT-PRG,
programs.
Shows the number of placing programs used in the selected teach program. The
can be used to email the teach program by means of the manual email function of
the robot as an email attachment (*.wip, *.htm and *.txt file).
is used to exit the window.
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3.2.4.13 Picture Viewer

Here the picture associated with the teach program can be viewed, provided that the
storage medium containing the associated picture is available.
The picture viewer can be accessed in the properties windows of the teach program
using the button .
Fig.: Picture viewer showing a picture
If the picture is too big, it can be moved horizontally and vertically using the sliders.
Associating a picture to a teach program is only possible, if the respective properties

window has been opened with the menu File / Properties inside one of the editors.
is used to return to the properties window.
3.2.4.13.1 Associate a picture with a Teach program

In order to be able to associate a picture to a teach program, first the properties
window must be opened with the menu File / Properties inside one of the editors. Now
the is used to open the picture viewer.
Here the button opens the file dialogue for selecting a picture.
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Fig.: Dialogue for selecting a picture
The following file formats are supported:

• BMP files with 256 colors
• BMP files with 24 bits color depth
• GIF files with 256 arbitrary colors
• JPG files (not all compression rates and color depths)
The icons used by the display of the contents of the current folder include the following:
for a sub-folder
for supported picture files
short file names.
associates the selected picture with the teach program.

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3.2.5 EDIT Menu
3.2.5.1 Selection Mode

The option Selection Mode On/Off is used to switch on or switch off the selection
mode of the text editor. The selection mode is needed to mark several program lines.
When the selection mode is off, single program lines can be selected by tapping on
them in the editor window. The currently selected line is displayed on a gray
background.
Fig.: a single selected line
If the selection mode is activated now, the selection can be expanded to several lines,
by tapping the last line to be included to the selection.
Fig.: several selected lines
The block of lines being selected this way, can now either be moved or copied via the
clipboard, or can be exported to a storage medium as a macro.
could be used to delete the selected lines.
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3.2.5.2 Copy, Cut, Paste

Using these functions of the Edit menu you can copy or move previously selected
program lines to a different location in the program via the clipboard.
Copy
The function Copy copies the selected lines to the clipboard.
Program Clipboard
Fig.: Copy
Cut
The function Cut moves the selected lines to the clipboard and deletes them at their
original position in the program.
Program Clipboard
Fig.: Cut
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Paste
The function Paste copies the lines, that were previously put to the clipboard, from the
clipboard to back to the program just before the selected line. In the example shown
below, the block of lines 2 has been previously cut out between blocks 1 and 3, and is
now inserted behind block 3.
Program Clipboard
Fig.: Paste
If labels or subroutines are copied, they are automatically renamed to LABEL_xxx or

SUBR_xxx. "xxx" represents a 3 digit number.
If an associated JUMP instruction is copied together with its label, the JUMP instruction
will also be changed to the new label name. The same applies to CALL instructions
that are copied together with their subroutines.
If a placing program is copied, it will automatically be renamed with the name of the
first unused placing program.
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3.2.5.3 Search-Toolbar
Use the option Show Search-Toolbar of the EDIT menu to activate or deactivate the
display of the Search-Toolbar of the text editor. The Search-Toolbar is used to search
for arbitrary text in the Teach program.
Fig.: Search-Toolbar
After tapping the input field use the dialogue for text input to input the desired search
text.
Use to access a list with previously used search texts.
Use to find the next occurrence of the search text before the current cursor
position in the Teach program.
Use to find the next occurrence of the search text after the current cursor position
in the Teach program.
Use to remove the Search-Toolbar from the display.
Use to open the window for the settings of the Search Toolbar.
Fig.: Window for the settings of the Search Toolbar
Search through entire program

The search will not stop at the end or begin of the program, but will continue until it
reaches the starting position of the search again.
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In all part programs

The search will not only be performed in the current part program, but in all part
programs.
Start search at begin of program

The search will not start at the current cursor position, but at the begin of the program.
Direction upwards / downwards

The search will be performed in the selected direction.
Press to recall the standard settings.
3.2.5.4 Show Prefixes

Use the option Debug - Show Prefixes of the EDIT menu to activate or deactivate the
display of prefixes before the names of elements in Teachcommands. Displaying
prefixes can increase the readability of a teach program, especially if the user has
given similar or equal names to different kinds of elements.
Example:
As they deal with the same function, an Autoswitch, a peripheral output and a counter
have been given the same custom name "EXAMPLE".
Without prefixes a snippet of that Teach program would be displayed by the text editor
like this:
IF EXAMPLE = ON
EXAMPLE: ON
EXAMPLE = EXAMPLE + 1
ENDIF
With prefixes, the same snippet would result in this display:
IF ASW_EXAMPLE = ON
PO_EXAMPLE: ON
CNT_EXAMPLE = CNT_EXAMPLE + 1
ENDIF
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3.2.5.5 Show Default Names

Use the option Debug - Show Default Names of the EDIT menu to activate or
deactivate the display of standard names in parentheses after the current names of
elements in Teachcommands. Displaying standard names can increase the readability
of a teach program, especially if the user has given similar or equal names to different
kinds of elements.
Example:
As they deal with the same function, an Autoswitch, a peripheral output and a counter
have been given the same custom name "EXAMPLE".
Without standard names a snippet of that Teach program would be displayed by the
text editor like this:
IF EXAMPLE = ON
EXAMPLE: ON
EXAMPLE = EXAMPLE + 1
ENDIF
With standard names, the same snippet would result in this display:
IF EXAMPLE(Autosw-01) = ON
EXAMPLE(PO-001): ON
EXAMPLE(Counter-001) = EXAMPLE(Counter-001) + 1
ENDIF
3.2.5.6 Show Internal IDs

Use the option Debug - Show Internal IDs of the EDIT menu to activate or deactivate
the display of internal IDs in parentheses after the current names of Placing Programs.
Example:
Without internal ID a Placing Program with the name EXAMPLE will be displayed in the
text editor like this:
Placing Program: EXAMPLE
With internal ID the same Placing Program will be displayed in the text editor like this:
Placing Program: EXAMPLE(ID 000)
3.2.5.7 Show Line Numbers

Use the option Debug - Show Line Numbers of the EDIT menu to activate or
deactivate the display of line numbers left of the teach commands in the text editor.
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3.2.5.8 Show Execution Times

Use the option Debug - Show Execution Times of the EDIT menu to activate the
display of the actually measured execution times of each command of the teach
program.
Fig.: Display of execution times
The times displayed are being refreshed with every execution of the respective
command line.
t=??????? indicates that the respective command line has not been executed yet.
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3.2.6 Teach program Settings in the SETUP Menu
3.2.6.1 Online / Offline Editor

This is to switch between Offline and Online Editor.
The Offline Editor is used to edit a teach program without the robot.
See also:
3.2.1.4 Online Editor
3.2.1.5 Offline Editor
3.2.1.6 Online Conversion
3.2.6.2 Axes Definition

Here you can assign the axes controlled by the robot control unit to the different part
programs and paths for automatic operation.
Fig.: Window for axes definition
Using the selection field Part Program the respective axis can be assigned to a
specific part program. The movements of that axis are then controlled by this part
program only.
With a at the option Included in path the respective (numerical) axis is included to
the path calculation. This enables the axis to be moved coordinated together with the
other path axes of the respective part program using 3D and Curve movements.
confirms the settings and closes the window.
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3.2.6.3 Safety Areas
Fig.: 3d view of a typical simple safety area configuration

including the working area
The R8.3 gives the possibility of setting up Teach program specific safety areas to
prevent the robot from crashing obstacles in all operating modes, except Reference
Missing. This is achieved by creating several overlapping, box-shaped, inclusive
areas, in which the robot can move safely. Every attempt to exit the resulting safety
area will make the robot stop at the border of the area and trigger an error message.
Furthermore, there is the possibility to use exclusionary areas to exclude box shaped
regions from the working area of the robot.
Individual safety areas can be activated dependent on the state of an input or output of
the robot.
A peripheral output can be switched on, when the robot is situated inside or outside a
certain safety area.
All settings for the safety areas of the robot are done in the Setup menu Safety Areas.
The safety areas will be automatically stored and loaded as part of the respective
Teach program. When you create a new program, you can choose to keep the safety
areas of the currently loaded program.
Fig.: Setup menu safety areas with working area and example areas
The Working Area is always present. It is defined by the Stroke Limits of the robot.
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is used to create a new safety area.
is used to edit the selected safety area.
When you press with the working area selected, the window for setting the
visibility of the working area in the graphical display will be opened.
is used to delete the selected safety area.
is used to copy the selected safety area. The dialog for editing the new safety
area will pop up.
is used to open the graphical display of the safety areas.
The safety areas of the R8.3 are Teach program specific. A new safety area or
changes to an existing safety area will only become valid after the Teach program has
been transferred to the CPU!
The safety areas of the R8.3 are inoperative in operating mode Reference Missing!
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3.2.6.3.1 Create / Edit Safety Areas
Fig.: Window to edit safety areas
Activate each single axis coordinate From / To with a , and approach them one after
the other to create the desired box-shaped safety area.
The desired name for the safety area can be entered after tapping the field Name using
the dialogue for text input.
The safety areas of the R8.3 are inclusive by default. This means, that as soon as at
least 1 area has been defined, the robot is only allowed to travel within the defined
areas. With a at the option exclusionary you can also define exclusionary areas.
The robot is not allowed to enter exclusionary areas.
Use the option Activate on to activate the safety area dependent on the state of an
input or output of the robot.
Use the option Set Output to switch on a peripheral output, when the robot is situated
inside or outside the safety area.
confirms the safety area and closes the window.
The safety areas of the R8.3 are Teach program specific. A new safety area or
changes to an existing safety area will only become valid after the Teach program has
been transferred to the CPU!
The safety areas of the R8.3 are inoperative in operating mode Reference Missing!
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3.2.6.3.2 Properties of the Working Area

Here you can set the visibility of the working area in the graphical display of the safety
areas.
Fig.: Window for properties of the working area
Working Area Color

Shows the color of the working area.
Working Area Transparency

With the dialogue for numerical input enter the percentage of transparency used for the
working area in the graphical display of the safety areas. The higher the value, the
more transparent the working area will be; and the more clearly visible the safety areas
will be, when displayed together with the working area.
Visible
Use this option to decide whether the working area will be shown in the graphical
display of the safety areas or not.
discards the settings and closes the window.
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3.2.6.3.3 Graphical Display of the Safety Areas
The graphical display of the safety areas can be opened either in the View menu
Safety Areas or in the Setup menu Safety Areas using the button .
It graphically displays the safety areas and the working area of the robot.
Fig.: Window showing the 3D view
Fig.: Window showing the projected views
Press to turn the transparency of the areas on or off.
Press to toggle between 3D view and projected views.
Press to reset the 3D view.
Press , or to select the action to be carried out, when dragging on the
display area or when pressing or .
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Press followed by , or to define in which axes the previously
selected action will work, when triggered with or . Multiple selections are
possible.
Press to quit the graphical display.
See also:
3.2.6.3 Setup Menu: Safety Areas
3.1.15.5 View Menu: Safety Areas
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3.2.6.4 Cylinder Definition

The cylinder function is useful to ease the teaching of pneumatic cylinders by
combining two peripheral outputs to a cylinder. Additionally you can use two peripheral
inputs and a time limit to monitor the correct function of the pneumatic cylinder. Does
the cylinder not approach the respective target position within the set time limit an error
message will be displayed on the teachbox.
Up to 255 such cylinders are possible in one teach program.
A cylinder consists of:

• 1 to 2 peripheral outputs (O1, O2).
O2 is optional, and negates the status of O1.
• 0 to 2 peripheral inputs (I1, I2) for acknowledging or
monitoring the action controlled by O1/O2 (optional),
where I1 always acknowledges O1 and I2 always acknowledges O2.
• A limit for the time that is allowed to elapse between
setting of Ox and acknowledgment of Ix.
Only if inputs are used.
If no cylinders have been defined previously, the editor will directly jump to the function
to edit cylinders. If any cylinders are defined already, the dialogue Cylinder Definition
will be shown.
Fig.: Dialogue Cylinder Definition
is used to create a new cylinder.
is used to edit the selected cylinder.
is used to delete the selected cylinder, if it is not applied in the teach program.
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3.2.6.4.1 Create / Edit Cylinders

This is to edit an existing cylinder or to create a new one.
Fig.: Window to edit a cylinder
After tapping the respective input fields you can pick the desired peripheral outputs and
peripheral inputs from selection windows.
If any conflict happens to occur because of some PO or PI being already used by the
current or any other cylinder, the icon will be shown next to the affected input or
output. The status field on the left bottom of the window will contain a description of the
conflict.
If inputs for position feedback are defined, it is possible to enter a time limit for the
movements of the cylinder after tapping the input field Timeout. The desired time is
entered using the dialogue for numerical input. If no inputs are defined, the timeout
must be set to zero.
A name for the cylinder can be entered after tapping the input field Name using the
confirms the cylinder and closes the window.
See also:
3.3.5.3.1 Applying cylinders in a teach program
3.3.5.3 Cylinder function
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3.2.6.5 Auto Switch Definition

Here the basic settings for the AutoSwitches can be done:
Fig.: Setup Menu - AutoSwitch Definition
and are used to define if the selected AutoSwitch has to act like a switch
(maintained contact) or like a key (momentary contact).
is used to reset the selected AutoSwitch to the factory settings.
is used to reset all AutoSwitches to the factory settings.
is used to open the setup window of the selected AutoSwitch:
Fig.: Setup window of an AutoSwitch
Current Name
This is the name of the AutoSwitch. That name is not only displayed on the AutoSwitch,
but also used as an identifier for the AutoSwitch in the Teach program. After tapping
the input field, the name can be altered using the dialogue for text input.
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Current Type
Activating the desired option selects whether the AutoSwitch has to act like a switch
(maintained contact) or like a key (momentary contact).
Current Image
This is the picture that will be shown on the AutoSwitch. Tapping the input field will
display a list with the available pictures already stored in the Teachbox:
Fig.: selection list for AutoSwitch pictures
Tap on the name of the desired picture to select it.
can be used to import pictures from the USB stick for display on the
AutoSwitches. Once imported, the pictures are available for all AutoSwitches in all
Teach programs permanently.
Imported pictures not exceed a width of 190 pixels and a height of 64 pixels. The
recommended size is 64 x 64 pixels - as the standard picture. The following file
formats are supported:
• BMP files with 256 colors (recommended)

• BMP files with 24 bits color depth
• GIF files with 256 arbitrary colors
• JPG files (not all compression rates and color depths)
can be used to remove the current picture from the memory of the Teachbox.
An AutoSwitch will be displayed only if it is actually used in the Teach program in the
robot.
See also:
3.3.10 AutoSwitches
3.3.7.8.6 Jump condition AutoSwitch
0 View Menu: AutoSwitch
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3.2.6.6 Counter Names

Here you can rename the 64 counters of the teach program. The name of a counter
should describe its function as good as possible, in order to ease reading the teach
program.
The names are always valid for the teach program loaded in the Teachbox. This means
the names of the counters can be different in every program.
Fig.: Window for counter names
is used to rename the selected counter. The name is entered using the dialogue
for text input.
renames the selected counter to its standard name.
renames all 64 counters to their standard names.
For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.
See also:
3.3.6 Counters
3.3.7.8.1 Condition: Counters
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3.2.6.7 Conveyor Names

Here you can rename the conveyors controlled by the robot control unit. The name of a
conveyor should describe its function as good as possible, in order to ease reading the
teach program.
the names of the conveyors can be different in every program.
Fig.: Window for conveyor names
is used to rename the selected conveyor. The name is entered using the dialogue
for text input.
renames the selected conveyor to its standard name.
renames all conveyors to their standard names.
See also:
3.3.5.1 Conveyor
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3.2.6.8 Peripheral Output Names

Here you can rename the peripheral outputs controlled by the robot control unit. The
name of a peripheral output should describe its function as good as possible, in order
to ease reading the teach program.
the names of the peripheral outputs can be different in every program.
Fig.: Window for PO names
is used to rename the selected peripheral output. The name is entered using the
renames the selected peripheral output to its standard name.
renames all peripheral outputs to their standard names.
See also:
3.3.5.2 Peripheral Outputs
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3.2.6.9 Peripheral Input Names

Here you can rename the peripheral inputs used by the robot control unit. The name of
a peripheral input should describe its function as good as possible, in order to ease
reading the teach program.
the names of the peripheral inputs can be different in every program.
Fig.: Window for PI names
is used to rename the selected peripheral input. The name is entered using the
renames the selected peripheral input to its standard name.
renames all peripheral inputs to their standard names.
See also:
3.3.7.8.3 Condition: Peripheral Inputs
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3.2.6.10 Stacking Sensor Names

Here you can rename the stacking sensors used by the robot control unit. The name of
a stacking sensor should describe its function as good as possible, in order to ease
reading the teach program.
the names of the stacking sensors can be different in every program.
Fig.: Window for stacking sensor names
is used to rename the selected stacking sensor. The name is entered using the
renames the selected stacking sensor to its standard name.
renames all stacking sensors to their standard names.
See also:
3.3.7.8.11 Condition: Stacking Sensor
3.3.1.3.8 Axis Command: Stacking Sensor
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3.2.6.11 Stopwatch Names

Here you can rename the 4 stopwatches of the teach program. The name of a
stopwatch should describe its function as good as possible, in order to ease reading
the teach program.
the names of the stopwatches can be different in every program.
Fig.: Window for stopwatch names
is used to rename the selected stopwatch. The name is entered using the
renames the selected stopwatch to its standard name.
renames all 4 stopwatches to their standard names.
See also:
3.3.9.5 Stopwatch
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3.2.6.12 Vacuum Names

Here you can rename the vacuum circuits controlled by the robot control unit. The
name of a vacuum circuit should describe its function as good as possible, in order to
ease reading the teach program.
the names of the vacuum circuits can be different in every program.
Fig.: Window for vacuum names
is used to rename the selected vacuum circuit. The name is entered using the
renames the selected vacuum circuit to its standard name.
renames all vacuum circuits to their standard names.
See also:
3.3.5.4 Vacuum
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3.2.6.13 Gripper Names

Here you can rename the grippers controlled by the robot control unit. The name of a
gripper should describe its function as good as possible, in order to ease reading the
teach program.
the names of the grippers can be different in every program.
Fig.: Window for gripper names
is used to rename the selected gripper. The name is entered using the dialogue
for text input.
renames the selected gripper to its standard name.
renames all grippers to their standard names.
See also:
3.3.5.6 Gripper
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3.2.6.14 Vacuum Reference States

This is to set the state that the vacuum circuits must be in to enable operating mode
Reference. The vacuum circuits have to be switched to the state by either the
reference program or manually. If at the end of the reference travel one of the vacuum
circuits happens not to be in the state set here, an error message will be shown;
switching to operating mode Reference will not be possible in this case.
Fig.: Window for vacuum reference states
means the reference state of the vacuum circuit is ON.

means the reference state of the vacuum circuit is OFF.
means the reference state of the vacuum circuit is not checked.
changes the reference state of the selected vacuum to ON.
changes the reference state of the selected vacuum to OFF.
sets the reference state of the vacuum to NOT CHECKED.
, or are used to set the reference states of all vacuum circuits to the
state of the selected one.
See also:
3.3.5.4 Vacuum
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3.2.6.15 Gripper Reference States

This is to set the state that the grippers must be in to enable operating mode
Reference. The grippers have to be switched to the state by either the reference
program or manually. If at the end of the reference travel one of the grippers happens
not to be in the state set here, an error message will be shown; switching to operating
mode Reference will not be possible in this case.
Fig.: Window for gripper reference states
means the reference state of the gripper is OPEN.

means the reference state of the gripper is CLOSED.
means the reference state of the gripper is RELEASED.
means the reference state of the gripper is not checked.
changes the reference state of the selected gripper to CLOSED.
changes the reference state of the selected gripper to OPEN.
changes the reference state of the selected gripper to RELEASED.
sets the reference state of the selected gripper to NOT CHECKED.
, , or are used to set the reference states of all grippers to the

state of the selected one.
See also:
3.3.5.6 Grippers
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3.2.6.16 Setup Standard Vacuum Pressure

Here you set the threshold under-pressure that is used by the vacuum monitoring and
the condition vacuum to determine whether the parts on the respective vacuum circuit
are sucked on or not. This threshold must be set for every product or Teach program.
The settings for vacuum pressure will be automatically stored and loaded as part of the
respective Teach program.
This setting is not valid, when the threshold has been set to a different value than
STANDARD with the Vacuum Level command in the Teach program.
The suggested method for doing the pressure setting is:
1) Select the desired vacuum circuit by tapping on the respective scale, then switch it
on using the button .
2) Put all parts onto all suction caps of the vacuum circuit.
3) Use the slider and the up/down buttons on the right side of the window to set the
threshold to a value just smaller than the displayed value of the current under-
pressure.
Fig.: Display with part on vacuum 1 and the threshold value set
The big bar and the field below the scale show the current under-pressure, the small
bar and the number right next to it display the set threshold value. At a correct
setting the big bar must be located in the green area of the scale, when all parts of
the vacuum circuit are sucked on.
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4) Remove one part from one suction cap of the vacuum circuit.
Fig.: Display with a part missing on vacuum 1 and the threshold value set
At a correct setting, now, the big bar must be located in the red area of the scale,
and the field below the scale must be red, too. If this does not apply, the setting of
the threshold under-pressure must be adapted accordingly.
After a successful setting you can switch off the vacuum circuit using the button .
See also:
Vacuum
Vacuum monitoring
Condition: vacuum
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3.2.7 Part program Settings in the PART PRG SETUP menu
3.2.7.1 Positions
Up to 255 different axis positions for the robot can be predefined here in each part
program. This is especially advisable for positions that are approached fairly often at
various locations in the teach program. In addition, offline teaching is made easier.
The predefined positions can be called up later using the selection field Position in the
windows of the axis commands.
If no positions have been defined previously, the editor will directly jump to the function
to Create New Positions. If any positions are defined already, the dialogue Positions
will be shown.
Fig.: Dialogue for Positions
is used to create a new position.
is used to edit the selected position.
is used to delete the selected position, if it is not applied in the teach program.
After activating an axis with a this selected axis can be moved to its target within the
selected position.
3.2.7.1.1 Create / Edit Positions

Here you can edit an existing position or create a new one.
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Fig.: Window to edit positions
Each single axis is activated with a and is moved one after the other until the robot is
on the desired position.
The desired name for the position can be entered after tapping the field Position name
using the dialogue for text input.
confirms the position and closes the window.
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3.2.7.2 Labels and Subroutines

This displays a list of all the labels and subroutines that exist in the respective part
program.
Fig.: Window for labels and subroutines
For each label (subroutine) the line number is displayed and the number of references
to it.
is used to rename the selected label (subroutine). The desired name is entered
using the dialogue for text input. Commands accessing the renamed label (subroutine)
are changed accordingly automatically.
See also:
3.3.7.2 Label
3.3.7.4 Call - Subr - Ret
3.2.7.3 Placing Program

Refer to Placing Programs.
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3.3 Teach Commands Of The Texteditor
3.3.1 Axes
3.3.1.1 Axes Selection

3.3.1.2 Terminology
3.3.1.2.1 Pneumatical Axes

Pneumatical axes are axes with pneumatical drive. They are controlled with magnetic
valves; position feedback is done with position limit switches.
3.3.1.2.2 Numerical Axes

Numerical axes are axes with numerical position feedback and control. On R8.3 robots
numerical axes are driven by synchronous servo motors.
3.3.1.2.3 Path Axes

Path axes are numerical axes which are included in a path axes calculation of a part
program. Path axes of the same part program can be move coordinated with each
other using 3D and Curve movements.
The main axes X, Y, Z of a standard robot are included in the path axes calculation of
the robot program Robot Prg. by default.
You can assign numerical axes to the path axes calculations of the different part
programs of the current Teachprogram using the Setup menu Axes Definition.
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3.3.1.3 Move
This tab provides teach commands to teach movements of the selected axes.
What kinds of movements are available is depending on the kind of drive of the axis
and if it is a path axis.
After selecting the kind of movement, the axis is moved to the desired target position
using the drive keys.
Fig.: Buttons for moving axes
If there are predefined positions available, alternatively one of these positions can be
picked from the selection list. In this case the axis is taken to the selected positions
using the buttons shown below. The axis will stop automatically when it has reached
the position.
Fig.: Buttons to move axes to predefined positions
Whether the numerical axes can be moved using variable or fixed manual speeds is
being set in the Init Menu Setup: Robot Settings.
is used to confirm and write the command to the teach program.
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3.3.1.3.1 Absolute Movement
Absolute
This instruction is used to approach a particular position with the corresponding axis.
3.3.1.3.2 Relative Motion
Relative
If a position was approached with a numerical axis, this function can be used to move
the axis relative to this position. This instruction is identified by the letter "R" after the
position entry.
Example:
Z: 500.0
X: 100.0
Z: 100.0R
With the Z axis, move to position 500.0 mm, and with the X axis, to position 100.0 mm.
Starting from this position, move the Z axis to position Z = 600.0 mm. Now if the first Z
position is modified, the second Z position will also shift by the same value, but the
distance between the two positions will remain constant and exactly 100.0 mm.
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3.3.1.3.3 Parallel Movements

A parallel movement is the simultaneous motion of several axes.
As a parallel command simply causes command processing to acknowledge the

command before its execution is finished, for a coordinated ending of all previously
started commands you have to use a WAIT SYNC command after every parallel
movement. This ensures that all previously started commands have to be finished
before the next command is executed.
The parallel commands are not available for path axes. You have to use 3D
movements to execute simultaneous movements with several path axes.
Two kinds of parallel movements are available:
• Synchronous
• Parallel At
3.3.1.3.3.1 Synchronous
Synchronous
When this instruction is started, the following (travel) instruction is also started
simultaneously.
Synchronous parallel motion is identified by the symbol "*" after the position to be
approached.
Example:
C: 0.0*
A: 0.0
WAIT SYNC
The A and C axes are started simultaneously and are moved to their 0 position. The
instruction WAIT SYNC ensures that both axis motions are completed before the
program is continued.
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3.3.1.3.3.2 Parallel at
Parallel
This function is used to drive the respective axis alone to an intermediate position
(Intermediate Pos.). When this intermediate position has been passed, the next
(travel) instruction is started, while the axis continues traveling to its target position
(Final position) in parallel.
Fig.: Parallel at
To teach this command, first the Intermediate Pos. is activated by tapping it. Now the
axis is moved to the position, where when passing it in automatic mode, the next
instructions shall be started.
The next step is to activate the Final position by tapping it, and to move the axis to its
target position.
Now the command can be added to the teach program using .
is used to exit without changing the teach program.
Example:
Z: 500.0* 200.0
C: 90.0
WAIT SYNC
The Z axis will travel to the position 500.0, and from position Z = 200.0 the instruction
C: 90 will be processed in parallel. The instruction WAIT SYNC ensures that both axis
motions will be carried to the end before processing of the program is continued with
the next instruction.
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3.3.1.3.4 Curve
Curve
With the curve function, the relevant position of a path axis is not approached, but is
passed using an adjustable radius R3D. The function is identified by the symbol "*"
before the respective axis.
Example:
*Z: 500.0
Y: 200.0
The position with the coordinates Z = 500.0 and Y = 200.0 is approached in one
motion. The Y axis is started around R3D before reaching the position Z = 500.
The curved movement can also be used to start a parallel motion of a non path axis
during the motion of a path axis when the path axis moves past a given position.
Example:
*Z: 500.0
C: 90.0*
Z: 1000.0
WAIT SYNC
The Z axis travels in one motion to the position 1000.0. When the Z axis travels past
the position 500.0, pivoting of the C axis is started in parallel. Parallel travels have to
be completed with a WAIT SYNC command.
Similarly, peripheral outputs for example can also be switched when a given position is
passed, without the motion of the axis concerned being affected.
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3.3.1.3.5 Stop
Stop
Processing of this instruction in automatic mode produces an immediate stop of the

selected numerical axis.
See also:
3.3.5.7 Vacuum Monitoring
3.3.1.3.6 Soft Torque Push

The Soft Torque Push function enables the robot to take out long parts with the
respective axis being pushed by the ejector.
The EOAT is moved to the piece and the piece is being fixed on the gripper already
before the ejector starts moving forward.
The PUSH command is used to start the ejector and to let the respective axis being
pushed by the ejector. This is done with adjustable torque assistance, thus eliminating
the resistance of the robot mechanicals.
From the Intermediate Position given by the command, the axis will use either
maximum velocity or the last measured velocity to travel to the target position. In the
second case, regarding the braking ramp of the ejector, the Intermediate Position
should be placed in a way to let the robot continue its travel with sufficient speed.
The permit for Ejector Forward must be turned off in the Teach program by the user.
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The sequence for teaching (shown for the X-axis) is:
1) Use Absolute to select the X-axis.

2) Travel to the part removal position.
3) Confirm the command with .

4) Program everything that is necessary to take the part
(switch on vacuums, close grippers).
5) Use to select the Soft Torque Push function.

The following window will appear:
Fig.: Window for the Soft Torque Push function
6) Activate the option Intermediate Pos. and move the X-axis to the end position
of the ejector.
7) Activate the option Final position and move the X-axis to the final kick stroke
position in the mold, from which the vertical arm can be moved up and out of
the mold.
8) Use the value Assistance to set the amount of torque assistance from 0 to
120% of the base settings.
9) Use the options Vmax and Uniform velocity to decide whether the movement
from the intermediate position to the target position shall be carried out with
either maximum speed or the last measured (ejector-) speed.
10) Press to add the command to the program.
Example:
...
*Y: 1000.0 travel to the part
Vacuum-01 = ON
X: 600.0
WAIT Vacuum-01 = ON fix the part
X: 100.0 PUSH 300.0 (100%) travel synchronously with the ejector
PERMIT IMM:EJECTORS FORWARD!=OFF switch off Ejector Forward
...
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3.3.1.3.7 Release (optional)
Release
The use of this function requires that the respective axis is equipped with a suitable
gearbox.
and are used to determine whether the command shall switch the axis
release on or off.
is used to add the command to the Teach program.
When the release is activated, the respective axis can be moved by auxiliary force.
After deactivating the axis release, the position of the axis will be controlled actively
again.
Example:
X: RELEASE = ON
FUNCTION IMM: EJECTORS FORWARD! WAIT
X: RELEASE = OFF
Here the X-axis is pushed by the ejector. The ejector is started after the axis has been
released. When the ejector has arrived at its most forward position, the axis release is
being deactivated again.
See also: 3.1.12.2 Axis Release in Manual Mode
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3.3.1.3.8 Stack Sensor (optional)
This function makes it possible to react to obstacles in travel of an axis by means of a

stack sensor. The axis is traveled until either the stack sensor is actuated or a
teachable maximum position is reached.
Fig.: Stack Sensor
At first the desired Stack Sensor is selected from the list box on the upper left of the
tab.
From Position: is the position that is first approached absolutely at the current speed;
this is where travel to the stack sensor starts.
To Position: is the position at which stack sensor travel ends when the stack sensor is
not activated during travel.
Each position has to be selected by tapping on it, and has to be approached with the
axis using the drive keys. Alternatively predefined positions can be selected.
Vabs: Absolute speed in mm/s, by which travel to the stack sensor is carried out
between From Position and To Position. (is not affected by the override)
Current: shows the current position of the axis.
writes the command to the teach program and closes the window.
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3.3.1.3.9 Find ń´ Pick
With this function the axis will use one of the analogue vacuum monitors to search for
the part to take or for any other obstacle. This may be useful when approaching the
takeout position in molding machines with big tolerances on the mold open position.
The function is also an alternative for a “real” stack sensor.
Fig.: Find ń´ Pick
Use the list box on the upper left corner of the window to select the desired vacuum
circuit. During automatic operation the selected vacuum circuit will be automatically
switched on when execution of the teach command begins.
Vabs
Determines the absolute speed in mm/s used for the search movement.
(Not influenced by the Override)
Vac. Level
This is the trigger level used for the vacuum monitor of the selected vacuum circuit.
When the vacuum under pressure exceeds this level, the robot recognizes the
part/obstacle and stops the search movement. In order for the robot to recognize the
part/obstacle as early as possible, the value should be set as closely as possible above
the value shown for the empty vacuum circuit shown in the View menu Vacuum
Pressure.
End position
Use the input box on the bottom of the window to determine the position where the
movement ends, if the trigger level of the vacuum monitor has not been exceeded
during the search. After tapping the input box, you can use the drive buttons to move to
the desiered position. Alternatively you can select a predefined position.
Current
This shows the current position of the axis.
adds the command to the teach program and closes the window.
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Example:
…
*Y: 567.8
*X: 234.5
X: 345.6 Vacuum-01 VABS = 100 Vacuum Level = 34%
Wait Vacuum-01 = ON
X: 123.4 PUSH: 200.0 (100%)
…
In this example the robot tries to find the part in a mold with a varying open position. It
uses the Find ń´ Pick command to search for the part between X=234.5 and X=345.6.
After the robot has sucked on to the part (Wait Vacuum), it lets itself being pushed back
by the ejector using the Push command.
3.3.1.3.10 Follow Conveyor (optional)
Additional hardware for measuring the velocity of the conveyor is prerequisite for the
Follow Conveyor function.
The Follow Conveyor function enables the robot to follow a conveyor synchronously.
Thus the robot can place products on a moving conveyor, or take them away from
there.
Abb.: Window for the Follow Conveyor commands
After opening the window in the text editor you can use the buttons and to
determine whether you want to create the command for starting the conveyor following
movement or the command for stopping the conveyor following movement.
adds the command to the teach program and closes the window.
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The indications in parentheses (1, 2, 3, 4, 5, ALT) in the description of the Follow

Conveyor commands relate to the schematic of a conveyor following movement in the
figure further down this chapter.
FOLLOW Conveyor-xx ON ALT Label
This command starts the conveyor following movement. The command will “wait” until
the robot moves synchronously with the conveyor (1 to 2). From this moment on, the
program will be executed parallel to the conveyor following movement (2 bis 5). For the
axes only relative movements are allowed during the conveyor following movement,
they will be executed additionally.
The robot will not travel to the positions P1 and P2 during the actual conveyor following
movement. The line between the coordinates of P1 and P2 only serves as a vector for
the direction of the conveyor following movement.
In order to teach program the positions P1 and P2, open the window for the Follow
Conveyor commands and activate every single axis position one after the other with a
. Use the axes drive buttons to move the currently activated axis until you reach the
desired position. Us two distant points for P1 and P2, located close above the same
border of the conveyor, in order to make the vector as parallel to the actual moving
direction of the conveyor as possible.
The normal plane of this vector at P2 is used as a limit for the conveyor following
movement. If the position of the robot touches this limit during the conveyor following
movement, the alarm 019-001-xxx Conveyor-xx FOLLOWING TARGET POSITON
REACHED will be triggered and the program will continue at the label for the alternative
routine. This will not stop the conveyor following movement; you will rather have to
program an escape movement in the alternative routine in order to make stopping
possible (ALT).
Thus the position of P2 should selected to enable the planned conveyor following
movement (1 to 5) to be finished before reaching the normal plane, and on the other
side leave enough space for the escape movement (ALT) of the alternative routine to
be finished before reaching the stroke limits.
For the label of the alternative routine you can either tap the input field Enter label to
input a new label using the dialogue for text input, or you can select an existing label
using the selection field Select Label.
FOLLOW Conveyor-xx OFF
This command ends the conveyor following movement (5, ALT).
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Fig.: Schematic of a conveyor following movement
Example:
A part is taken away from a continuously moving conveyor. The indications in

parentheses relate to the schematic of a conveyor following movement in the figure.
...
*Z: 92.1 Move to the start position (1) above the conveyor, where
*X: 123.4 the conveyor can still move without colliding and where
Y: 300.0 also is enough space upwards for the escape movement
of the alternative routine.
-
WAIT PI-001 = OFF (1) Wait for the positive slope of a trigger signal
WAIT PI-001 = ON (1) (light sensor, camera, etc.).
-
FOLLOW Conveyor-01 ON ALT: TOO_FAR (1) to (2) Start the conveyor following movement and
switch to the next line once the robot moves
synchronously with the conveyor.
Vacuum-01 = ON (2) Switch on the vacuum.
Y: 200.0R (2) to (3) Move down.
WAIT Vacuum-01 = ON (3) to (4) Wait until the part is sucked on.
Y: -200.0R (4) to (5) Move up with the part.
FOLLOW Conveyor -01 OFF (5) End the conveyor following movement.
-
...
JMP ...
-
TOO_FAR: In case the conveyor following movement did

not end before the normal plane at P2:
Y: -200.0R to (ALT) Execute an escape movement,
FOLLOW Conveyor -01 OFF (ALT) and stop the conveyor following movement.
... Execute whatever else shall happen in this
error case.
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3.3.1.3.11 Mold Opening Synchronization (optional)

Mold Opening Synchronization (MOS) enables the robot to enter the mold during its
opening movement, thus saving valuable time.
A way measuring system the opening width of the mold of the IMM is necessary for this
feature.
The command WAIT MOLDPOSITION is used to wait until the mold has opened wide
enough for the robot to enter.
Now the (normally) X-axis can follow the moveable plate of the mold with a teachable
distance using the MOS command. The MOS command behaves like a Synchronous
command (the respective axis is taken out of the pre-calculated path), enabling the
robot to enter the mold with the Y-axis simultaneously. The MOS command is
terminated by the signal Mold Is Open of the IMM.
Finally a WAIT SYNC command must be introduced to end the parallel movement.
This also includes the MOS-axis to the pre-calculated path again.
The two commands for mold opening synchronization are added to the program like
this:
WAIT MOLD POSITION

This is used to wait until the mold is opened wide enough for the robot to enter. After
accessing the command with Mold Position you have to pick

one of the operators <=, >=, <, >, <>, = to select whether you want to wait until the
actual position of the mold is equal, below or above the selected value. Move the Mold
of the IMM to the desired position to select the value for the command.
Press to add the command to the teach program.
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RELATIVE TO MOLD
This axis command lets a robot axis (most likely X) follow the mold in a teachable
distance.
In order to teach the command, open the mold and access the command with
R to mold. Now move the robot to the desired distance from the
moving plate of the mold, which the robot should use to follow.
Example:
...
X: 50.0 travel X to the waiting position over the mold.
WAIT MOLDPOSITION > 400.0 wait until the mold is opened sufficiently for the robot to enter
X: 100.0 R TO MOLD let the X-axis follow the mold with the chosen distance; and at the
same time execute the next commands
(like "synchronous").
Y: 800.0 travel Y to 800.0 mm (while X is following the mold).
WAIT SYNC wait until all axes (X and Y) have finished their movements.
...
The distance displayed within the MOS command does not show the actual value of
the distance between EOAT and mold plate, but shows the calculated difference
between the value measured by the measurement system for the width of the mold
opening and the value of the axis position.
The value displayed within the command WAIT MOLDPOSITION only relates to the
actual value of the width of mold opening, if the MOS-Offset has been adjusted for the
mold currently in use.
The measured value of the mold position must not change, when one of the signals
Mold Is Open or Mold Is Closed is active. This would trigger the error message Mold
Monitoring.
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3.3.1.4 3D Motions
In 3D motions, a position is approached simultaneously with the selected path axes.
3D-motions can be executed as

• 3D-Absolute Motion
• 3D-Curve
• 3D-Relative Motion
Fig.: Window for 3D-Motions
can be used to open the window for selecting the path axes to
participate in the 3D movement.
Fig.: Axes selection for 3D commands
Use to confirm the selection.
Use to close the window and discard the selection.
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After selecting the type of motion, the position is approached with the participating path
axes. Use the window for 3D motions to activate every single axis with a and move
one after the other, using the drive keys, until the desired target position is reached.
Fig. Drive keys for numerical axes
When all axes are on target position, use to add the command to the teach
program.
Use to close the window, without changing the teach program.
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3.3.1.4.1 3D Absolute Motion
Absolute
In automatic operation, in processing of this instruction, the path axes are moved to the
indicated position simultaneously in a straight movement.
3.3.1.4.2 3D Relative Motion
Relative
In automatic operation, in processing of this instruction, the path axes are moved to the
indicated position simultaneously in a straight movement.
This function is identified in the teach program by the letter "R" after the axis
coordinates.
The axis coordinates in this instruction are added to the axis coordinates of the starting
position of the axes, i.e., motion is executed relative to this starting position.
The position to which the relative motion is to refer must already have been taught
before this function is entered.
If the starting position is changed, the position that is approached with the 3D relative
motion is also changed. The distances between the two points remain the same.
3.3.1.4.3 3D Curve
Curve
This function is identified in the teach program by the symbol "*" in front of the axis
coordinates.
In automatic operation, when this instruction is processed, the indicated position is

bypassed using the adjustable radius R3D and switched to the next instruction.
See also: 3.3.1.3.4 Curve
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3.3.1.5 Speed
This tab provides teach commands to set speed and acceleration for subsequently
teached movements of the specific axis.
3.3.1.5.1 VMAX
Vmax
This function is used to set the maximum speed as a percentage of the configured
maximum speed of a numerical axis. The actual axis speed in automatic operation is in
addition affected by the Override. The Vmax instruction remains effective until the next
Vmax or Vabs instruction, and affects all subsequently taught motions of the axis
concerned.
The value of VMAX can be altered by moving the slider, or can be input using the
numerical Input after tapping the input field.
3.3.1.5.2 VABS
Vabs
This function permits Override-independent speed setting in mm/s of a numerical axis

for adaptation to secondary motions (for example, ejector motion in piece transfer). The
Vabs instruction is effective until the next Vmax or Vabs instruction, and affects all
subsequently taught motions of the axis concerned.
The value of VABS can be altered by moving the slider, or can be input using the
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3.3.1.5.3 AABS
Aabs
This function permits the maximum acceleration or retardation in mm/s² of a numerical

axis to be adjusted when the configured acceleration (deceleration) is too big for the
application.
This instruction is effective until the next AABS instruction and affects all subsequently
programmed motions of the respective axis.
The value of AABS can be altered by moving the slider, or can be input using the
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3.3.1.5.4 R3D
R3D
R3D is the radius for curve motions motion in mm. This is the distance before the
taught end position at which the motion of the next axis instruction is started.
The parameter has to be taught in the program routine before the 3D motion to be
affected.
The value of R3D can be altered either by using the slider, or by typing the value using
the numerical input dialogue after tapping the input field.
3.3.1.5.5 V3D
V3D
This parameter limits the resulting path speed of path axes movements. The path
speed is the geometrical sum of the speeds of the involved single axes. The value of
V3D is given in mm/s.
V3D as a limiter overrules the settings performed with VMAX, VABS and the Override.
A limit set with V3D is valid until the next V3D command in the teach program. Without
a V3D command, the path speed in a teach program remains unlimited.
The parameter has to be programmed in the program sequence before the path axes
movement to be affected.
The value of V3D can be altered either by using the slider, or by typing the value using
the numerical input dialogue after tapping the input field.
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3.3.1.6 Wait Sync
Sync
This instruction is used to terminate parallel motions.
Program processing is stopped until all active axis motions have been completed.
3.3.1.6.1 Wait Path Sync
Path Sync
WAIT PATH SYNC is a version of WAIT SYNC especially designed for moving path
axes. The pre-calculation of the path axes is stopped until the last path-movement is
active and all other axes are no longer active.
If at the beginning of the curve radius of the path axes still any other axis is not in its
target position, the path axes will stop at their respective last target positions. The pre-
calculation will be continued after all other axes have reached their target positions.
Example:
*Y: 200.0
C: 90.0*
*Y: 0.0
*X: 0.0
*Z: 2000.0
WAIT PATH SYNC
*Z: 0.0
At Y=200 the synchronous movement to C = 90 is started. If the C-Axes reaches its

position more than the curve radius prior to Z = 2000 the robot will continue traveling to
Z = 0 without stopping. If the C-Axes does not reach its position the robot stops at Z =
2000 and waits until C reaches its position. Only after that the robot will continue
traveling to Z = 0.
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3.3.1.7 Movements and Parameters for Scara Robots

The „normal“ (3D) Motion commands are also available for Scara robots. Those
commands are used to move the robot within the spatial system of coordinates. With
the additional angular movements it is possible to move the axes of the robot outside
the spatial system of coordinates.
3.3.1.7.1 Pathmode
The Parameter Pathmode is used to determine how the robot moves to its target
position.
The parameter has to be programmed in the program sequence before the movement
to be affected. A setting made with PATHMODE is valid until the next PATHMODE
command in the teach program.
Linear Mode:
The axes move to the target position coordinated in a way that the resulting movement
draws a straight line in the spatial system of coordinates. The single axes cannot move
with full speed. In linear mode the robot cannot change the bending orientation of its
elbow joint β.
Joint Mode:
The axes move optimized for speed. The resulting movement in the spatial system of
coordinates is not straight. Angular movements („in degrees“) will always be executed
in joint mode.
Select the desired mode by tapping it.
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3.3.1.7.2 Angular Motions - „in degrees“
Absolute in degree
Curve in degree
Use the angular motions to move the axes (joints) α, β, γ of a Scara robot outside the
spatial system of coordinates in angular degrees.
The angular motions are 3D-motions.
Angular motions will always be carried out in joint mode, regardless of the Pathmode
set.
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3.3.2 Placing Programs
Placing Programs are used for the automatic calculation and approach of several
stacking positions. This makes it possible to stack parts without programming each
position separately.
The R8.3 control offers the following possibilities for this:
• 16 freely definable placing programs

• up to 6 different placing sequences
• up to 6 different axis sequences
• approach of stacking positions with 3D function
• programmable box height
• programmable displacement
• approach stack sensors with adjustable speed
• stacking / un-stacking
• support of double arm robots
Programming a Placing Program has to be done in two steps:

1) Creating the Placing Program.
2) Adding the created Placing Program as a command to the teach program.
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3.3.2.1 Create/Edit Placing Programs

For creating and editing of placing programs open the menu
Part Prg Setup – Placing Program. The dialogue for selecting existing placing
programs will be shown.
Fig.: Dialogue for selecting a placing program
In the selection list on the left side of the window you can select one of the existing
placing programs. The table Placing Program Information shows how many positions
in the different axes dimensions the selected placing program will travel to. If no placing
programs have been defined in the current teach program yet, the message "No
placing programs available" will be displayed instead of the selection list.
is used to create a new placing program.
is used to create a new placing program for a double arm robot that additionally
contains the parallel axes X2 and Y2. Prerequisite for this is that the parallel axes have
been added to the path in the current teach program.
is used to edit the selected placing program.
can be used to delete the selected placing program, if it is not used in the teach
program.
can be used to create a copy of the selected placing program. The dialogue for
text input will appear. Here you can input a name for the copy of the placing program,
or confirm the suggested standard name with .
When you create a new placing program, first the dialogue for axes selection will be
displayed.
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Editing of the other parameters of the placing program will be done using five tabs:
1. ........................... Position of the first piece, Name

2. ........................... Number and distances of the other pieces
Options .................. Axis sequence, placing sequence, 3D, box height
STS ....................... Stacking Sensor
Displacement ........ Displacement
The dialogue for axes selection and the tabs for stacking sensor and displacement will
not be displayed at a placing program for a double arm robot.
See also:
3.3.6.2 Reset Placing Counters
3.1.15.7 VIEW Menu: Placing Counters
3.3.2.1.1 Dialogue for Axes Selection

When creating a new placing program, this window is used to select the axes available
for the new placing program.
Fig.: Dialogue for axes selection
Select up to 3 axes to be used with the placing program with a .
Press to confirm the entries, the tab for the first stacking position will be
displayed next.
Press to cancel the process and discard the entries.
The dialogue for axes selection will not be displayed at a placing program for a double
arm robot.
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3.3.2.1.2 Tab 1. - 1st Position, Name

This tab is used to determine the stacking position of the first piece in the placing
sequence; furthermore the name of the placing program can be changed here.
Fig.: Tab for the 1st position
Tap the input field Name of placing program and input a name for the placing
program using the dialogue for text input.
After selecting one of the axes, you can move it to its previously programmed 1st
stacking position using the buttons for moving to an existing position.
If you want to change the axes positions for the first stacking position, first press the
button . Now select each axis and move it to its desired position, until all axes of
the robot are on their first stacking position.
You can also use the selection field on the right bottom of the window to recall a
predefined position for the first stacking position.
When all parameters on this tab are entered, either open the next tab by tapping it, or
accept the placing program by pressing .
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3.3.2.1.3 Tab 2. - Stacking Pattern

This tab is used to determine the stacking pattern.
Fig.: Tab for the stacking pattern
In order to determine the stacking pattern, for each axis the number of pieces to be
placed in the axis direction and the position of either the second or the last piece have
to be specified. The second or last position is calculated as a distance relative to the
first stacking position (this is indicated by the letter R after the positions)
When the first position is changed, the entire placing program will be shifted and the
stacking pattern remains intact.
Choose one of the axes and select whether you want to determine the position of the
second piece (2nd Pos.) or the position of the last piece (End Pos.) in the respective
axis direction.
Now move the axis to its desired position using the drive buttons.
When you activate the option Numeric Input you can input the positions using the
dialogue for numerical input without moving axes.
Finally tap the field Number of parts and use the dialogue for numerical input to input
the number of pieces to be placed in the respective axis direction.
With the option Keep gap constant the distance between stacking positions will be
kept constant automatically, when changing the number of parts in an existing placing
program.
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3.3.2.1.4 Tab Options

This tab is used to set options about approach and placing order for the placing
program.
Fig.: Tab for approach and placing order
Axis Order
This sequence will be used during automatic operation to move the axes to the current
stacking position.
Placing Order
This sequence will be used during automatic operation for going to the different
stacking positions.
Fig.: Example - Placing Order ZXY
3D
A at this option activates the 3D approach. The axes will move to their positions
simultaneously by means of a 3D motion. The parameters Box Height and Axis
Sequence make the last axis in the axis sequence end the 3D motion displaced at the
box height, and then travel into position alone. Otherwise, the robot would "move
through" the wall of the crate. R8.3 does not execute the 3D movements as a straight
line, but as a curve to box height. Use the option straight line to get a straight line.
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Box Height
This value depends upon the dimensions of the crate. Select the axis to be moved into
the crate. This has already been done in the Axis Sequence parameter; select an axis
sequence in which this axis is the last to be moved (e.g., ZXY for the Y axis). Move the
selected axis toward a position outside the crate that can be approached without
collision (with a 3D motion). Box height will be used during single axis approach also, in
order to trigger the error message 170-007 – BOX CRASH MONITORING. If you do
not want to use box height, deactivate the option.
3.3.2.1.5 Tab STS - Stacking Sensor

On this tab you can activate that the last axis of the axis sequence uses a stacking
sensor to approach the stacking positions. Above all this is helpful during un-stacking.
Fig.: Tab for a stacking sensor
With the selection field at the right top of the tab you can select which stacking sensor
is to be used. With the selection "000 - none -" the stacking sensor function is
deactivated, the axis will travel to the calculated position directly.
Offset
This is the distance from the calculated stacking position where the search movement
to the stack sensor shall start. After pressing , set the Offset by moving the
respective axis using the drive buttons.
Vabs
This is the absolute speed used for the stacking sensor search movement. After
tapping the input field, input the desired value using the dialogue for numerical input.
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This tab will not be shown at a placing program for a double arm robot.
3.3.2.1.6 Tab Displacement

Certain pieces cannot be stacked one over the other (or side by side), but may have to
be displaced in relation to the previous layer. Use the parameter Displacement of the
placing program to achieve this for the respective axis direction.
Fig.: Tab for displacement
With every layer change of the last axis in the placing order, the displacement value set
for the respective axis will be added to the stacking positions of that axis.
Set the displacement value can be set after activating the respective axis by moving
the axis with the drive buttons.
This tab will not be shown at a placing program for a double arm robot.
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3.3.2.2 Add Placing Program Commands to the Teach Program

Before you can add a placing program to the teach program, you have to create it in
the menu Part Prg Setup – Placing Program.
When you have created a placing program in the current teach program already, and
you want to add it as a command, press to open the selection window for adding
placing programs.
Fig.: Selection window for adding placing programs
Select the desired placing program from the list on the left top of the window. The table
Placing Program Information shows how many positions in the different axes
dimensions the selected placing program will travel to. If no placing programs have
been defined in the current teach program yet, the message "No placing programs
available" will be displayed instead of the selection list.
Use the buttons on the right side of the window to decide whether the placing program
shall stack or un-stack:
creates a placing program command for stacking. The counters of the placing
program will be incremented after traveling to a position. Pieces will be “added” to the
stack.
creates a placing program command for un-stacking. The counters of the placing
program will be decremented before traveling to a position. The placing program is
running “in reverse” – pieces will be “removed” from the stack. In the program this will
be indicated by adding the extension UNSTACK to the command.
Use the option Additional Counter and the selection box below to select a counter
that will be incremented when stacking and decremented when un-stacking.
Press to cancel the action.
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3.3.3 Injection Molding Machine IMM
3.3.3.1 Injection Molding Machine IMM - Standard Functions
Here you can program signals to the IMM.
Fig.: Window for IMM Signals
First pick the desired signal from the selection list.
and are used to select if the chosen signal is to be turned on or off.
When the robot is equipped with 2 interfaces for injection molding machines, one of the
options IMM 1 or IMM 2 has to be tapped in order to select which Injection Molding
Machine is the targeted by the signal.
is used to cancel the entry.
If a signal has been enabled in the teach program, it also has to be disabled again.
These signals are only permits (inhibits) to the injection molding machine. The actual
control of the movements is done by the IMM.
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3.3.3.1.1 MOLD CLOSE and FULLY MOLD OPEN
Use the permission signals MOLD CLOSE and FULLY MOLD OPEN to program the
permits for the movements of the mold of the injection molding machine. The signal
FULLY MOLD OPEN is only available with the extended E67 / E12 interface; here the
mold is automatically only opened to an intermediate position. The robot does not
control the standard opening of the mold - the IMM opens the mold when the part is
finished.
Furthermore the IMM utilizes E67 / E12 signals to send feedback about the position of
the mold. This is done using the signals MOLD OPEN and MOLD CLOSED. Only when
the mold is fully open, it is possible for the robot to enter the mold.
The extended E67 / E12 interface additionally supplies the feedback signal MOLD
INTERMEDIATE POSITION. Here the robot can already enter the mold, when it is
opened to the intermediate position. According to the mode used at the IMM the robot
then may have to permit the mold to fully open.
Example for standard E67 / E12

WAIT IMM: MOLD OPEN = ON wait until the mold is fully open
AND IMM: MOLD WAS CLOSED = ON and was fully closed
PERMIT IMM: MOLD CLOSE! = OFF switch off permission
enter the mold area,

remove the part,
exit the mold area, then ...
PERMIT IMM: MOLD CLOSE! = ON close the mold.
Part placement …
Example for extended E67 / E12

WAIT IMM: MOLD INTERMEDIATE POS = ON wait until the mold is open
AND IMM: MOLD WAS CLOSED = ON and was fully closed
PERMIT IMM: MOLD CLOSE! = OFF switch off permission
enter the mold area; fix the part on the EOAT
PERMIT IMM: FULLY MOLD OPEN = ON fully open the mold

WAIT IMM: MOLD OPEN = ON wait until the mold is fully open
PERMIT IMM: FULLY MOLD OPEN = OFF switch off permission
exit the mold area
PERMIT IMM: MOLD CLOSE! = ON close the mold.
Part placement …
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3.3.3.1.2 EJECTORS FORWARD/BACK and COREPULLERS PULL/SET
Using the commands EJECTORS FORWARD/BACK and COREPULLERS PULL/SET

the movements of the ejectors and core pullers of the IMM are teached. The most
basic way to do so, is to switch on the permit for the desired movement, then wait until
the target position is reached using a WAIT command, and then to switch off the permit
again.
The following example moves the ejectors forward:
PERMIT IMM: EJECTORS FORWARD! = ON switch on permission

WAIT IMM: EJECTORS FORWARD = ON wait ...
PERMIT IMM: EJECTORS FORWARD! = OFF switch off permission
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3.3.3.2 Injection Molding Machine IMM - Automatic Functions
The automatic functions simplify programming the movements of the IMM.
Fig.: Window for IMM signals
First pick the desired movement from the selection list.
The permits are toggled correctly by the commands automatically. When the option
Wait for completion of the command is activated, the command will wait until the
movement is finished. In that case command will have the extension WAIT added in the
Teach program.
options IMM 1 or IMM 2 has to be tapped in order to select which Injection Molding
Machine is the targeted by the signal.
These signals are only permits (inhibits) to the injection molding machine. The actual
control of the movements is done by the IMM.
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3.3.3.2.1 MOLD CLOSE! WAIT
The command
FUNCTION IMM: MOLD CLOSE! WAIT
eases programming the closing movement of the mold. The command equals the
following sequence of "standard" commands:
PERMIT IMM: MOLD CLOSE! = ON

WAIT IMM: MOLD CLOSED = ON
AND IMM: MOLD OPEN = OFF
3.3.3.2.2 EJECTORS FORWARD/BACK (WAIT) and

CORE PULLERS PULL/SET (WAIT)
The automatic functions will ease the programming of the movements of the ejectors
and core pullers essentially. The respective permits are simply toggled by the
commands automatically.
The automatic function for "ejector back" will look like this:
FUNCTION IMM: EJECTOR BACK!
This equals the following sequence of "standard" commands:
PERMIT IMM: EJECTOR FORWARD! = OFF

PERMIT IMM: EJECTOR BACK! = ON
If additionally the option Wait for completion of command is activated, the extension
WAIT is added to the command, and the command will wait for the respective
movement to be finished.
The Wait function for "ejectors back" will look like this:
FUNCTION IMM: EJECTOR BACK! WAIT
This equals the following sequence of "standard" commands:
PERMIT IMM: EJECTOR FORWARD! = OFF

PERMIT IMM: EJECTOR BACK! = ON
WAIT IMM EJECTOR BACK = ON
AND IMM EJECTOR FORWARD = OFF
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3.3.3.3 Injection Molding Machine IMM - Logical Functions – Mold Was Closed
Here you can program the command for manipulating the latch Mold Was Closed for
the condition with the same name.
This will for example be necessary when at the first cycle the condition Mold Was
Closed has to be overridden for entering the mold, because the mold is going to be
closed for the first time only after inserting inserts.
Fig.: Window for logical IMM commands
and are used to select if the latch shall be set or reset.
options IMM 1 or IMM 2 has to be activated, in order to select the Injection Molding
Machine, whose latch will the targeted by the action.
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3.3.4 Smart Removal
3.3.4.1 Smart Removal: In
The command Smart Removal: IN is used to program a time optimized movement

into the mold of the IMM in a very simple way. For this purpose the command starts a
curved movement of Y and X during the mold opening movement already, in order to
travel off the Y mold safety switch shortly after full mold opening has been achieved.
Waiting for the mold signals is processed automatically. A distance for X moving in
straight can be set. The integrated "parallel at time" allows pre-triggering of the
ejectors.
Use the first window to determine, which axes will be moved in what order by the
Move-In command.
Fig.: Axes selection for Smart Removal In
Use to confirm the selection and to open the dialogue for inputting the other
parameters.
Fig.: Dialogue for Smart Removal In
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Start position
This is the position where Smart Removal starts moving in. Is retrieved automatically
from the teach commands before Smart Removal: IN.
Takeoutposition
This is the target position of the Smart Removal movement into the mold. At this
position the gripper of the robot should take over the parts from the IMM. After
activation with a , the participating axes can be moved to their desired positions one
by one using the drive buttons.
Position of the S5 mold safety switch
This is the position where the Y axis travels off the cam of its mold safety switch, thus
entering the mold. It is determined automatically.
Straight movement to takeout position from dx
This is the distance before the X takeout position, where the Y movement must be
finished, in order for X to travel to the takeout position with a straight movement. Input
the desired distance after tapping the input field or after pressing using the
dialogue for numerical input. Furthermore, after tapping the input field you can use
and to tune the distance.
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Parallel at time dt before takeout-position
This is the time before the takeout position is reached with Y and X, when the
command Smart Removal: IN acknowledges itself, thus starting the Teach
commands after itself, before it is actually finished. This way you can pre-trigger the
ejectors, for example. The resulting parallel movement has to be completed with a
WAIT SYNC command at an adequate position in the Teach program. Input the
desired time after tapping the input field or after pressing using the dialogue for
numerical input. Furthermore, after tapping the input field you can use and
to tune the time.
Mold Intermediate Position

If Smart Removal: IN shall enter the mold already when mold opening reaches the
mold intermediate position, access the tab and activate the option Use
mold Intermediate position there. This option is only available when the optional
signal Mold Intermediate Position is available on the machine interface.
Press to add the command to the Teach program.
Press to discard the entries.
Example:
...
Travel to the start position of Smart Removal over the mold.
*Y: 0.0
*Z: 4711.0
*X: 123.4
Smart Removal: IN
Pre-triggered vacuum and ejectors using the time dt.

Vacuum-01 = ON
WAIT SYNC
WAIT Vacuum-01 = ON
...
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3.3.4.2 Smart Removal: Out
The command Smart Removal: OUT is used to program a time optimized movement
out of the mold of the IMM in a very simple way. For this purpose the command triggers
the closing of the mold already while it moves X and Y out of the mold with a curved
movement. A distance for a straight movement of X can be set. An adjustable time
allows permitting the closing movement of the mold before the Y axis travels onto the
cam of its mold safety switch, thus eliminating any switching delays of the machine
interface.
Use the first window to determine, which axes will be moved in what order by the
Move-Out command.
Fig.: Axes selection for Smart Removal Out
Use to confirm the selection and to open the dialogue for inputting the other
parameters.
Fig.: Dialogue for Smart Removal Out
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Takeoutposition
This is the position, where Smart Removal starts moving out. Is retrieved automatically
from the teach commands before Smart Removal: OUT.
Straight movement form takeout position to dx
This is the distance from the X takeout position, where the Y movement is started, after
X has moved away from its takeout position using a straight motion. Input the desired
distance after tapping the input field or after pressing using the dialogue for
numerical input. Furthermore, after tapping the input field you can use and
to tune the distance.
Set close mold before S5 is reached dt
This is the time before the S5 cam is reached, when the command Smart Removal:
OUT already turns on the permit to close the mold, in order to eliminate any switching
delays of the machine interface. Input the desired time after tapping the input field or
after pressing using the dialogue for numerical input. Furthermore, after tapping
the input field you can use and to tune the time.
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Position of the S5 mold safety switch
This is the position, where the Y axis reaches the cam of the mold safety switch, i.e.
where it exits the mold. It is determined automatically.
Position over mold
This is the target position of the Smart Removal movement out of the mold. From this
position it should be possible for the robot to move off the machine. After activation with
a , the participating axes can be moved to their desired positions one by one using
the drive buttons.
Press to discard the entries.
Example:
...
After the parts have been delivered to the robot gripper using the ejectors.
FUNCTION IMM: EJECTORS BACK! WAIT
Smart Removal: OUT
Travel to the placement position ...

Z: 123.4
...
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3.3.5 Peripherals
3.3.5.1 Conveyor
This command is used to control a conveyor.
Fig.: window for conveyors
and are used to select if the command shall switch the conveyor on or off.
When the option Time is activated with a , the selected state is only kept for the
selected time, without interrupting the teach program. The value for the time is input
using the numerical input dialogue after tapping the input field.
is used to add the command to the teach program.
is used to cancel the input.
See also:
3.2.6.7 Setup Menu: Conveyor Names
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3.3.5.2 Peripheral Outputs PO
This command is used to control peripheral outputs (POs).
Fig.: window for peripheral outputs
First, the desired peripheral output is selected.
and are used to select whether the command shall switch the selected
peripheral output on or off.
When the option Time is activated with a , the selected state is only kept for the
selected time, without interrupting the teach program. The value for the time is input
using the numerical input dialogue after tapping the input field.
Part monitoring can be activated for peripheral outputs. In monitoring, outputs and
inputs having the same number will always correspond to one another. As an example,
monitoring for peripheral output 1 will be performed through peripheral input 1.
Peripheral outputs will remain set when shifting to manual, block stop or in the event of
an error.
See also:
3.3.5.7 Monitoring
3.3.5.3 Cylinders
3.2.6.8 Setup Menu: PO-Names
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3.3.5.3 Cylinder function
This function is useful to ease the teaching of pneumatic cylinders of some peripheral
equipment, by combining two peripheral outputs to a cylinder. Additionally you can use
two peripheral inputs and a time limit to monitor the correct function of the pneumatic
cylinder. If the cylinder does not reach the respective target position within the set time
limit, an error message will be displayed on the teachbox.
Up to 255 cylinders can be defined. Mapping of the peripheral outputs and inputs, also
setting the time limit is done using the cylinder definition.
After selecting the function, first the desired cylinder is selected from the list.
, and are used to select if the command has to move the cylinder to
either one of its final positions or to release it. Release means, that both outputs are
switched off.
In case of cylinders that are equipped with position limit switches, in automatic
operation the next command is not executed before the desired target position of the
gripper is approached. The option Parallel enables to move several cylinders
simultaneously in that case.
This allows starting additional functions during the motion of the cylinder already.
In order to prevent uncontrolled motions, the instruction WAIT SYNC has to be entered
after every parallel motion. This will ensure that all motions have been completed
before the next instruction is started.
Peripheral outputs will remain set when shifting to manual, block stop or in the event of
an error.
See also:
3.2.6.4 Setup Menu: Cylinder Definition
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3.3.5.3.1 Applying cylinders in a teach program

Without using the cylinder function, moving a pneumatic cylinder forward and backward
will be programmed somehow like this:
PO-002: OFF switch off the valve for "backward"

PO-001: ON switch on the valve for "forward"
WAIT PI-001 =ON wait until the limit switch "cylinder forward" is actuated
...
PO-001: OFF switch off the valve for "forward"

PO-002: ON switch on the valve for "backward"
WAIT PI-002 =ON wait until the limit switch "cylinder backward" is actuated
Using the cylinder function simplifies the example like this:
CYL-01: ON switch off the valve for "backward"

switch on the valve for "forward"
wait until the limit switch "cylinder forward" is actuated
...
CYL-01: OFF switch off the valve for "forward"

switch on the valve for "backward"
wait until the limit switch "cylinder backward" is actuated
If also the time limit is set correctly at the cylinder definition, one benefits a monitoring
function with error message for time limit exceeded without additional programming.
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3.3.5.4 Vacuums
This command is used to control vacuum circuits.
Fig.: window for vacuum circuits
First, the desired vacuum circuit is selected.
and are used to select whether the command shall switch the selected
vacuum circuit on or off.
When the robot is equipped with the corresponding valves, a blow-off function will be
available at the turn off command. You can activate the blow off function with a at
Blow out time. After tapping the input field, input the duration of blowing using the
dialogue for numerical input. With the option Infinite the command will switch on
blowing permanently.
See also:
3.3.5.5 Vacuum Level
3.3.5.7 Monitoring
3.2.6.12 Setup Menu: Vacuum Names
3.2.6.14 Setup Menu: Vacuum Reference States
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3.3.5.5 Vacuum Level
Use the Vacuum Level command to set the vacuum threshold for vacuum monitoring
and the condition vacuum independent from the preset Standard Vacuum Pressure.
Thus you can use different thresholds in different parts of the Teach program. The
threshold for a specific vacuum circuit set with the Vacuum Level command will be
valid until the next Vacuum Level command for the same vacuum circuit.
Fig.: Window for the Vacuum Level command
After selecting the desired vacuum circuit and tapping the input field Set vacuum level
you can input the desired threshold using the dialogue for numerical input. Alternatively
you can use the slider on the right side of the window.
Select the option Standard with a to generate the command for using the threshold
preset with Setup Standard Vacuum Pressure.
Use to add the command to the teach program.
Use to discard the entries.
See also:
3.3.5.4 Vacuums
3.3.5.7 Monitoring
3.3.7.8.5 Condition: Vacuum
3.2.6.16 Setup Standard Vacuum Pressure
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3.3.5.6 Grippers
This command is used to control gripper circuits.
Fig.: window for gripper circuits
First, the desired gripper circuit is selected.
, and are used to select whether the command shall switch the selected
gripper circuit to opened, closed or released.
valves.
In case of gripper circuits that are equipped with position feedback, in automatic
operation the next command is not executed before the desired target position of the
gripper is approached. The option Parallel enables to move several grippers
simultaneously in that case.
This allows starting additional functions during the closing or opening motion.
In order to prevent uncontrolled motions, the instruction WAIT SYNC has to be entered
after every parallel motion. This will ensure that all motions have been completed
before the next instruction is started.
See also:
3.3.5.7 Monitoring
3.2.6.13 Setup Menu: Gripper Names
3.2.6.15 Setup Menu: Gripper Reference States
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3.3.5.7 Monitoring of Vacuum Circuits, Grippers and Peripheral Outputs

Using (part-) monitoring the robot can react on the loss of parts, in order to avoid
damage caused by parts that got stuck, were not taken out or have fallen down.
The monitorings are background functions that from their activation until their
deactivation check, if all parts are still present on the respective vacuum circuit, gripper
or peripheral circuit.
At vacuum circuits part monitoring is done using the analogue vacuum pressure
monitoring. Use the menu Setup Vacuum Pressure to set the trigger value for the
current Teachprogram.
At grippers the state of the respective gripper input Part Monitoring is monitored. This
input must be actuated by a suitable sensor.
At peripheral outputs the state of the peripheral input with the same number is
monitored.
When a monitoring is triggered (by part loss), the action (Stop or Alternative Routine)
selected on activation of the monitoring will be carried out.
Action STOP
When the monitoring is triggered, the robot will switch to operating mode Manual. This
results in an immediate stop of the axes. The error message Element: PART LOST will
be emitted.
Action ALT: label

When the monitoring is triggered, the robot will remain in operating mode Automatic.
Nevertheless an immediate stop of the axes will be carried out. The execution of the
Teachprogram will continue at the designated label (in the alternative sequence). The
error message Element: PART LOST will be emitted.
Alternative sequences have to be made dependant on the current position, in order to

avoid collisions.
It is possible to assign a separate alternative sequence to each of the vacuum, gripper

and peripheral circuits; however, it is likewise possible to use a single alternative
sequence for all circuits.
Alternative sequences have to be ended with an unconditional jump and the IMM
signals have to be switched according to the relevant needs. In alternative sequences,
the monitoring system of the addressed circuit or the circuit itself should be turned off;
otherwise the program will jump back to this alternative sequence after having
completed the alternative sequence.
In order to avoid collisions during or after an alternative sequence, the Y-axis should
possibly be moved to its initial position before the other axes are being moved.
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If an alternative sequence is used by several monitorings, all monitorings must be

disabled at the beginning of the alternative sequence! Otherwise multiple call-ups of
the alternative sequence may occur, and instructions at the beginning of the alternative
sequence will be processed more than once!
After activating the tab in the command window of the element (vacuum circuit,
gripper or peripheral output) to be monitored, you can select the desired monitoring
command:
Fig.: Window for the vacuum monitoring
Use the list on the left side of the window to select the element to be monitored.
Deactivating a monitoring
Deactivation is done automatically when switching off / opening the respective

element or with the monitoring OFF command.
Press to select the command for deactivation of a monitoring:
Element = M-OFF
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Activating a monitoring
Press to select the command for activation of a monitoring.
Without further options the command to activate a monitoring with the action STOP will
be created:
Element = M-ON STOP
Using the option Alternative the command to activate a monitoring with the action
ALT will be created:
Element = M-ON ALT: label
You can either input a new label or select an existing label.
Using the option Smart (only with vacuum) the monitoring will be activated delayed to
let it become active in the moment before the permit to close the mold is being
switched on. This is especially helpful in connection with the Smart Removal: OUT
command, in order to avoid false triggering during acceleration of the exiting (Y-) axis,
while making sure that the mold will not close in case of a part lost inside it.
Example:
…
Smart Removal: IN Y: 678.9 X: 234.5
Vacuum-01 = ON
WAIT Vacuum-01 = ON
FUNCTION IMM: EJECTORS BACK! WAIT
Vacuum-01 = M-Smart ON STOP
Smart Removal: OUT Y: 0.0 X: 123.4
…
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3.3.6 Counters
3.3.6.1 64 freely usable Counters
The primary use of counters is to program repeat functions or to carry out an event
count. Furthermore counters can be used like variables to save e.g. states and
settings. Counters are also useful to interchange parameters and to do handshakes
between part programs. Incorporating Stopwatches makes timer functions possible.
Fig: Window for counters
64 freely usable counters are available.
After entering the counter menu or after tapping the field Result type use the field
Select result type to select the counter to be modified by the operation.
Use the buttons , and to select one of three common cases:
Counter-xxx = 0
Counter-xxx = Counter-xxx + 1
Counter-xxx = Counter-xxx – 1
This selection also defines the basic format of the command (1 or 2 operands).
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Use the field Operator to select one of the operators + (Addition), - (Subtraction),
* (Multiplication), DIV (Division) or REM (Division Remainder).
After tapping one of the fields Left Operand or Right Operand you can choose the
values to be placed right and left of the operator. Possible are:
Counter ... the value of a counter

Row Counters X/Y/Z ... the value of one of the row counters of a placing program
Part Counter ... the value of the part counter of a placing program
Value ... a number ranging from -2147483648 to 2147483647
Stopwatch ... the result of a time measurement of a Stopwatch in 1/100s of seconds
According to the type of the chosen operator, the suitable field for completion of the
entry will be shown on the right side of the window.
For the operand Stopwatch additionally use the buttons , , , to

select the desired value of the stopwatch.
Use to close the window without changing the teach program.
Example:
Counter-001 = 0
-
START:
...
Removal process
...
Counter-001 = Counter-001 + 1
JMP QUALI Counter-001 = 50
...
Normal placing
...
JMP START
QUALI:
...
Placing for Quality Control
...
Counter-001 = 0
JMP START
Every 50th piece will be placed on a special position for quality control.
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3.3.6.2 Reset / Manipulate Placing Counters
The placing counters are required in the placing program in order to memorize how
many pieces have been already placed for each axis and to approach the next placing
position. Once the placing program is finished (the last piece has been placed), the
associated placing counters for the axes X, Y and Z are reset to zero prior to a new
start of the placing program.
The reading of the number of pieces previously deposited by the respective placing
program is in the part counter. After the placing program has been completed (last
piece has been placed), the value of the part counter remains unchanged until the first
part of the sequence has been placed again.
Placing counters and part counters always change together.
By manipulating the part counter it is possible to let the placing program continue on
any position of the placing sequence.
The teach program function Placingp-XXX RESET can be used to clear the placing
counters and part counter of the placing program XXX at any time.
After opening the counter menu select PlcProgram-PC as the Result type. Now you
can select the placing program to be manipulated by the command in the field Select
result counter.
The command Placingp-XXX RESET will be offered by default. Tap the field
Operand if you want to select another option for manipulating the part counter.
Press to close the window without changing the teach program.
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Example:
SUBR NEW_BOX
Conveyor-01: ON 5.0 s
Placingp-001 RESET
RET
The subroutine NEW_BOX executes a box change, when called. The placing program
is being reset, and will continue with the first part in the new box.
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3.3.7 Program branching
3.3.7.1 Jump
JMP
Basically a teach program is executed command after command, from top to bottom,
starting at program line no. 0001. If the robot has to be able to react on certain events,
a change in this sequence of execution will be required.
Using the JMP (Jump-) command it is possible not to continue with the next program
line, but to jump to a different location somewhere in the program, and to continue the
execution of the program from there on. The JMP command requires a Label as a
target to jump to.
You can either type in the name of a new label after tapping the input field Enter label,
or choose an existing label from the selection field Select label.
If the jump command is not combined with a condition, the jump to the label will be
executed with every execution of the command. This unconditional jump is referred to
as absolute jump.
is used to generate such an absolute jump.
Example:
JMP START
is used to generate a conditional jump, that is only executed when the selected
jump condition is true.
Example:
JMP QUALI CNT01 = 15
The label QUALI is only jumped to, if counter CNT01 equals 15.
is used to confirm all parameters and to add the command to the teach
program.
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3.3.7.2 Label
Label
A label is the target for Jump commands.
Tap the input field Input label to enter the alphanumeric name of the label using the
Text input dialogue. The name can be up to 12 characters long.
Example:
BOX_01:
is used to add the label to the program.
A label with a certain name may only exist once in a teach program, but it can be
targeted by any number of Jump commands.
3.3.7.3 If - Elseif - Else - Endif
jump condition
jump condition
Using the IF - ELSEIF - ELSE - ENDIF commands it is possible to execute or not

execute program parts if jump conditions are true or not true.
You must not exit the program part between IF and ENDIF using a jump command.
There are 3 possible variants.
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3.3.7.3.1 Variant 1:
The instruction IF defines a condition for the execution of an alternative program
sequence. This sequence is programmed in the program lines after the instruction IF.
The END IF instruction is programmed at the end of the alternative sequence.
If the jump condition is false, the instructions between IF and END IF will not be carried
out. The program routine will be continued with the first instruction after END IF.
If the jump condition is true, first the instructions between IF and END IF will be carried
out. Only then will the program routine be continued after END IF.
Example:
3.3.7.3.2 Variant 2:
The instruction IF is used to specify a condition for the execution of two alternative
program sequences.
Sequence 1 is to be executed only when the condition is true. Sequence 2 is to be

executed only when the condition is false.
Sequence 1 is programmed in the program lines after the instruction IF. Then the
instruction ELSE and, following that, sequence 2 is programmed. At the end of
sequence 2, the instruction END IF is programmed.
If the jump condition is false, the instructions between IF and ELSE will not be carried
out, and the program routine will be continued with the first instruction after ELSE (=
sequence 2).
If the jump condition is true, first the instructions between IF and ELSE will be carried
out (= sequence 1), and then the program routine after END IF will be continued.
Example:
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3.3.7.3.3 Variant 3:
The commands IF and ELSEIF are used to define conditions for the execution of
various program routines; where only one of them has to be executed at a time.
In automatic mode the conditions of the IF command and of the ELSEIF commands are
checked one after the other, following their sequence in the program. The program
routine attached to the first true condition will be executed, after that the execution of
the program will continue behind the ENDIF.
The optional ELSE command is used to define a routine, which will only be executed if
none of the conditions of the IF and ELSEIF commands had been true.
This variant may especially be helpful creating sequencers, where in dependence of

the value of a counter a different step of a sequence has to be executed.
Example:
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3.3.7.4 Call - Subr – Ret
Subroutine Name
Return
Using CALL-SUBR-RET commands it is possible to structure a Teach program with

subroutines, and to call these subroutines conditional (based on the jump conditions) or
unconditional.
Subroutine callups permit branching into a sequence of instructions. After their

execution, the process will jump back to an instruction located directly after the related
callup. In this way, program sections that are needed more often have to be
programmed only once.
When programming subroutines, the following rules have to be kept in mind in order to
ensure proper execution:
• Subroutines must always be terminated with the instruction RET.

• A subroutine must not be exited with the instruction JUMP.
• A subroutine routine must never be processed without callup with the instruction
CALL.
Instruction CALL
The instruction CALL Name is used to call up the subroutine Name. Execution of the
program will be continued at the subroutine.
Instruction SUBROUTINE
The instruction SUBR Name is used to define the start of a subroutine.
Instruction RETURN
RET is used to terminate a subroutine and to return to the main program. Return is
made to the line after the CALL instruction by which the subroutine was called up.
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Example
CALL INIT
START:
CALL REMOVAL
CALL PLACE
JMP START
SUBR INIT
...
RET
SUBR REMOVAL
...
RET
SUBR PLACE
...
RET
This example shows the possibility for structured programming. The first 5 lines form
the main routine, that simply calls the subroutines one after the other, using a
sequence of CALL-commands. The subroutine INIT is only called once when the
program is started, during the further cycles only the subroutines REMOVAL and
PLACE are executed. By using conditional CALL commands, routines for events like
reject part or quality control can be added to the program easily. The advantage of this
programming method is the short main routine, which gives a quick overview of the
general sequence and the functions of the program. The details of the functions are
programmed in the subroutines.
Subroutines can call other subroutines, i.e. they can be nested. Maximum nesting level
is 160.
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3.3.7.5 And
Jump Condition
The AND and OR functions allow to execute IF, JMP, CALL and WAIT commands on
the basis of several jump conditions.
First, program the IF or JMP command with the first jump condition. Then, using the
AND/OR function, program the other jump conditions in the following program lines.
Example:
JMP Label Counter-001 = 1
AND Counter-002 = 1
The Jump is only executed when both counters Counter-001 and Counter-002 have the
value 1.
AND and OR instructions must be programmed in the line(s) directly after the
instruction to which they refer. Otherwise logical operation will not take place.
3.3.7.6 Or
Jump condition
The AND and OR functions allow to execute IF, JMP, CALL and WAIT commands on
the basis of several jump conditions.
First, program the IF or JMP command with the first jump condition. Then, using the
AND/OR function, program the other jump conditions in the following program lines.
Example:
JMP Label Counter-001 = 1
OR Counter-002 = 1
The Jump is executed when at least one of the counters Counter-001 or Counter-002
has the value 1.
AND and OR instructions must be programmed in the line(s) directly after the
instruction to which they refer. Otherwise logical operation will not take place.
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3.3.7.7 End
End
Every program should be terminated with the instruction END, in order to avoid
unintended processing of additional subroutines.
The robot program and the all modes program will continue their automatic processing
at program line 0001 after processing the END command.
Reference programs, the peripheral program, the additional part programs and also the
EOAT Change program will terminate at the END command.
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3.3.7.8 Jump Conditions

Using jump conditions the commands JMP, IF, CALL, WAIT, OR and AND can make
the robot react on internal and external events.
After calling up the above mentioned commands, the following tabs are available to
access the desired event:
• Counter
• Placing Program
• PI
• IMM
• Vacuum
• AutoSwitch
• Misc part program, area, position, mode, stacking sensor, start, production end active
• Input
• Output
3.3.7.8.1 Jump condition: Counter

The branch is executed dependant on the result of a comparison. The operands for the
comparison can be counters, placing counters, part counters and constant values.
After selecting the event, the desired operands for the left and the right side of the
comparison are picked from the respective lists.
If counters are chosen, a window to select one of the 64 counters is shown.
If pacing counters or part counters are chosen, a window with the available placing
programs is shown.
If value is chosen as an operand, it can be input after tapping the Input value field,
using the dialogue for numerical input.
Additionally, one of the operators <=, >=, <, >, <>, = must be chosen. This is to define
how the numerical value of the left operand must relate to the numerical value of the
right operand in order to trigger the branch.
Example:
IF PLCPRG01-PC = 12
CONVEYOR_01 ON 5.0 S
ENDIF
...
The conveyor is switched on if 12 parts have been placed by the placing program.
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3.3.7.8.2 Jump Condition: Placing Program

The branch will be triggered by events of placing programs.
After selecting the condition, the desired placing program and one out of three events
can be chosen.
Stack ready
The stack is completed. All row counters are zero, the next piece will be the first of the
placing sequence again. This can be used to index the conveyor.
Layer ready
A layer is completed. The row counters of the first two axes of the placing sequence
are zero, the next piece will be the first of the next layer. This can be used to trigger
intermediate layers.
Row ready
A row is completed. The row counter of the first axis of the placing sequence is zero;
the next piece will be the first of the next row.
Example:
…
IF Placingp-001 ZXY STACK READY
Conveyor-01: ON 5.0 S
ENDIF
…
The conveyor is switched on every time a complete stack has been placed by the
placing program.
3.3.7.8.3 Jump Condition: PI-Peripheral Input

The branch will be executed if a selectable signal of the peripherals is ON or OFF.
After selecting the event, a list with the available signals is displayed. Select the
desired signal by tapping it.
and are used to specify if the branch has to be executed when the signal is
ON or OFF.
With a at Latch the latch function is activated. At the displayed command an

exclamation mark is added after the peripheral input:
JMP LABEL PIxxx! = ON
With this function activated, the control also triggers on very short ON-impulses of the
input, and memorizes them until the next request occurs in the respective part
program.
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3.3.7.8.4 Jump Condition: IMM - Injection Molding Machine

The branch will be executed dependent on one of the signals of the IMM.
and are used to determine if the branch has to be executed when the signal
is ON or OFF.
When a signal of the IMM interface is ON, the condition described by the signal is true.
The condition MOLD WAS CLOSED = ON indicates if the mold has been closed since
the last takeout cycle. You can override the automated latch for this condition using its
logical teach command.
The condition WAS REJECT-PART = ON indicates if the reject part signal of the
machine had been set for the last part taken out. When dealing with rejects, you should
prefer checking this latch instead of checking the signal directly, because the reject part
signal may be invalid after switching on the permission to close the mold. The latch will
be set during the execution of the command for switching on the permit Mold Close,
and will be reset next time when entering the mold or at the start of the reference
travel.
The condition OP. WITH IMM = ON represents the result of a logical AND operation
with the signals Operation with Robot and Automatic. Both signals must be ON in
order for the condition to be TRUE. If the condition is used in a WAIT command, the
robot will go to operating mode Wait IMM while waiting for the condition to be fulfilled.
When waiting for the mold to open, both signals should be tested. This will detect a
possible failure of the interface, thus avoiding crashing the mold. Additionally, waiting
for Mold was closed inhibits the robot from entering the mold, if no part has been
produced since the last cycle. The first Wait command should wait for the Mold is
open signal in order for the waiting time detection of the speed calculation of the ECO-
Mode to work correctly.
Example:
WAIT IMM: MOLD OPEN = ON
AND IMM: MOLD CLOSED = OFF
AND IMM: MOLD WAS CLOSED = ON
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3.3.7.8.5 Jump Condition: Vacuum

The branch will be executed depending on the feedback of the vacuum pressure
monitoring of one of the vacuum circuits. The state of a vacuum pressure monitor is
ON, when all parts of all suction cups of the respective vacuum circuit are completely
sucked on. Use the Setup menu Vacuum Pressure to set the trigger values of the
vacuum pressure monitors for the current Teachprogram.
This serves to ensure, upon pickup of a piece, that the piece is really held tightly on the
cup before further motions are carried out.
After selecting the event, a list with the available vacuum circuits is displayed. Select
the desired vacuum circuit by tapping it.
and are used to specify if the branch has to be executed when the state of
the vacuum pressure monitor is ON or OFF.
3.3.7.8.6 Jump Condition: AutoSwitch

The branch will be executed depending on the selectable ON / OFF state of an
AutoSwitch.
After selecting the event, a list with the 32 AutoSwitches is displayed. Select the
desired AutoSwitch by tapping it.
and are used to specify if the branch has to be executed whether the
AutoSwitch is ON or OFF.
When AutoSwitches are configured as keys, in many cases the use of the latch
function may prove as useful. With the latch function activated, the control unit will
trigger on even very short ON impulses, memorizing them until the next request occurs
in the respective part program.
The latch function is activated with a at the option latch. At the displayed command
an exclamation mark is added after the AutoSwitch:
3.3.7.8.7 Jump Condition: Part program

The branch will be executed if a peripheral program is running or ready.
After selecting the event, a list with the available peripheral programs is displayed.
Select the desired program by tapping it.
and are used to specify if the branch has to be executed when the program
is running or not.
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3.3.7.8.8 Jump Condition: Area

The branch will be executed dependant on the roller switch S6 of the Z-axis. The jump
conditions Mold Area and Placing Area are used to execute different reference travels
and alternative routines.
Mold Area
The roller switch of the Z-axis(S6) is not actuated. The robot is above or inside the
IMM.
Placing Area
The roller switch of the Z-axis(S6) is actuated. The robot is outside the IMM.
3.3.7.8.9 Jump condition: Position

The branch will be executed in accordance with the actual position of one of the robot
axes.
After selecting the event, the desired axis is picked from the list with of available axes.
It is now possible to move the chosen axes to the desired target position by using the
drive buttons on the right side of the window.
At last, you have to select one of the operators <=, >=, <, >, <>, = to define how the
actual position of the axis has to relate to the target position given within the command
for triggering the branch.
Example:
JMP INPERI Z >= 1000.0
AND Z =< 1500.0
AND Y > 350.0
...
Could be part of a reference program. It only jumps to the label INPERI if the Z-axis is
positioned within the range from 1000 to 1500 mm, and at the same time the Y-arm
holds a position bigger than 350 mm.
The operator = should possibly not be used together with numerical axes.
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3.3.7.8.10 Jump Condition: Mode
The jump condition Mode is available in an All Modes Program only.
The branch is executed dependent on the mode of operation of the robot.
After selecting the event, the desired mode of operation is chosen from the list Select
mode.
Then select one of the operators <=, >=, <, >, <>, = to define how the attached value of
the actual has to relate to the mode of operation given within the command in order to
trigger the branch.
The attached values of the different modes of operation are:
0 ... Reference missing
1 ... Manual
2 ... Reference
3 ... Blockstop
4 ... Automatic
Use IN BLOCK STOP DRIVE to check if the robot finishes the current block after a
block stop request. The effective mode during this is Automatic still.
Use IN REFERENCE DRIVE to check if the robot is currently executing one of the
reference travels in operating mode Manual. This mode has an attached value of 1,5.
The reference travel in the operating mode Reference Missing will be ignored.
Example:
IF MODE < BLOCK STOP
...
ENDIF
The program part between IF and ENDIF will only be executed during operation modes
Reference missing, Manual, Reference and during the reference travels.
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3.3.7.8.11 Jump Condition: Stacking sensor

The branch will be executed if the signal of one of the up to 8 stacking sensors is ON or
OFF.
After selecting the event, a list with the available stacking sensors is displayed. Select
the desired stacking sensors by tapping it.
and are used to specify if the branch has to be executed when the stacking
sensor is actuated or not.
3.3.7.8.12 Jump Condition: Start
The branch is executed when the automatic start button is pressed.
3.3.7.8.13 Jump Condition: Production End Active

The branch will be executed, if earlier during automatic mode, with the Production End
function activated, the command for closing the mold has been processed (without
actually closing the mold).
3.3.7.8.14 Jump Condition: Input

The branch will be executed if a selectable input signal of the robot is ON or OFF.
For keys on the right side of the window help you to access certain groups of input
signals:
signals of the injection molding machine
signals of the peripheral inputs
signals of the grippers
signals of the vacuums
ON or OFF.
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3.3.7.8.15 Jump Condition: Output

The branch will be executed if a selectable output signal of the robot is ON or OFF.
For keys on the right side of the window help you to access certain groups of output
signals:
signals of the injection molding machine
signals of the peripheral outputs
signals of the grippers
signals of the vacuums
ON or OFF.
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3.3.7.9 Start/Stop Part Program
The commands START part program and STOP part program are used to start or stop
the peripheral program, all modes program or one of the 115 additional part programs
from another part program.
Fig.: Window for the Start/Stop part program commands
First pick the desired part program from the selection list Select part program.
Then use or to determine whether the command shall start or stop the
selected part program.
is used to discard the entries and to close the window.
Example:
START PERI. PRG.
Starts the peripheral program
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3.3.8 Wait functions
3.3.8.1 Wait
jump condition
The WAIT command is used to halt the execution of the program until the event
defined by the jump condition occurs.
3.3.8.2 Wait Timer
Timer
The command WAIT TIMER is used to link waiting for events with a time (limit).
First the time is set with the command WAIT TIMER, then the other jump conditions are
added using OR and AND commands.
After opening the menu and tapping the input field Time the desired value for the time
can be entered using the dialogue for numerical input.
Example:
WAIT TIMER = 3.00 s

OR Vacuum-01 = ON
This waits for a part to be sucked on. If the set underpressure is not achieved within the
time limit of 3 seconds, the wait command terminates, and the execution of the
program is continued without the part. Afterwards a service routine for that case could
easily be triggered using a command like JMP label Vacuum-01 = OFF.
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3.3.8.3 Time
delay time
If a certain delay in the sequence is required, this can be achieved by means of the
time function. The time function can be used to program time delays from 0.00 to
9999.99 seconds.
After calling up the function, the desired delay time can either be adjusted using the
slider, or after tapping the field input time the desired time can be input using the
dialogue for numerical input.
In the automatic mode, processing of a program will be halted at a time function until
the time has elapsed. Only then will the next instruction be started.
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3.3.9 More Commands
3.3.9.1 More
This key opens a window with some additional teach commands.
Those commands are:
• Remark (REM)
• Production end
• Block stop
• Stopwatch
• Operating Mode
• ECO Mode
• Area Switch
3.3.9.2 Remark (REM)
Remark
In order to facilitate future editing, every program should be provided with a sufficient
number of remarks. Remarks are shown in the teach program preceded by "REM":
0045 REM THIS IS A REMARK
After calling up the function and tapping the input field "Enter remark" use the dialogue
for text input to enter the desired text.
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3.3.9.3 Production End
Production End
This instruction is used for selective stopping of automatic operation at the end of
production, without a part remaining inside the mold or on the EOAT.
Activate this function in automatic operation by actuating the (REFERENCE) key.

The control lamp of the key will begin to flash in confirmation of this function.
The exact sequence is like this:
Automatic operation
During normal automatic operation the command PRODUCTION END is being
ignored, the jump condition Production End Active will be FALSE.
The button REFERENCE is being actuated during automatic operation

The LED of the button REFERENCE starts flashing. By pressing the button
AUTOMATIC the production end function could be aborted. The jump condition
Production End Active continues to be FALSE. The robot remains in normal automatic
operation until the mold is not closed and the command for closing the mold is being
executed.
At the command that switches on the permit MOLD CLOSE

The permission signal MOLD CLOSE is not being switched on, the mold stays open.
The jump condition Production End Active will be TRUE from here on. Production end
can no longer be aborted.
After the command that switches on the permit MOLD CLOSE

Commands waiting on the mold not-being-open will be ignored, in order to be able to
deposit the last piece. The jump condition Production End Active can be used for
triggering a special sequence (e.g. moving to the reference position) during production
end.
At the command PRODUCTION END

The robot switches to the operating mode given by the command. Production end
becomes inactive again, from now on all mold signals will be observed again.
After the command PRODUCTION END

When automatic operation is continued or restarted, the state of the function
Production End will be normal automatic operation as described above.
Use , and to select the operating mode to be triggered by the

command.
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3.3.9.4 Blockstop lock/unlock
Blockstop
Normally, if you press the block stop key in automatic operation the currently
processed instruction (axis motion) will be completed and the robot will be halted and
shifted into the block stop mode. The LED of the key will flash during this process.
The instruction LOCK BLOCK STOP allows a block stop to be carried out only after the
UNLOCK BLOCK STOP instruction has been reached and all instructions found before
it in the routine have been processed.
Thus an entire motion sequence (e.g., travel out of the mold area) can be completed
with a block stop.
After calling up the function, use the keys (lock) and (unlock) to select the
desired command.
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3.3.9.5 Stopwatch
The Stopwatch function allows measurement of times that go by during the processing
of arbitrary parts of a teach program. Four such software timers with a resolution of
0,01 seconds are available.
After calling up the function, first the select the desired stopwatch, then use the keys on
the right side of the window to select the desired command.
Stopwatch-xx START
Starts the selected stopwatch. The current value of the stopwatch is incremented ins
steps of 0,1 seconds starting from zero while processing the program.
Stopwatch-xx STOP
Stops the selected stopwatch. The measured value is used to recalculate the minimum,
average and maximum values for the Info menu Stopwatch.
Stopwatch-xx RESET
Resets the calculation of the minimum, average and maximum values of the selected
stopwatch.
The actual measured value can be loaded to a Counter for further processing, even
while the stopwatch is running. 1 in the counter will represent 0,01 seconds.
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Example:
-
Vacuum-01 = ON
Enter the IMM, use the ejectors to push the part to the vacuum suction cap(s)
-
Stopwatch-01 START
-
WAIT_VAC:
Counter-001 = Stopwatch-01 CURRENT
JMP TIMEOUT_VAC Counter-001 > 500
JMP WAIT_VAC Vacuum-01 = OFF
-
Standard sequence with part on the EOAT
-
JMP ...
TIMEOUT_VAC:
Alternative sequence if the vacuum switch does not detect a part on the suction caps within timeout
-
JMP ...
Instead of WAIT VACUUM here a jump back to WAIT_VAC occurs until either the part
is sucked on, or the time set for timeout is over. If the part is sucked on within time
(here 5 seconds), the standard sequence is continued. During each run in the
jumpback loop, the actual value of the stopwatch is loaded to Counter-001. If the value
is bigger than 500 hundreds of a second, the program will jump to the alternative
routine after the label TIMEOUT_VAC.
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3.3.9.6 Operating Mode
Operating Mode
The commands OPERATING MODE BLOCK STOP and OPERATING MODE MANUAL
can be used to interrupt the automatic execution of the teach program, and to switch
from operating mode Automatic to operating modes Block Stop or

Manual. This is useful to stop the robot, especially if the teach program is able to
detect error conditions.
The command OPERATING MODE PRODUCTION END requests Production End. This
is the equivalent of pressing the button during automatic operation.
The command OPERATING MODE REFERENCE can be used in the Robot Reference
Teach program ROBOT-REF to switch the operation mode from Manual to

Reference. This opens the possibility to start automatic execution of the Teach
program at any desired position within the working range of the robot.
When the operating mode is set to Reference by the command OPERATING

MODE REFERENCE, no verification of any kind is performed about axes
positions or vacuum and gripper states. Also the standard reference travel will
not be executed. This implies that if the command OPERATING MODE
REFERENCE is used, any mistake in the Reference Teach program will almost
certainly lead to collisions and damage during automatic operation.
After selecting the function use , or to choose the desired command.
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3.3.9.7 Eco Mode
Eco Mode
The command ECOMODE is used to control the ECO-Mode from within the Teach
program.
Press to select the command ECOMODE ON. The command ECOMODE ON

turns the ECO-Mode on. Thus, there is no need then for the operator to manually turn
on the ECO-Mode with a at the option ECO-Mode in the window Override.
Press to select the command ECOMODE BUFFER-TIME. This command sets the
ECO-Mode buffer time. Thus, there is no need then for the operator to manually set the
ECO-Mode buffer time in the window Override each time when changing programs with
different requirements for that time. After tapping the input field ECO-Buffer (s) you
can input the desired buffer time with the dialogue for numerical input.
Press to select the command ECOMODE INACTIVE. The command ECOMODE

INACTIVE sets the ECO-Mode inactive for the current cycle, the ECO-Mode returns to
active state automatically with the next cycle. This is used to execute special motions
(that take significantly longer or shorter than the standard motion, e.g. reject part
sequence) without ECO-Mode. For this cycle the robot will use the settings done with
VMAX, VABS, AABS and the Override.
Press to select the command ECOMODE RESET. The command ECOMODE

RESET resets the calculations of the ECO-Mode. The robot will use the settings done
with VMAX, VABS, AABS and the Override until it will have determined new values,
and will be able to reduce acceleration and speed again.
See also: 3.3.9.7 ECO-Mode
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3.3.9.8 Area Switch
This command is only available on robots with absolute encoders.
You can use the command Area Switch to set the switching points of the virtual mold
interlock switches S5 and S6 according to the needs of the respective teach program.
This should be done in the first lines of the robot reference teach program Robot Ref.,
in order for the conditions Mold Area and Placing Area to work correctly, when
executing the teach programmed reference travel for the first time.
The new position values for the mold interlock switches will not be set before executing
the area switch commands. While moving manually before executing the teach
programmed reference travel, values may be active, that keep the mold monitoring
from working correctly.
The area switch commands will set the position values for the mold interlock switches
permanently. For the settings to be correct at all times, the commands – once they are
used - have to be used in all Teachprograms of the robot.
Fig.: Window for the Area Switch command
Use the selection field in the upper left corner of the window to select which switch you
want to set with the command.
After tapping a field Switching Point on the right side of the window, you can set the
selected switching point by either travelling there with the connected axes, or by
inputting it numerically.
Use the options on the left bottom of the window to select the state of the switch on the
0 Position of the connected axis. Mold Area means off; Placing Area means on.
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3.3.10 AutoSwitches
AutoSwitches are virtual switches and keys, that are displayed on the main screen of
the Teachbox, when they are used in the Teach program. They serve as a replacement
for real switches, which would have to be connected using peripheral inputs in order to
use them in a Teach program. The AutoSwitches can be accessed directly by means of
their jump condition.
Fig.: Main screen with AutoSwitches
Up to 32 AutoSwitches are possible in one Teach program. If all the AutoSwitches

used cannot be displayed in one line, a scroll bar for shifting to the desired line is
shown.
The button in the bottom right corner is used to select whether the AutoSwitches
are displayed or not.
Settings in the Setup Menu
The basic settings for the AutoSwitches are made using the Setup menu AutoSwitch
Definition.
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3.3.10.1 The Teach command AutoSwitch
The Teach command AutoSwitch is used to switch on or off an AutoSwitch that is

configured as a switch from within a Teach program.
After calling the function and selecting the desired AutoSwitch, the buttons and
are used to define if the AutoSwitch shall be switched on or off.
discards the entries.
adds the command to the Teach program.
See also:
3.2.6.5 Setup Menu: AutoSwitch Definition
3.3.7.8.6 Jump condition AutoSwitch
0 View Menu: AutoSwitch
Example: Part for quality control
The Autosw-01 has been renamed to CHECKPART and has been configured as key.
...
START: cycle start (label START)
...
Removal from IMM
...
JMP CONTROL CHECKPART!=ON Branch to the label CONTROL, if the key CHECKPART has
been pressed previously (latch!)
...
Placement, etc.
...
JMP START Jump to the cycle start
-
CONTROL: Label CONTROL
...
Deliver the part to the control station
...
JMP START Jump to the cycle start
-
After the key CHECKPART has been pressed shortly, the next part is delivered to the
quality control station.
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Example: start-up-parts
The Autosw-01 has been renamed to STARTUP, and has been configured as switch.
...
STARTUP=ON Switch on the switch STARTUP
...
STARTUPCYCLE: Start of the startup cycle - IMM "without" robot
PERMIT IMM:MOLD CLOSE! = ON
WAIT IMM:MOLD CLOSED = ON
JMP START STARTUP=OFF If the switch STARTUP is off, and the mold is closed, branch to
the start of the normal cycle
WAIT IMM:MOLD OPEN = ON
FUNCTION IMM:EJECTORS FORWARD! WAIT
FUNCTION IMM:EJECTORS BACK! WAIT
JMP STARTUPCYCLE Jump to the start of the startup cycle
-
START: Start of the "normal" cycle (label START)
...
Robot moves over the IMM, waits for the mold to open, etc. ...
...
The robot and the IMM are started together. The robot automatically switches on the
AutoSwitch STARTUP at the beginning of the program. The sequence between the
label STARTUPCYCLE and JMP STARTUPCYCLE toggled the permits for the IMM in
a way to let the machine produce parts "without" the robots (and let them fall down).
When the switch STARTUP has been switched off, the normal production cycle at the
label START will be executed after closing the mold.
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3.3.11 User Defined Error Messages
3.3.11.1 Introduction
At the R8.3 control you can use the teach command Alarm to emit your own error
messages.
Prerequisite is that a message table UserErr.txt is stored in the robot. Without this file,
the teach command Alarm will not be offered by the Teachbox.
3.3.11.2 Creating and Storing the File UserErr.txt

The file Usererr.txt is a Unicode text file. The columns of the contained table are
separated by tab stops. Use spreadsheet software like Microsoft Excel to create it, and
save it as Unicode text.
Use ISO 639-2 language codes to define messages in up to 40 languages. The file
must contain at least 3 columns (i.e. at least 1 language).
Fig.: Example for a UserErr.txt with 2 messages in 2 languages
In row 1 you define the columns for the different languages.
In column A you define error group 126 of the error number 126-XXX-YYY.
In column B define the unique error XXX inside of group 126. XXX can be any number
from 0 to 255.
Write the message texts for the different languages into the other columns.
If a language is set on the Teachbox which is not available in the table, the texts from
the first defined column will be displayed. In the example shown above this would be
English from the column ENG.
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The supplemental number YYY will be set by the teach command Alarm. You can
display the contained information in the message texts using escape sequences:
\U … 3-digit number with leading zeros. It shows the number YYY+1.

\N … 3-digit number with leading zeros. It shows the number YYY.
\I … 3-digit number no leading zeros. It shows the number YYY.
\i … 3-digit number no leading zeros. It shows the number YYY. 0 displays nothing.
\J … 3-digit number no leading zeros. It shows the number YYY. 0 displays nothing.
If this results in two spaces in a row, only one will be shown.
\A … axis designation: 0=X, 1=Y, 2=Z, 3=A, 4=B, 5=C, 6=X2, 7=Y2, 8=Z2, 9=A2,
10=B2, 11=C2
\V … vacuum name (current name of vacuum YYY+1)
\G … gripper name (current name of gripper YYY+1)
\O … peripheral output name (current name of peripheral output YYY+1)
\Y … cylinder name (current name of cylinder YYY+1)
\C … conveyor name (current name of conveyor YYY+1)
\S … stacking sensor name (current name of stacking sensor YYY+1)
\R … safety area, 3 digits, YYY+1.
\E … peripheral input name (current name of peripheral input YYY+1)
\Z … counter name (current name of counter YYY+1)
\M … IMM Name (current name of IMM YYY+1)
\K … Autoswitch Name (current name of Autoswitch YYY+1)
\W … stopwatch name (current name of stopwatch YYY+1)
\P … placing program name (current name of placing program YYY+1)
\p or \T … part program name
\H ... mode of operation: 0=Reference missing, 1=Manual, 2=Reference, 3=Block stop,
4=Automatic
If you actually want to show a „\“ in your text, you’ll have to write „\\“ instead.
Store the finished table as a Unicode text file with the name UserErr.txt into the folder
..\robot\tablo\language on the system USB stick of the robots and use this to boot
the robot. The file UserErr.txt will automatically be stored in the robot during the boot
process.
Once the file has been stored on the robot, the included error messages will be
available for all teach programs on that robot.
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3.3.11.3 The Teach Command ALARM
Alarm
Using the teach command Alarm you can emit your own error messages.
Prerequisite is that a message table UserErr.txt is stored in the robot. Without this file,
the teach command Alarm will not be offered by the Teachbox.
Fig.: Window for the teach command ALARM
After selecting the command, you select the desired message in the selection field
Number.
Use the field Info to input the desired supplemental number. If the supplemental
number is used in the message text, you can see the result already in the command
display at the top of the window.
With the buttons , and you define to which mode of operation the robot
shall switch when the error message is triggered.
With the button you define that the mode of operation of the robot will not change,
when the error message is triggered.
With the options for State you select whether the error shall be displayed as active
(red) or inactive (gray):
Off (inactive) results in the error being shown in the state inactive permanently, or that
an active error changes its state to inactive.
On (active) results in the error being shown in the state active permanently.
Momentary results in the error being shown in the state active for some seconds, and
then changing to the state inactive automatically.

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3.4 Quick Editor
3.4.1 Introduction
The Quick Edit gives the possibility to display (even complex) Teach programs in a way
that makes it easy to do simple program changes and adaptations.
Therefore only those parameters are displayed, which have been released for possible
editing in the Teach Program.
3.4.2 Operation of the Quick Edit
3.4.2.1 Entering the Quick Edit
Use the button on the main screen to enter the Quick Edit.
This is not only possible in Manual and Reference modes, but also when the robot is
working in Automatic mode. In Automatic mode the same limitations as in the Text
Editor apply; meaning that positions of numerical axes can only be changed within
+/- 10mm.
3.4.2.2 Display and Editing Functions

The Quick Editor always shows the Teach program currently loaded in the robot.
Use Buttons on the right side of the screen select what types of parameters to display:
displays percentage parameters only (speed, acceleration, vacuum level).
displays time parameters only.
displays absolute speed parameters only.
displays position parameters only.
displays counter value parameters only.
displays placing program parameters only.
displays distance parameters only
displays all parameters.
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The parameters out of the Teach program are displayed in numbered fields:
Fig.: Fields in the Quick Edit
The upper part of a field contains explanations of what the displayed parameter is used
for in the program sequence. The quality of those explanations strongly depends on the
skills of the creator of the respective Teach program.
The lower part of a field displays the parameter with its name and its changeable
values. Tap the respective display field to open a pop up that you can use to edit the
respective value.
Abb.: Pop-Up in the Quick Edit to change a Position
Changes will be transferred to the Teach program in the robot immediately
If the alterations are intended to be permanent ones, the Teach program has to be
stored to a storage medium using the functions of the File menu.
3.4.2.3 Exit the Quick Edit
Use the button or the option Exit to Main of the File menu to exit the Quick Edit.
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3.4.3 FILE Menu of the Quick Edit
3.4.3.1 Open
This function is used in the Quick Edit to load a teach program from a storage medium
to the robot.
Fig.: Window to open a file in the Tooling Editor
for a sub-folder
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short file names.
is used to load the selected program to the robot.
The program stored in the robot will be irretrievably deleted by loading another teach
program.
Every newly loaded teach program must be run through at least once in step mode
before automatic operation.
The file name of a teach program is not necessarily the same as the teach program
name.
3.4.3.2 Open Template

Use this function to open Teachprogram Templates. Templates are programs prepared
for certain standard applications in a way that you only need to parameterize them in
the Quick Edit.
Teachprogram Templates are stored in a Read-Only location, where you can only load
them from, but not overwrite. The Teachprogram you create from the template, you can
store to any location available for storing Teachprograms using the function Save As.
The rest of the functionality of the menu Open Template is the similar to the menu
Open.
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3.4.3.3 Save (NAME.ZIP)

This function is used to save the teach program from the Teachbox a storage medium
as a *.ZIP file. Both name and path of the file will be the ones used before. The name
of the target file is shown in brackets right next to the menu entry Save. If no name is
displayed, Save will call the function Save as instead.
The previous version of the program stored on the storage medium with the same
name will be deleted irretrievably.
3.4.3.4 Save As
medium as a *.ZIP file. Path and name of the file are selectable.
Fig.: Window to save a teach program
for a sub-folder
filename as desired. The extension will always be ZIP. By tapping it in the display of
the current folder, you can also use the name of an existing file.
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is used to create a new folder.
short file names.
is used to save the teach program to the current folder, applying the name
from the field Filename.
Before storing is executed, a check is made to see whether a program of the same
name is already stored in the selected folder, and a checkback message may appear.
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3.4.3.5 Properties
Here the properties of the teach program in the robot are displayed. That is the
program which is executed when the robot is in automatic operation.
Fig.: Window for properties of the CPU program

Shows the name of the teach program of the robot. This name is not necessarily the
same as the file name of the program. After tapping the input field, the name can be
edited using the dialogue for text input.
Displays whether the teach programs of the robot (CPU) and the Teachbox are equal
or unequal.
Tooldata
Displays the Tooldata text of the teach program of the robot. The text for Tooldata can
Size
Displays the size of the teach program of the robot. The maximum size of a teach
Shows the number of part programs of the teach program of the robot: ROBOT-PRG,
programs.
Shows the number of placing programs used in the teach program of the robot. The
can be used to email the Teach program as an email attachment (*.wip, *.htm and
*.txt file) using the manual email function of the robot.
Use to discard the entries and to close the window.
Use to confirm the entries and to close the window.

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3.4.3.6 Print
This function is used to print the teach program loaded in the Teachbox to either a
UNICODE-textfile *.TXT or an HTML-file *.HTM on the USB stick. Path and name of
the file are selectable. The default folder is D:\ROBOT\PRINT. The generated file can
be opened, displayed and printed with a PC.
Fig.: Window to print a teach program to a file
The button right next to the field for the filename is used to select the type of file for
printing:
activates printing to a textfile
activates printing to an HTML-file
The field Save in displays the path of the current folder.
for a sub-folder
for a textfile *.TXT
for an HTML-file *.HTM
Only files of the same type as selected for the printout will be displayed.
filename as desired. By tapping it in the display of the current folder, you can also use
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short file names.
is used to save the printout to the current folder, applying the name from the
field Filename.
Before storing is executed, a check is made to see whether a file of the same name is
already stored in the selected folder, and a checkback message may appear.
3.4.3.7 Exit to Main
Use the button or the option Exit to Main of the File menu to exit the Quick Edit.
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3.4.4 Parameters for the Quick Edit

In order to display values out of a Teachprogram in the Quick Edit, you will have to
create parameters for those values and apply them in the Teachprogram.
3.4.4.1 Create Parameters

You can create parameters in the Text Editor using the function Quick Edit Definition
of the Setup menu.
Fig.: Quick Edit Definition
Use the buttons on the left side of the screen to create parameters:
creates a percentage parameter for speed, acceleration and vacuum pressure.
creates a time parameter.
creates an absolute speed parameter.
creates a position parameter.
creates a counter value parameter.
creates a placing program parameter.
creates a distance parameter for commands with relative position values.
creates a parameter for predefined positions.
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Press to open the dialogue for changing the name of the parameter.
Press to open the dialogue for inputting an explanation text for the parameter.
Press to open the dialogue for managing axes values for axes related
parameters. Here, press to add an axis value to the parameter. You can remove
axes values marked with a from the parameter with .
Press to open the dialogue for determining the initial values, minimum and
maximum values for the parameter.
Press to open the dialogue for activating one or more display filters for the
parameter. The filter for the parameter type of the parameter is activated by default.
Press to open the dialogue for adding a picture or an animation to the parameter.
For pictures use PNG files. For animations MNG files are supported. The
recommended size is 150 x 175 pixels. Press to remove pictures and animations
from the parameter.
If several parameters are present, you can use the buttons and to move
the blue active one up and down in the sequence of parameters.
Press to exit Quick Edit Definitions.
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3.4.4.2 Apply Parameters

Previously created parameters can be applied to teach commands in the text editor.
For this display the parameter toolbar with Show Parameter Toolbar in the Edit menu
first.
When you select a teach command now, for which a parameter is available, you can
use to open the dialogue for applying parameters.
Fig.: Applying a parameter
Tap the parameter you want to apply to the teach command.
You can use to remove the parameter from the selected teach command.
You can use to remove all parameters from the selected teach command.
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4 How to Teach a Program
Before teaching the robot a program for the first time, please read the safety
instructions and the operating manual completely.
Familiarity with the operating functions of the R8.3 control is essential for creating a
teach program.
4.1 Using the Quick New Wizard and the Quick Edit
Using the Quick New Wizard and the Quick Edit you can create simple pick and place
programs. No programming skills are necessary.
First the Quick New Wizard will ask you some questions about the requirements for the
program to be created. From your answers the wizard will then create the desired
program and open it in the Quick Edit. Finally you will use the Quick Edit to input the
required values for positions, times and speeds.
Proceed as follows:
1) Press to start the Quick New Wizard.
2) In the first step you define if you want to takeout the parts using vacuum suction
caps or grippers. Gripper-01 is reserved for the sprue, but can be used for parts
nevertheless, if you do not take out sprue. Decide if you want to take out sprue
using Gripper-01, and if you want to place the sprue before or after placing the
parts.
Press to enter the next step of the wizard.
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3) Define the number of placing positions per cycle that the robot has to travel to.
Additionally define which vacuum / gripper circuits shall be used to carry the parts
to the different placing positions.
4) Decide if rejects shall be placed separately. This functionality uses the reject part
signal of the injection molding machine. Activating this option additionally gives
you the possibility to separate an adjustable number of parts as startup rejects.
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5) Decide for the possibility of using a button on the screen of the Teachbox to
request a quality sample to be placed on a dedicated position.
6) Decide if the robot shall bring the removed parts to a device for cutting sprue, and
define how many cutting positions shall be used. The cutting device will be
triggered using peripheral output PO-001.
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7) Decide if the ejectors shall move parallel to the in and out movements of the
robot in order to save cycle time. Activate a softer, slower departure at the
beginning of the out movement of the robot, if the parts have to be separated
from the mold slowly.
8) Decide if the program shall use the EcoMode for automatic adaption of the speed
of the placing travel to the requirements of the machine cycle.
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9) Name your new program, and add a comment, if necessary.
Press for the wizard to create your program and to open it in

Quick Edit.
10) Work through the displayed parameter values from top to bottom, and set the
desired values. Use the display- and editing functions of the Quick Edit for this.
11) Test your program with reduced velocity using the Dry Cycle function of the
virtual sub pendant, or use the Step functionality of the Text Editor.
12) Use the File menu Save as to store your new program on a storage medium. This
is possible in the Quick Edit and in the Text Editor.
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4.2 Programming the Robot in the Text Editor

The robot is programmed simply by manually moving the robot through the motions
and functions that you want it to make in automatic mode. The instruction sequence
created in this way is stored in a teach program and is then processed step by step in
automatic operation. When the last instruction is reached, the program sequence is
begun again at the first instruction.
A program may be created completely new (as described below) or may be a revision
of an existing program. Once you are familiar with programming, revising an existing
program and saving it with a new name is a much quicker way to create programs.
4.2.1 Creating a New Program in the Text Editor
1) Enter the Text Editor by pressing .

2) To start with a blank program, the program stored in the editor must first be
deleted. This can be done by selecting the option New in the menu File. In the
dialogue Options for new teach program certain elements of the existing
program can be selected to be kept with the new program.
3) Set the threshold of the vacuum under-pressure for the utilized vacuum circuits.
4) Starting from the reference position, move the robot manually to trace the
movements that you want the robot to make. Manual movements are made by
selecting the desired axis (labeled on the robot) with the buttons
. After selecting the kind of motion, the axis can be moved to the
desired position using the drive keys. (+ direction is away from reference position
and - direction is toward reference position.)
When you reach the desired position, press and the instruction will be
stored as a line in the program. (Only the instruction active when you press the
key will become a line in the teach program – all other motions made will
be ignored.)
5) Repeat the process for the remainder of the motions and functions that you want
the robot to reproduce.
6) The program is complete once you have programmed all of the motions and
functions desired and the robot is in a suitable position to restart from the
beginning of the program.
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Caution!
After placing the parts the Y and X axes must be positioned suitable for traveling
over the IMM, since the first motion in the program is typically a Z-axis (traverse)
motion towards the molding machine.
4.2.2 Verifying Your Program Using STEP Mode
1) Bring the cursor back up to the beginning of the program using the button .
2) Move the robot to reference position with the key.
3) Test the program one line at a time in the STEP mode.
Each time the key is held down, the next instruction will be executed.
4) Releasing the key will cause the robot to be halted immediately, in order to
avoid collisions or other program errors. A flag will appear.
Correct the program line if necessary and then continue to step through the
program.
5) When the end of the program is reached, press the key and the cursor will
jump back up to the beginning of the program.
It is important to continue stepping through the program a second time to
verify that there is no problem with the robot’s position at the end of the
program.
4.2.3 Storing Your Program on a storage medium
1) Connect a USB stick to the Teachbox, if required.
2) Press the button to enter the text editor again.

3) Use the option Save as in the menu File to callup the function for saving programs.
After tapping the field Save in select either the internal storage medium of the
Teachbox or the USB stick as the target medium. The teach programs *.WIP
already stored on the selected medium will be displayed.
4) Enter the desired name for the program using the dialogue for text input and
confirm with .
5) Press to store the program and to exit the function.
6) Use to exit the editor, press to transfer your new program into the
robot. Decide to reset all counters and placing programs or not.
7) You are now ready to run the program in full AUTOMATIC mode.
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4.3 Program Example

The following example will help you to further understand and practice the teach
programming of the system.
Please note that this is only an example. At a minimum, axis positions, IMM interface
signals and program functions must be adjusted to your specific application!
The program example is based on a robot with 2 vacuum circuits and 2 gripper circuits.
4.3.1 Function of Program

Plastic housings are to be injection molded.
The robot’s job is first to move into waiting position above the injection molding
machine. When the mold opens, the robot removes the molded part. The molded part
is stacked on a conveyor by means of a placing program. When the stack is finished, it
is carried away by the conveyor.
4.3.2 Sequence
• The mold is closed manually for the first time. Then the robot is started in
automatic operation. It is also possible to start robot and machine simultaneously.
• The robot travels to the waiting position above the mold, and waits for the „Mold
Open“ signal from the machine.
• The molded part is removed from the mold using vacuum circuit 1.
• The robot travels back and up out of the mold and turns on the „Mold Close“
signal.
• The removed part is stacked using a placing program.
• When the stack is finished, the conveyor is indexed for 5 seconds.
• The presence of the removed part is sensed during the entire cycle by the vacuum
sensor. If the part is lost, a STOP of the robot is executed.
• Speed settings shall be automated using Eco Mode.
• The robot shall execute a programmed reference sequence. If a part is on the
gripper, it shall be placed on a safe position.
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4.3.3 Sketch of Sequence

The ejector presses the parts on the vacuum cup.
Fig.: Sequence
1 ... Reference position

2 ... Waiting position over the mold
3 ... Part removal position inside the mold
4 ... Placing positions in the box on the conveyor
4.3.4 Sketch of Depositing Program

The numbers below indicate the sequence of part depositing. Three layers are stacked
in the vertical (Y) direction.
4.3.5 Reference Travel of Robot

The robot reference program must include axis motions in the mold, in order to allow
reference travel out from the mold area. If a part is on the gripper, it shall be placed on
a safe position. In reference position, all vacuum circuits are switched off and all
grippers are opened.
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4.3.6 Robot Teach Program (Robot Prg.)
0001 ECOMODE ON Turn on automatic speed settings.

0002 PERMIT IMM: MOLD CLOSE! = ON Close the mold for the first time.
0003 CALL CONVEYOR Clear the conveyor belt using the
0004 – subroutine CONVEYOR (line 32).
0005 CYCLE-START: Label for starting a new cycle.
0006 PRODUCTION END MANUAL Stopping point for production end.
0007*Y: 0.0 Travel to a waiting position above the mold.
0008*Z: 2353.0
0009*X: 123.6
0010 Smart Removal: IN Travel to the takeout position using
Y: 648.4 X: 202.4 ΔX: 30.0 Δt = 250ms Smart Removal:
Checks if the mold was closed,
waits for mold opening,
turns off the permit for mold closure,
moves to takeout position time efficiently,
with a straight X-movement of 30mm,
and continues with the next line 0,25s
before reaching the takeout position
0011 Vacuum-01 = ON to turn the vacuum on earlier.
0012 WAIT SYNC Wait for finishing moving in.
0013 FUNCTION IMM: EJECTORS FORWARD! WAIT Move ejectors forward.
0014 WAIT Vacuum-01 = ON Wait until the product is sucked on.
0015 FUNCTION IMM: EJECTORS BACK! WAIT Move ejectors back.
0016 Vacuum-01 = M-Smart ON STOP Activate vacuum monitoring before Smart
Removal permits mold closure.
0017 Smart Removal: OUT Travel out of the mold with Smart Removal:
X: 119.0 Y: 0.0 ΔX: 50.0 Δt = 0ms After 50mm of straight X movement,
it travels out of the mold time efficiently,
and permits mold closure when reaching
the Y mold safety switch.
0018*X: 0.0
0019*Z: 1927.0 Outside of the door of the machine
0020 C: 90.0* start turning the C axis.
0021 Placing Program: Placingp-001 Move to the next placing position.
0022 Vacuum-01 = OFF Place the product.
0023 TIME = 1.00s
0024*Y: -200.0R Move the axes from the placing position to
0025 C: 0.0* a position that enables moving over the
0026*Y: 0.0 machine.
0027 X: 0.0
0028 WAIT SYNC Wait for the C axis.
0029 CALL CONVEYOR Placingp-001 ZXY STACK READY
Once the stack is finished, index the
conveyor using the subroutine CONVEYOR
(line 32).
0030 JMP CYCLE-START Begin a new cycle
0031 – (label CYCLE-START in line 0005).
0032 SUBR CONVEYOR Subroutine for the conveyor.
0033 Conveyor-01: ON 5.00 s Turn the conveyor on for 5 seconds,
0034 Placingp-001 RESET and reset the placing program.
0035 RET Continue in the „main routine“, after the
CALL command that called the subroutine.
0036 -
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4.3.6.1 Placing Program Placingp-001
Name of placing program: Placingp-001

Drive: 1D
Sequence of axes movement: ZXY
Sequence of placing: ZXY
Stacking sensor: No
Axis: X Y Z
Start position: 100.0 1000.0 600.0
relative endposition: 100.0 -300.0 -400.0
Number of Parts: 2 3 4
Displacement: 0.0 0.0 0.0
4.3.7 Reference Program for the Robot (Robot Ref.)
0001 IF MOLD AREA Reference travel from in and over the mold.
0002 IF I(ROLLER SWITCH S5) = OFF If inside the mold,
0003 WAIT IMM: EJECTORS BACK = ON check for the ejectors,
0004 X: 114.9 and position the X axis first.
0005 ENDIF
0006 Y: 0.0 Move out from the machine.
0007 X: 0.0
0008 C: 0.0
0009 ELSE Reference travel in the placing area.
0010 Y: 0.0 Move up from the placing area.
0011 X: 0.0
0012 ENDIF
0013 –
0014 IF Vacuum-01 = ON If a product is on,
0015 Z: 1267.8
0016 C: 90.0
0017 X: 173.8
0018 Y: 804.7
0019 Vacuum-01 = OFF place it on a safe position.
0020 TIME = 1.00s
0021 Y: 0.0
0022 X: 0.0
0023 ENDIF
0024 –
0025 C: 0.0 Move to the reference position.
0026 Z: 0.0
0027 Vacuum-01 = OFF Switch all vacuum and
0028 Vacuum-02 = OFF
0029 Gripper-01 = OPEN gripper circuits to their reference state.
0030 Gripper-02 = OPEN
0031 -
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5 Troubleshooting
5.1 Operating Errors
These errors are the result of operational causes. If such an error occurs, the relevant
text error message will be displayed on the teachbox. Multiple errors are listed
according to their priority:
Every error message is preceded by an error code with the following meaning:
Error group – Error number – Supplementary number
In addition, the error icon is displayed on the right in the status line.
The majority of these errors cause an immediate stop of the robot and a switch to
MANUAL mode. In order to continue automatic operation, first clear the errors by
pressing the key, after their causes have been eliminated. The robot must be
moved to reference position before restarting automatic operation.
Errors whose cause is still present are displayed in red. If the cause of error is
eliminated or is no longer active, the display color changes to gray.
Errors whose cause is still present cannot be acknowledged.
Pressing closes the window, but cannot acknowledge or delete errors.
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5.1.1 Operating Errors in Plain Text Messages
5.1.1.1 Axis Errors
Group No. Supplement Message Cause/Remedy

004 000 0-11 xx: CONTOURING ERROR Actual speed of axis lags behind
internal calculations; can be caused
by mechanical friction in
guides/bearings or by too high a
payload. May also indicate a
defective converter or servo module.
004 001 0-11 xx :ENDSWITCH 0-POSITION While the axis was moved, the end
switch in - direction was hit.
004 002 0-11 xx :ENDSWITCH END-POSITION While the axis was moved, the end
switch in + direction was hit.
004 003 0-11 xx :MOTOR TEMPERATURE
004 004 0-11 xx :FREQ. INVERTER FAULT There may be many causes of
converter fault. The display on the
Inverter should be read and our
nearest service facility should be
contacted.
The error messages of the controller
can be confirmed be sending a drive
command (selecting the axis emits
the release signal). If for example 3
errors are active at the controller, the
axis has to be selected 3 times.
However, this error may also
indicate a mechanical defect or
sluggishness of guides/bearings.
004 006 0-11 xx :ENCODER FAULT This error indicates that the
incremental encoders do not count
as provided. The reason for this
could be a cable failure in the
incremental transmitter line or a
defect in the scoring logic. Another
cause might be increased
mechanical friction between guide
shaft and bearing. In this case this
error occurs mainly at very low
speeds, especially in the first
acceleration or last braking phase.
004 007 0-11 xx :STROKE LIMIT The axis reported an actual position
outside its stroke limits.
004 008 0-11 xx :SPEED LIMIT FAILED During operation with dead-man-
keys the axis moved faster than 250
mm/s
004 009 0-11 xx : SAFETY CONTACT FAILED
004 010 0-11 xx : AXISPOSITION NOT ALLOWED The pneumatic axis has stopped
between valid positions, none of the
position limit switches is actuated.
004 012 0-11 xx :ILLEGAL SET POSITION There is an invalid set position in the
teach program for the robot or the
stroke limit was set too low. With
activated safety areas this message
appears when the robot would leave
the safety areas.
004 013 0-11 xx :UNCONTROLLED SPEED The numerical axis has left its set
position during standstill. Brake or
axes contactors might be defective.
004 015 0-11 xx : ROLLER SWITCH The axis moved and the roller switch
UNEXPECTED input changed its state without a
memorized switching point near this
position.
The related mold safety switch (or its
circuitry) is defective, or the position
of its cam has changed.
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004 016 0-11 xx :OUT OFSAFETY AREA
004 017 0-11 xx :AXIS NOT IN 0 POSITION Before the start of the standard
reference travel the B axis is
checked for being in 0 position. If
it is not, the reference travel is
aborted with this error message.
004 018 0-11 xx : ROLLER SWITCH EXPECTED The axis moved past a
memorized switching point, but
the roller switch input has not
changed its state.
The related mold safety switch
(or its circuitry) is defective, or
the position of its cam has
changed.
004 019 0-11 xx :POSITION MONITORING Position monitoring compares
internally the listed end position
with the actual position. If they
do not coincide this error
message appears.
004 020 0-11 xx :LATCH NOT OPEN
004 021 0-11 xx :EJECTOR TOO FAST At the Push function. The
movement of the ejector was too
fast, or the distance between
intermediate position and target
position is too small.
004 022 0-11 xx :TIME MONITORING A pneumatic axis has not
reached its set position within the
time limit.
004 024 0-11 xx :COLLISION MONITORING One of the (partly optional)
collision monitorings has been
triggered: Mold Monitoring,
Roller Switch Monitoring, Safety
Areas, Collision Monitoring
AND/OR, Carrier Monitoring.
According to the configuration of
the robot.
004 025 0-11 xx :MANUAL MOVEMENT DENIED Either the dead-man-key has not
been released and pressed
again, when switching between
axes in manual mode of the
safety package;
or somebody tried to move
further towards the obstacle, with
the axis already positioned in
violation of a safety area.
004 026 0-11 xx : ROLLER SWITCH REPEATEDLY The roller switch input changed
its state without an axis
movement.
The axis moved in negative
direction and has travelled over
the first memorized switching
point already, but the roller
switch input changed its state
again.
The axis moved in positive
direction and has travelled over
the last memorized switching
point already, but the roller
switch input changed its state
again.
The related mold safety switch
(or its circuitry) is defective, or
the position of its cam has
changed.
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004 027 0-11 xx : LATCH NOT CLOSED The latch of a digital B-axis could
not be closed at the end of the
movement.
004 028 0-11 xx : CRANE IN ROBOT AREA With the optional crane interlock
active, the robot may not be
moved, while the crane is in the
robot area.
004 029 0-11 xx : CABLE BREAK All four inputs 0° Position, 90°
Position, Track A and Track B of a
digital (B-) axis are LOW.
004 030 0-11 xx : TORQUE MONITORING The actual torque was bigger than
the calculated maximum torque.
Possible causes include collision,
overload and sluggishness.
004 031 0-11 xx : CARRIER MONITORING The collision monitoring "carrier
monitoring" has been triggered.
004 032 0-11 xx : POSITION MONITORING The robot left its set position while
(WAIT IMM) being in the operation mode Wait
IMM.
004 033 0-11 xx : BELT INSPECTION INTERVAL When the belt inspection interval is
REACHED reached the error message will
display one time. Additionally, it
will appear whenever the robot is
being powered up and the interval
has already been reached prior to
powering off. The belt should be
checked and checking must be
confirmed.
004 034 0-11 xx : BELT REPLACEMENT INTERVAL When the belt replacement interval
REACHED is reached the error message will
display one time. Additionally, it
will appear whenever the robot is
being powered up and the interval
has already been reached prior to
powering off. The belt must be
replaced and the replacement
must be confirmed.
004 035 0-11 xx : CARRIER MONITORING VABS The collision monitoring "carrier
monitoring" has been triggered
during automatic mode while
performing a VABS movement.
004 036 0-11 xx : PAYLOAD EXCEEDED Overload was detected. Reduce
(ENABLE DYNAMIC DRIVE) payload or acceleration or enable
Dynamic Drive.
004 037 0-11 xx : ROLLERSWITCH OUT OF A switching point of an emulated
STROKE LIMIT roller switch is located outside of
the stroke limits of the axis.
004 038 0-11 xx : BRAKE HOLDING FORCE TOO The automated brake test returned
LOW not enough holding force for the
brake. This may lead to
unexpected, uncontrolled
movements of the axis at an idle
robot. Have the brake (motor) of
the respective axis be
repaired/replaced absolutely.
The supplementary number indicates the axis, xx stands for the axis designation.
000 ... X, 001 ... Y, 002 ... Z, 003 ... A, 004 ... B, 005 ... C, 6 ... X2, 7 ... Y2, etc.
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5.1.1.2 Vacuum Errors

006 000 0..n VACUUM xx PART LOST This error message appears when
the vacuum monitoring for the
indicated circuit is activated and
the vacuum pressure of that circuit
falls below the preset threshold.
006 001 0..n VACUUM xx NOT OFF The vacuum reference position
was chosen to be OFF, but at the
end of the reference travel this
vacuum circuit was not OFF.
006 002 0..n VACUUM xx NOT ON The vacuum reference position
was chosen to be ON, but at the
vacuum circuit was not ON.
006 003 0..n VACUUM PUMP THERMO- Thermal contact of the vacuum
MONITORING pump responded to increased
temperature of motor.
006 004 0...n VACUUM xx DEAD-MAN-KEY NOT With safety not met, the selection
PRESSED switch has to be on manual and a
dead-man-key must be actuated to
enable switching of a vacuum.
006 005 0...n VACUUM xx BLOW OUT NOT OFF Vacuum blow out was not off at the
end of the reference travel.
xx indicates the vacuum number, e.g., 01
Supplementary numbers: 000 = VACUUM 01

001 = VACUUM 02, etc.
5.1.1.3 Gripper Errors

007 000 0..n GRIPPER xx PART LOST This error message appears when
the gripper monitoring for the
indicated circuit has been
activated and the part monitoring
input of that gripper signals part
loss.
007 001 0..n GRIPPER xx NOT OPEN The gripper reference position was
chosen to be OPEN, but at the end
of the reference travel this gripper
was not OPEN.
007 002 0..n GRIPPER xx NOT CLOSED The gripper reference position was
chosen to be CLOSED, but at the
gripper was not CLOSED.
007 003 0..n GRIPPER xx TIME MONITORING The gripper has not reached its set
position within the time limit.
007 004 0...n GRIPPER xx DEAD-MAN-KEY NOT With safety not met, the selection
PRESSED switch has to be on manual and a
dead-man-key must be actuated to
enable switching of a gripper.
007 005 0...n GRIPPER xx NOT PRESSURELESS The reference state of the gripper
is RELEASED, but the gripper was
actually OPENED or CLOSED at
the end of the reference travel.
xx indicates the gripper number, e.g., 01
Supplementary numbers: 000 = GRIPPER 01

001 = GRIPPER 02, etc.
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5.1.1.4 Peripheral Equipment Output Messages

009 000 0..n xx MONITORING This error message is displayed when part
monitoring for the indicated peripheral output is
activated, and the peripheral input with the same
number is OFF.
xx shows the PO names: e.g., PO-001
Supplementary numbers: 000 = PO-001

001 = PO-002, etc.
5.1.1.5 Cylinder Messages

010 000 0...n CYLINDER xx NOT ON The cylinder has moved off its position limit
switch during standstill. Possible causes are loss
of air pressure or mechanical problems.
010 001 0...n CYLINDER xx NOT OFF The cylinder has moved off its position limit
switch during standstill. Possible causes are loss
of air pressure or mechanical problems.
010 003 0...n CYLINDER xx TIME The cylinder has not reached its target position
MONITORING within the set timeout.
010 004 0...n CYLINDER xx DEAD- With safety not met, the selection switch has to
MAN-KEY NOT PRESSED be on manual and a dead-man-key must be
actuated to enable moving a cylinder.
5.1.1.6 Conveyor Belt Messages

019 000 0..n CONV. xx TEMPERATURE The thermal contact of the conveyor belt
MONITORING responded to increased temperature of
the motor.
019 001 0..n CONV. xx FOLLOWING TARGET The conveyor following command has
POSITON REACHED reached the target position P2. The error
message has been triggered, and the
Teach program will continue at the label
for the alternative routine.
xx shows the belt number: e.g., 01
Supplementary numbers: 000 = CONVEYOR BELT 01

001 = CONVEYOR BELT 02, etc.
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5.1.1.7 General Hardware Error Messages

124 000 000 EMERGENCY STOP An emergency stop button was actuated
either at the IMM or at the robot.
After resetting the emergency stop
switch, the power on key at the
subpendant must be pressed to switch
on the control-voltage again.
124 001 000 AIR PRESSURE TOO LOW Operating pressure dropped below 3.5
to 4 bars.
124 002 000 PHASE MONITORING Phase monitoring in the control cabinet
reports voltage fluctuations and
asymmetries in supply exceeding a
given adjustable range.
124 005 000 OPERATION WITHOUT ROBOT In order to change to automatic
operation, "Operation With Robot" must
be on. Use the button on the
Subpendant to switch on "Operation
With Robot".
124 006 000 IMM IN MANUAL MODE The injection molding machine was in
manual operation when the
AUTOMATIC key was pressed.
124 007 000 MOLD MONITORING Mold safety ensures that the robot does
not travel into a closed mold or that the
mold does not close while the robot is in
the mold area. Mold safety is realized
with the roller switches S5 (Y axis) and
S6 (Z axis).
124 008 000 IMM SAFETY DOOR OPEN The safety door of the injection molding
machine was opened during automatic
operation.
124 009 000 DOOR NOT LATCHED The door of the safety package could
not be locked mechanically. The door
contact may have become bent, not
allowing the bolt to lock.
124 010 000 DOOR NOT SEQUENCED The safety system of the robot reports
that the safety requirements for
operation have not been met.
124 011 000 DEAD-MAN-KEY TIME The permit key on the Teachbox must
MONITORING be pressed and released at regular
intervals.
124 012 000 REFERENCE IN MOLD NOT For safety reasons, the standard
ALLOWED reference travel may not be carried out
in the mold area. The error message
appears when the robot is in the mold
area and the operator did not program a
reference travel. Note that in the NO
REFERENCE mode the reference travel
cannot be carried out in the mold area.
124 015 000 RELEASE DEAD-MAN-KEY The permit key on the teachbox must be
pressed and released at regular
intervals.
124 016 000 COMMUNICATION FAILED A communication problem with an
inverter with CAN bus connection has
occurred.
124 017 000 TIME MONITORING PROCESS Time out at communication with an
COMMUNICATION emergency stop block or with a
Teachbox. In most cases normal
operation is possible after confirming the
error message.
124 018 000 SAFETY SYSTEM NOT ENABLED The safety system of the robot reports
that the safety requirements for
operation have not been met. Also
check EMERGENCY STOP of robot and
IMM.
124 019 000 BM IN MANUAL MODE
124 020 000 SR: x VIOLATED A robot axis tried to enter an
exclusionary safety area. Move the axis
back out of the safety area.
124 028 000 CHECK CENTRAL LUBRICATION Stop the robot as soon as possible and
check the central lubrication system.
(Run out of grease?)
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124 029 000 CENTRAL LUBRICATION FAILED Check and repair the central lubrication
system (Run out of grease?)
124 030 000 AUTOMATIC-MODE NOT “opm” represents the current mode of
POSSIBLE “opm“ operation:
0...Reference Missing, 1…Reference
Travel, 2...Reference, 3...Manual,
4...Block Stop, 5...Block Stop Travel,
6...Automatic
124 031 000 CENTRAL LUB. PRESSURE Check and repair the central lubrication
DROP NOT OCCURED system (blocked?)
124 032 mmm IMM “mmm“ MOLD IS OPEN The "Easy Automatic Start Sequence"
cannot be started.
124 033 mmm IMM “mmm“ MOLD POSITION The "Easy Automatic Start Sequence"
INDEFINITE cannot be started.
124 034 mmm IMM “mmm“ MOLD MONITORING An attempt was made to enter the
BRAKING DISTANCE respective IMM while its mold was not
completely open.
124 035 000 LUBRICATION INTERVAL Is triggered once, when the lubrication
REACHED interval is being exceeded. Additionally
the message will appear each time the
robot is being powered up with the
lubrication interval exceeded.
124 036 000 CONTROL VOLTAGE NOT ON Indicates that the control voltage is not
on. In order to be able to meet safety,
the control voltage must be switched on,
using the button "Control Voltage On" at
the Subpendant (emergency stop
block).
124 037 000 CONTROL VOLTAGE CIRCUIT Hardware defect in connection with the
PROBLEM control voltage relay.
124 038 000 CENTRAL LUBRICATION TANK The central lubrication system signals
EMPTY that its tank is empty.
124 039 000 IMM-INPUT DIFFERENCE When restarting the robot after a stop,
DURING STOP one or more IMM signals states are
different than at the moment of stopping.
124 040 mmm IMM “mmm” ROBOT OUTSIDE A problem with the generation of the
MOLD CIRCUIT PROBLEM “robot mold area free” signal was
detected. Check related electrical
circuitry and relay.
124 041 mmm IMM “mmm” MOLD STATE NOT The states of the inputs from the iMM
SAFE FOR ENTRY are different from their reference (stored
at the falling edge of the IMM signal
Mold Is Closed) and they do not match
the states of the outputs to the IMM.
124 043 000 REFERENCEDRIVE BLOCKED The function "Prevent the reference
BY INPUT drive" is configured. The standard
reference drive is inhibited because the
input S5 and/or S5.2 is not ON. Use a
reference teach program to avoid the
error message or use manual functions
to drive onto the S5/S5.2 switch.
124 044 000 SAFETYRELAY MONITORING The safety relay monitoring hardware
24 V CIRCUIT PROBLEM signals a 24 volts circuit problem.
124 045 000 SAFETYRELAY MONITORING The safety relay monitoring hardware
0 V CIRCUIT PROBLEM signals a 0 volts circuit problem.
124 046 mmm “mmm” MOLD OPEN SYNC IMM The mold movement changed its
DIRECTION CHANGE direction while the Mold opening
synchronization command was being
executed.
124 047 mmm “mmm“ ROBOT MOVES INTO An attempt was made to move in to the
MOLD WITH ACTIVE MOLD mold while the permit Mold Close was
CLOSE SIGNAL on.
124 048 mmm “mmm“ MOLD POSITION Nothing is connected to the analog input
MEASUREMENT INPUT OPEN for the mold position measurement.
124 049 000 OUTSIDE WORKING AREA SR: x A robot axis tried to exit the inclusive
safety areas. Move the axis back in to
the permitted area.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
5.1.1.8 System Error Messages

127 003 ggg EXTERNAL TEACH PROGRAM A Teachprogram from an external source
CHANGE was received. The supplemental error
number indicates the source like this:
0...Teachbox 1, 1...Teachbox 2, 10...IMM,
23...Remote Access
127 010 ttt REAL-TIME VIOLATION Internal software fault. Processing of the
axes calculations was started too late. The
supplemental error number shows the
delay in milliseconds.
127 011 ttt SEVERE CLOCK OVERFLOW Internal software fault. Processing of the
axes calculations was started too late. The
supplemental error number shows the
delay in milliseconds.
127 012 000 QUIT QUEUE FULL Internal software fault while processing
axes drive commands.
127 013 000 STROKE LIMIT CHANGE NOT In case of axes being assigned to the All
ALLOWED Modes Program, the Stroke Limits cannot
be changed while the All Modes Program
is running.
127 014 000 USER REALTIME-FUNCTION: Executing the user function "RTFunc" has
EXECUTION TIME TOO LONG taken too much time. The execution is
stopped. Please check the user dll
functions and restart the CPU.
5.1.1.9 CAN Device Messages

141 000 aaa xx :FREQ. INVERTER FAULT ff Only on robots equipped with CAN-BUS
controlled inverters. Please contact our
service department for further information.
The error messages of the controller can

be confirmed be sending a drive command
(selecting the axis emits the release
signal). If for example 3 errors are active
at the controller, the axis has to be
selected 3 times.
However, this error may also indicate a

mechanical defect or sluggishness of
guides/bearings.
141 001 mmm mm : CAN-MODULE An error occurred while trying to
COMMUNICATION ERROR communicate with the CAN module with
the indicated number.
141 002 bbb Can Bus “bbb” WARNING This indicates communication problems on
or the indicated CAN bus line.
Can Bus “bbb” BUS OFF WARNING indicates bad communication.
BUS OFF indicates no communication.
141 003 bbb “bbb” ROBOT INTEGRATION The communication between two robots is
COMMUNICATION ERROR interrupted because of an unpowered
second robot or a cable break.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
5.1.1.10 Teach program Compiler Messages

160 000 000 TEACH PROGRAM TOO The program exceeds the memory size.
LARGE
160 001 lll LABEL NOT FOUND The label used by a JMP command could
not be found. The supplemental error
number indicates the label number.
160 002 sss SUBROUTINE NOT FOUND The subroutine used by a CALL command
could not be found. The supplemental
error number indicates the subroutine
number.
160 003 000 COMMAND UNSUPPORTED The command is not supported by the
software version used in this robot.
160 004 NOT CONFIGURED DEVICE The Teach program uses a device that is
not present on this robot.
160 005 aaa aa: TARGET OUT OF STROKE The target for the respective axis is
LIMITS outside its stroke limits.
160 006 000 TEACH PROGRAM INVALID The Teach program is broken. Try to use a
safety copy of the Teach program, if
available.
160 007 000 CHECKSUM ERROR IN TEACH The Teach program is broken. Try to use a
PROGRAM safety copy of the Teach program, if
available.
160 008 ppp PLACING PROGRAM The Teach program contains the
UNDEFINED undefined placing program with the
number indicated by the supplemental
error number.
160 009 nnn “part program name“ AXIS The axis definition of the respective part
DEFINITION INCORRECT program contains an axis that is not
present on this robot.
160 010 CYLINDER DEFINITIONS DO An attempt was made to transfer a Teach
NOT MATCH THE RUNNING program, while the All Modes Program
ALLMODE PROGRAM was running, with cylinder definitions not
matching the running program.
160 011 VACUUM DEFINITIONS DO An attempt was made to transfer a Teach
NOT MATCH THE RUNNING program, while the All Modes Program
ALLMODE PROGRAM was running, with analog vacuum settings
not matching the running program.
160 012 CAN NOT REPLACE “part An attempt was made to transfer a Teach
program name “WITH NEW program, while the All Modes Program
ALLMODE PROGRAM was running.
160 013 TEACH PROGRAM NOT In the current mode of operation it is not
ACCEPTED IN „opm“ possible to transfer the Teachprogram.
The supplemental error number indicates
the current mode of operation like this:
0...Reference Missing, 1...Reference
Travel, 2...Reference, 3...Manual, 4...Block
Stop, 5...Block Stop Travel, 6...Automatic
160 014 TEACH PROGRAM HEADER The Teach program is broken. Use a valid
INVALID Teach program.
160 015 TEACH PROGRAM VERSION The version of the Teachprogram loaded
NOT SUPPORTED to the robot is not supported. Eventually
the program can be converted to a
compatible version by loading it to the
Teachbox and transferring it back to the
robot.
160 016 ERROR ON READING TEACH When a broken Teach program was
PROGRAM FROM FILE transferred as a file, e.g. at integration.
160 017 TEACH PROGRAM FROM The control number stored in the Teach
ANOTHER ROBOT program does not match the control
number of the robot. The Teach program
can be loaded to the Teachbox, and after
thorough checking be stored back into the
robot.
CAREFUL: The sequence and the
positions of the program probably do not
suit the current application! !
160 018 LOGICAL AND/OR SEQUENCE AND/ OR commands were found without a
ERROR preceding IF, JMP, WAIT, CALL command
with a condition in the lines directly before
the AND/OR commands
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015

160 019 RELOADED PREVIOUS TEACH The new Teach program could not be
PROGRAM transferred; the existing Teach program in
the robot has been retained.
160 020 ppp “ppp“ AXISCOUNTERVALUE The axes used in the indicated placing
NOT SUITABLE program do not match the axes definition
of the part program.
160 021 INVALID COMMAND The execution of the command is either
not possible or not allowed.
Examples:
Release axis teach command but release
function not configured.
Numeric axis teach command but the axis
is a digital axis.
160 022 MANUAL CONVERSION OF The All Modes program has the wrong part
TEACH PROGRAM program number. The program must be
NECESSARY converted manually.
160 023 INVALID PARAMETER A Teachcommand has a parameter
applied that doesn't exist.
160 024 POSITION NAME NOT An axis movement command or placing
DEFINED program uses an undefined position name.
160 025 “ppp“ INVALID DIRECTION OF The stacking sensor movement of the
STACKINGSENSORDRIVE indicated placing program is pointing into
the opposite direction of the approaching
movement.
160 026 GLOBAL TEACHPROGRAM The global teach program has been
COMPILE ERROR loaded, but it can’t be executed. In a
global teach program only All Modes
programs may contain commands; axes
may not be used.
The supplementary number indicates the axis, aa stands for the axis designation.
000 ... X, 001 ... Y, 002 ... Z, 003 ... A, 004 ... B, 005 ... C, 6 ... X2, 7 ... Y2, etc.
5.1.1.11 Teach program Interpreter Messages

170 000 000 DIVISION BY ZERO The Teach program attempted to do a
division by zero
170 001 000 TOO MANY CALL-COMMANDS This error appears when the nesting depth
of subprogram calls becomes too big. The
cause could be a teach program error or
too frequent calling of CALL instructions
without previous encounter of RET
instructions.
170 002 000 RET WITHOUT CALL- Execution of the teach program has
COMMAND encountered a RET instruction before
having executed a CALL command.
170 003 000 “part program name“ ALREADY The Teach program attempted to start a
ACTIVE part program that was already running.
170 004 000 RESULT OUT OF RANGE The result of a counter / placing counter
calculation is out of the range of possible
values.
170 005 000 RUN ON SUBROUTINE The program ran on a Subroutine
WITHOUT CALL COMMAND command, without calling it with a CALL
command.
170 006 sss “stacking sensor name“ The stacking sensor was actuated while
UNEXPECTED processing a stacking sensor command or
a placing program with stacking sensor,
before the intermediate position was
reached.
170 007 ppp „ppp“ BOX CRASH An attempt was made to use the placing
MONITORING program to travel over the box below the
box height.
Check the position of the robot before
execution of the placing program.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015

170 008 ppp “ppp“ STACK CRASH An attempt was made to use the placing
MONITORING program to travel over the box below the
height of the stack.
170 009 ppp “ppp“ MOVEMENT CONTRARY The traveling direction of the placing axis
TO STACKING DIRECTION does not match the calculated placing
direction.
170 010 aaa “aaa“ ABSOLUTE MOVEMENT During the execution of the conveyor
DURING CONVEYOR following command only relative
FOLLOWING movements are allowed.
170 011 000 SMART REMOVAL STRAIGHT The distance for straight travel in the
FORWARD DISTANCE TOO Smart Removal command is bigger than
LONG the overall distance programmed for the
respective axis.
170 012 aaa “aaa“ IS RELEASED An attempt was made to drive the
released axis using an axis drive
command.
170 013 000 „part program name“ POSITION A Teach program command uses an
UNDEFINED undefined or not completely defined
position.
170 014 000 AXIS PUSH INVALID MOTION Axis Push command:
DIRECTION The direction from current actual axis
position to intermediate position is different
than the direction from intermediate
position to target position.
A correct motion is not possible.
170 015 000 IMM PERMISSION TEACHCMD Occurs on execution of a IMM permission
BUT NO OPERATION WITH teachcommand when the operation with
ROBOT robot for that IMM is inactive.
170 016 000 WAIT IMM INPUT SIGNAL, BUT Occurs on execution of a Wait IMM
IMM IN MANUAL MODE teachcommand when that IMM is in
manual mode.
170 017 000 MONITORING ALREADY USED A Teachcommand tried to activate a
device monitoring that is already active.
170 018 000 PERMIT MOLD CLOSE The Teach program attempted to switch
ALREADY ACTIVE on the permit Mold Close although it was
already on.
170 019 000 MOLD CLOSE THAUGHT The Teach program attempted to switch
INSIDE MOLD on the permit Mold Close while the robot
was situated inside the mold of the IMM.
5.1.1.12 Configuration Errors

180 000 000 CONTROL VOLTAGE The output 511 - Control Voltage On is configured
CONFIGURATION but not all other required IOs are configured.
Required IOs:
Input 511 - Control Voltage On,
Input 510 - Control Voltage On Monitoring,
Input 164 - Key Control Voltage On,
Output 511 - Control Voltage On
180 001 000 ANALOG VACUUM An analog vacuum monitoring is not correctly
CONFIGURATION assigned to a vacuum device or a hardware device.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6 Maintenance
Following the recommended maintenance schedule is required to ensure trouble-free
operation of the robot. The robot warranty does not cover neglected or poorly
maintained equipment.
Maintenance must be performed by qualified personnel only.
6.1 General
The user of the robot is responsible for maintenance and monitoring of the safety
devices and systems.
In particular, the safety systems marked must be checked according to the

instructions to ensure a safe and fully functioning robot system.
Before entering the work envelope of the robot to perform maintenance work, lock out
the main power disconnect switch and turn off the compressed air supply to the robot.
IMPORTANT! Robots with pneumatic linear axes often use 5-way or 3-way valves,
which can leave trapped high-pressure air in a cylinder even with air pressure
removed. This can result in uncontrolled axis motions if one side of the cylinder is
exhausted during a maintenance procedure. For this reason, it is recommended that all
pneumatic axes be blocked to prevent unintended hazardous motions.
For workings that cannot be executed standing on the floor use standardized and
certified ascent devices only.
For safe operation of the robot use original spare parts only.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.2 Lubrication Instructions for Linear Guides and Gear Racks
6.2.1 Lubrication Intervals for Standard Robots

The lubrication intervals are calculated automatically by the control system and are
displayed with a message “lube interval reached“ and the lubrication flag on the
upper right-hand corner of your screen. Generally, it is necessary to lubricate the tracks
and the bearings after a distance of 4000 km; the axis that completes this distance first
is the one that determines the beginning of the lubrication interval.
6.2.2 Lubrication Procedures

LINEAR RAILS: Remove old grease from the bearing wipers with a
rag. Use a grease gun to fill the bearing until grease
begins to come out of the bearing wipers.
GEAR RACKS: Remove old grease with a rag and apply fresh
grease to the entire length of the gear rack using a
spatula or a brush.
6.2.3 Grease Specification

GREASE: MANUFACTURER: TYPE:
Bosch Rexroth AG Dynalub 510
Castrol Longtime PD2
Chemie-Technik Ekalub GLS 135/N2
Klüber Klüberplex BEM 34-132
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.3 Drive Belts

Drive belts have to be visually checked for wear and tear or cracks every 6 month. If
any such are found, the affected drive belt has to be replaced immediately, in order to
prevent damages and idle times.
For safety reasons we recommend to replace the drive belts every 24 months during a
general maintenance session. Drive belts of high speed robots should be replaced
every 12 months.
The refit of a drive belt may only be carried out by trained personal equipped with the
proper tools, because also the tension of the belt has to be set correctly.
Our skilled technicians are available to perform the refit.
6.4 Motor Brakes

When entering the protective gate (operating mode BlockStop or Manual), please
check if any sagging is visible at the axes.
If this should be the case, the brake of the respective motor must be renewed
immediately.
A brake refit may only be carried out by trained personal. Before starting to work on a
vertical axis ensure that the axis is inhibited from falling down by suitable precautions.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.5 Battery Replacement
6.5.1 IPC
The capacity of the battery of the IPC in the cabinet is sufficient to secure the data over
a period of 3 years without supply voltage. We recommend replacing the battery
accordingly.
In order to replace the battery, remove

the cover plate of the IPC.
The two screws securing the cover plate

are marked with arrows in the adjacent
illustration.
Now you can remove the old battery and

install the new one.
When inserting the new battery, take

care about the correct polarity according
to the adjacent illustration.
Finally, re-attach the cover plate of the IPC.
The battery should only be replaced while the robot is powered down! After switching
off the 24V supply, the battery of the IPC will be buffered for 5 minutes. The battery
must be replaced within this time, else data loss will occur!
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.5.2 Sanyo R Inverters at Axes with Absolute Encoders

The capacity of the batteries in the Sanyo R inverters is sufficient to secure the zero
points of the axes for a period of 5 years without supply voltage. We recommend
replacing the batteries accordingly.
Fig.: Battery in a Sanyo R inverter
The procedure for replacing the batteries is as follows:

1. Move all affected axes to their zero points (with a reference travel).
2. Power down the robot.
3. Open or dismantle all covers as needed for accessing the inverters.
4. Flip open the front lid of the inverter.
5. Pull out the old battery and unplug it.
6. Push the new battery into the holder and plug it on. Make sure you feel the plug
locking in correctly.
7. Close the lid of the inverter.
8. Repeat steps 4 to 7 for all affected inverters.
9. Close and re-attach all covers.
10. Power up the robot.
11. Login as Admin.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
12. Open the menu Init – Absolute Encoders.
13. Select all affected axes.
14. Press in order to use the current positions of the axes as the zero point. Wait
until the positions of all selected axes show 0.0.
15. Exit the menu with .
Do not move the robot while you carry out steps 3 to 15. Else the zero point settings of
the robot will be lost!
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.6 Mold Safety Relays

The signals of the mold safety switches (“Roller Switches”) are processed and
forwarded using safety relays. These have a limited number of switching cycles as their
life expectancy.
We recommend having the mold safety relays replaced before the end of their life
expectancy.
The life expectancy of the mold safety relays is determined by the cycle time of the
robot and the number of switching cycles of the relays per robot cycle.
Relay life expectancy in years
Robot cycle time in seconds
shows the life expectancy of relays with 1 switching cycle per robot cycle:
Z-axes mold safety relays of standard robots with 1 placing area,
Mold safety relays of standard robots with absolute encoders,
Mold safety relays of IML units.
shows the life expectancy of relays with 2 switching cycles per robot cycle:
Y- axes mold safety relays of standard robots.
Example:
A robot runs an application with a cycle time of 10 seconds.
The life expectancy of the Y-axis mold safety relay is 8 years.
The life expectancy of the Z-axis mold safety relay is 16 years.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.7 Maintenance Schedule

INTERVAL IN
Description of Service OPERATING HOURS
PER CYCLE TIME
<10 s 10-30 s >30 s
1) Safety Systems and Devices

Emergency Stop Buttons: 150 150 150
When the device is at a standstill, activate the Emergency Stop switch
and check to see if „EMERGENCY STOP“ is indicated on the hand set.
The injection-molding machine must also indicate Emergency Stop.
Function of Permit Keys on the Teachbox: 150 150 150
Switch robot to manual operation, set selector switch at the safety door
to Set-up Mode. When the permit key is pressed, the “robot enabled“
light must go on. This function must be tested with both permit keys.
Safety Roller Switches S5+S6: 150 300 500
Switch to operation without robot (robot LED key does not light ).
Close mold slightly (Mold Open signal must be out). Now try to ride
into the mold area with the Y axis. The Y axis should ride only until
leaving S5. The error message “mold monitoring“ must be displayed
on the robot. Acknowledge message with ESC. Now try to close and
open the mold. This should not be possible, and an error message
should appear on the IMM. Now raise the Y axis.
See 6.2 See 6.2 See 6.2
2) Guides and Gear Racks
3) Other Components
Function of Vacuum Switches: 150 150 150
The vacuum switch inputs should be checked using the Input
Display screen on the teachbox. The input must only be on when a
complete set of parts is on the vacuum cups. Be sure that the input
switches back off when just one part is removed.
Air Filter: 150 300 500
Drain the filter bowl and check and fill the oiler as required.
IMPORTANT: Use only oil in accordance with ISO VG 32 KL1.
Control Cabinet Cooling Fans: 150 150 150
Visually check if all fans are operating. Clean the filters of the fans
or replace them when dirty (In high dust environments reduce the
interval for checking).
Drive Belts: 300 600 800
Visually check belt alignment and tension while the axis is moved
through first full stroke. Inspect the belt for damage and “necked-
down“ areas which indicate approaching belt failure.
Rack and Pinion Clearance: 300 600 800
Check for minimum rack to pinion clearance of 0.1 mm (0.004“).
Gearbox Gaskets and Drain Plugs: 500 800 1000
Check for leaks.
Cable Chains:
Inspect for proper alignment of cables in cable chain (IMPORTANT: 500 800 1000
Loose cable clamps can cause cable binding and chafing)
Motor Brakes: 800 1200 2000
Visually check, if vertical axes sag during standstill.
Screws: 800 1200 2000
Check robot screws and bolts for tightness.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.8 Automatic Lubrication
6.8.1 Description
The optional, automatic system lubricates all linear bearings and the respective
sprockets and racks of the robot. The system measures the X, Y, and Z-axis travel
distances to determine when grease should be applied. When the lubrication interval
(50 km) is reached, a fixed quantity of grease is injected into each bearing through the
grease distributors.
The grease-pump is equipped with a pressure sensor. If the given pressure is not
reached within 15 seconds after switching on the pump, or if the pressure doesn’t drop
below the given value within 15 seconds after switching off the pump, the error
message „CHECK CENTRAL LUBRICATION“ will be displayed on the Teachbox. This
will not interrupt the automatic execution of the robot teach program, but can be
confirmed with . The lubrication system should be checked as soon as possible,

and the cause of the error should be fixed. Possible causes for the error are:
Lack of grease in the container

Leaking, unplugged or burst hoses
Functional breakdown of the pump
If the cause of the error is not fixed before the next lubrication interval, the error
message “CHECK CENTRAL LUBRICATION” will be displayed again, and can be
confirmed with again.
Should the cause of the error again not be fixed until the 3rd lubrication interval, the
error message “CENTRAL LUBRICATION FAILED” will be displayed, and the robot will
switch to block stop. Now the cause of the error must be fixed.. After the cause of the
error was fixed, the grease pump can be started by pressing inside the menu
INIT/LUBRICATION INTERVAL a number of times until lubrication was executed
correctly without error message. This enables the start of automatic mode again.
During filling of the grease pump container, extra precaution must be taken to avoid air
bubbles in the grease and to use only the specified greases.
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
6.8.2 System Maintenance

It is important to remember that the automatic lubrication system does not
eliminate maintenance requirements for the robot! It just reduces the frequency of
the maintenance intervals. Lubrication system maintenance is crucial in detecting
system faults, such as:
• Burst Hoses
• Plugged Tubes
• Air Pockets
• Faulty Lubrication Pump or Solenoid Valve
• Faulty Injectors
6.8.2.1 Lubrication System Maintenance Procedure:

1. Inspect the system for burst, leaking, or disconnected tubes and hoses.
2. Check that some grease build-up is present on all linear bearings wipers to verify
that grease is reaching all bearings. Clean the grease off of the wipers to "reset"
this test for next time.
Refill the grease pump as needed, being careful not to leave any air pockets. Use only
the specified greases!
6.8.2.2 Suitable greases
Manufacturer Type
Bosch Rexroth AG Dynalub 520
Castrol Longtime PD00
Chemie-Technik Ekalub GLS 135/N00
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015
7 Key Terms
For better understanding of these operating instructions, some key terms are explained
below:
Term Explanation
EJ Ejector
BM Blow machine
DIAS BUS DIAS – Decentralized Intelligent Automation System
CNC CNC - Computer Numerically Controlled – microprocessor

control system
CPU Central Processor Unit
Euromap 12 Interface standard between IMM and robot
Flag Various letters/symbols indicating particular operating
conditions
CP Core puller
Position control In the case of servo devices, in automatic operation the motor
will be triggered continuously after a numerical axis has been
positioned, so as to hold the position.
LCD Display Liquid Crystal Display
Master Control system in control cabinet
MS-DOS Microsoft Disk Operating System – standard operating system
for IBM-PCs and compatibles
Emergency Stop Additional keypad for full operator control of the robot without
keypad manual control unit
Offline No communication between partial subgroup control units
Online Communication between all partial subgroup control units is
functioning
Override Adjustment - speed adjustment
PO Peripheral outputs
PI Peripheral inputs
Robot Control on the robot
IMM Injection molding machine
Soft key Key of uppermost row of keys on the teachbox, whose
assignment varies depending on the current function.
Soft key line Shows current assignment of soft keys.
Teach mode Operating mode for programming of sequence programs
Teachbox Manual control unit
Teaching Programming of robot
Teaching Programming of sequence programs
Teach program Sequence program
T/M Tool / Mold
R83_V8_20cL2_PDF_EN.DOC / 23.03.2015

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R8.

3 USER MANUAL Page 1

Safety Warnings marked .

Proper function of the equipment can be ensured only if maintenance is performed

The noise emission of this device does not exceed 70 dB(A).

2.5.2.2 Robot Signals ..............................................................................35

3.1.14.7 Setup: Date / Time .....................................................................75

3.2.2.1 Procedure Step ..........................................................................114

3.2.7.1 Positions ....................................................................................166

3.3.5.4 Vacuums ....................................................................................219

3.4.2.3 Exit the Quick Edit......................................................................263

6.2.3 Grease Specification ........................................................................298

1.1 Safety Regulations

1.2 Safety Features

1.2.2 Emergency STOP Buttons

The emergency stop button can be released by pulling it.

1.2.3 Permit Key on Teachbox

Categories of users Task Qualifications / Impairments

1.4 Capability of the Safety Control

1.5 Control of Hazardous Energy – (Lockout / Tagout)

The following is a glossary and general description of the LOTO procedure.

Always refer to applicable local codes in performing Lockout/Tagout procedures

1.5.2 Lockout/Tagout Kit

Fig.: Examples of LOTO devices

1.5.3 Lockout/Tagout Procedure

1.5.4 Removal of LOTO

Installation and startup shall be performed by authorized personnel only, in order to

Our trained service engineers are available to assist you.

2.1 Mechanical Installation

2.1.1 Dimensional Drawing – Adapter Unit

2.1.2 Mounting of the Robot

The axes are in a balanced position, when the respective

2.1.3 Demounting of the Robot

The axes are in a balanced position, when the respective

Before dismounting, all electrical and pneumatical connections have to be

2.2.1 Compressed Air Connection

Required air pressure: 60 - 100 psi (4 – 7 bar)

Air consumption per robot cycle:

Consumption per stroke * Cons. per sec. **

*: In ft³ at 90 psi (6 bar)

Example of calculation of compressed air consumption:

W833CNC: with X , Y, Z axes motor driven

2.3 Electrical Connections

2.3.1 Mains Power Supply

The power connection must be made by a qualified electrician in accordance with

2.3.1.1 Fault Current Safety Switches

• In frequency converters with 3-phase input voltage, in the event of a ground

• Parasitic capacities in the converter can in principle cause leakage currents,

Alternative safety measures are for example grounding or protective isolation.

2.3.2 Interface with the Injection Molding Machine

In particular, the functions of the safety circuits must be thoroughly checked:

• Emergency stop signals from and to the IMM

2.3.3 Mold Monitoring S5/S6

Function and Adjustment of Roller Switch S5:

Function and Adjustment of Roller Switch S6:

2.3.3.1 Settings for Virtual Roller Switches (Mold Safety Switches)

Fig.: Roller Switches Position

Fig.: Roller Switches Init

Once you finished all settings, press to exit the window.

2.3.3.2 Initialize Roller Switch Monitoring