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be the first.

ERC 23/1-F
Serial No.:

163251

Year of construction:

2007

operator manual - robot

Manufacturer:

ENGEL AUSTRIA GmbH


A-4311 Schwertberg
Tel.:
Fax:

+43.50.620.0
+43.50.620.3609

e-mail: service@engel.at
Version:
Printing date:
Language

www.engel.info

G/11/401/1/11
5.1.2007
Englisch

The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed,
transmitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (12 and 13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
Copyright by ENGEL Austria Ges.m.b.H.

Version: G/11/401/1/11

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1
1.1
2
2.1
3
3.1
3.2

USE AS DIRECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
APPLIED STANDARDS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TEXT FORMATTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIVISION OF SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL AUTOMATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ERC 2X OVERVIEWW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ROTARY AXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1
2
3
4
4.1
4.2
4.3
5
5.1

ACCIDENT PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SURVEY SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION OF THE SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP BUTTONS FOR CELL SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY GATES INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROBOT SAFETY GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEHAVIOUR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USE AN ABC CLASS FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16
18
22
23
23
24
26
29
29

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1
1.1
1.2
2
2.1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
3
3.1
3.2
3.3
3.4
4
5
6
6.1
6.2
6.3
6.4
6.5
6.6
7
7.1
7.2
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.2
9
10
10.1
10.2
11
11.1
11.2
11.3
11.4

CONTROL PANEL MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


CONTROL SYSTEM CC200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL SYSTEM EC 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAND TERMINAL ROBOT KETOP C30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAND TERMINAL FUNCTION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAND TERMINAL FUNCTION KEYS KETOP C30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY OF THE HAND TERMINAL KETOP C30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPLAY AND NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WAITING MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEACH PREVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXIS ACTUAL VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAND CONTROL DEVICE KETOP C100E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOIL KEYS ON THE KETOP C100E HAND CONTROL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN KEYS ON THE KETOP C100E HAND CONTROL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAND TERMINAL FUNCTION KEYS KETOP C100E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCHING ON THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOP LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN PAGE SELECTION AND FUNCTION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUAL AXIS VALUE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAM KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INPUT KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USER ACCESSS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USER ACCESS CARD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASSWORD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP SCREEN PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USER ADMINISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CREATING NEW USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING USER ACCESS AUTHORIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DELETING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAVING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HELP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DELETING AND ACKNOWLEDGEMENT OF ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERACTIVE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DATA DIALOGUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STORAGE MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
READ DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WRITE A PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COPY PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

operator manual - robot

31
31
33
34
35
35
37
41
41
42
42
42
43
43
43
45
46
47
50
51
55
55
56
56
56
57
57
57
58
60
60
60
61
62
62
63
64
64
65
66
67
68
69
70
71
72
73
73

4
11.5
12

Version: G/11/401/1/11
DELETE DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

BASIC ROBOT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79


1
1.1
1.2
1.3
2
3
3.1
3.2
3.3

QUICK SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ROBOT GENERAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
QUICK SETTING OF ROBOT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ROBOT STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ROBOT PROGRAM SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
POWERING UP THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SERVO AXES REFERENCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
NORMAL POSITION (BRING ROBOT IN NORMAL POSITION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
MOUNT TAKEOVER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

ROBOT WORK AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107


1
1.1
1.2
1.3
1.4
1.5

WORK AREA SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107


SETTINGS ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SETTINGS WORK AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3D VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
WORK AREAS AND PROHIBITED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

TAKE-OFF-DEPOSITING VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119


1
1.1
2
2.1
2.2
2.3
2.4
2.5
3

ENGEL - TAKE-OFF VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119


TAKE-OFF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ENGEL DEPOSITING VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
PART DEPOSITING IN SHOT GRID WITH CONVEYOR-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
REJECT DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
QUALITY CONTROL PART DEPOSITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
SPRUE DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INTERMEDIATE LAYERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
SET UP ROBOT ON INJECTION MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

GRAPHIC SEQUENCE EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


1
2
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
4
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.2
4.3
4.4
4.5
4.6
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9

SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
READING OF A ROBOT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
EDITING A ROBOT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
STORING THE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
EXCHANGE VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
PROGRAMMING SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
USING THE TEACH POINTER TO INSERT THE ROBOT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSERT ROBOT POSITION MANUALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSERT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
CREATE TEACH VARIANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
REMOVING VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
DELETE VARIABLES FROM USER-DEFINED SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
SEQUENCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT MOVE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT POSITION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
ROBOT SPECIAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ROBOT FUNCTION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
PERIPHERAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
SEQUENCE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
STRUCTURE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
TEACH POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
EXECUTE AS LONG AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
REPEAT UNTIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
IF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PARALLEL OPEN BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
PARALLEL CLOSED BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAITING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAIT FOR TIME OR MARKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAIT UNTIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Version: G/11/401/1/11
4.7.10
COMMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.11
ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.12
JUMP TO SEQUENCE END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.13
ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.14
DELETE ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.15
SET POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.16
COPY ACTUAL POSITION TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.17
INCREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.18
DECREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.19
CHECK WHETHER INTERMEDIATE LAYER POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
CONDITION EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
DIALOG WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

184
184
185
186
186
186
186
186
186
186
187
187

GRID EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195


1
1.1
1.1.1
1.2
1.2.1
1.3
1.3.1
1.3.2
1.3.3

GRID TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOT GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDIVIDUAL PART GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TACH GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONFIGURE TEACH GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196
196
196
201
202
208
208
210
214

SCREEN PAGE EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217


1
2
3
4
5
6
7
8
9

COMPONENTS OF SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDIT SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASTE OF EXISTING STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASTE NEW STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASTE VARIABLES FROM OTHER SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASTE VARIABLES FROM A LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASTE A COMMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOVING VARIABLES AND STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218
219
219
219
220
221
221
222
222

OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1
2
3
4
5
6
7
8
9
10

USER PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAKE-OFF STROKE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOLD SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EJECTOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOFTSERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITION COMPENSATION FOR TIEBAR-LESS MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRUE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMEDIATE DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEIGH SCALE INTERMEDIATE DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225
225
225
226
226
227
228
231
234
236

SPECIAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

operator manual - robot

Version: G/11/401/1/11

Version: G/11/401/1/11

GENERAL
You have decided on an ENGEL product which is produced and supplied under the most strict
quality controls.
The instruction manual must be considered as part of the robot and is destined for those
persons who are charged with activities on the plant. The instruction must be kept during the
life of the product and must be passed on to each following owner or user. Each obtained
addition must be integrated into the instruction manual.
The documentation for the robot comprises 3 manuals:
Operator manual (Operation)
Instruction manual (Start-up, maintenance, spare parts)
Technical manual (Elimination of faults)
The instruction manual is available in the following forms:

in paper form (without Technical manual). One electric schematic is in the control
cabinet.

as online help on the control unit (without spare parts and schematics)

on CD in PDF format

ENGEL reserves the right to update the documentation.

WARNING!
Do not use the robot without corresponding training.
Improper use of the cell can lead to personnel injury and equipment
damage.
Before the cell is put into operation read through the Safety section to
become familiar with the safety equipment.
Participation at an ENGEL training center is highly recommended.
The main aim of this manual is to provide a concise overview of the robot operation and to help
eliminate production malfunctions as quickly as possible.
An alarm list can be found in the index directory under *Symbols.

operator manual - robot

Version: G/11/401/1/11

USE AS DIRECTED
ENGEL products are constructed using the latest technological developments and the
accepted safety standards.
The robot for this cell is designed exclusively to handle injection molded parts, including takeoff from the mold and part placement into the mold.
Installation, operation, service and maintenance on ENGEL products is authorized only to
personnel trained at ENGEL.
ENGEL is not liable for any damage resulting from improper use and failure to follow the
information outlined in the standard manuals.
If any modifications are made to the machine by the customer, EC conformity is invalid and the
machine must not be put into operation!

1.1

APPLIED STANDARDS AND GUIDELINES

98/37 EWG

Machine guidelines

73/23/EWG
93/68 EWG

Low voltage guidelines

89/336/EWG
92/31 EWG
93/68 EWG

EMV guideline electromagnetic compatibility

EN 12100-1

Machine safety

EN 12100-2

Machine safety

EN 294

Machine safety, safety distances

EN 201

Safety information for injection molding machines

EN 418

Machine safety, EMERGENCY STOP equipment

EN 60204-1

Machine safety, machine electric equipment

EN 61310-1

Machine safety, mark and operate displays

EN 61310-2

Machine safety, mark and operate displays

EN 775

Industrial robot safety

Version: G/11/401/1/11

TEXT FORMATTINGS
DANGER!
Information provided with this symbol points out immediate dangers,
which can lead to death or serious physical injuries!

WARNING!
Information provided with this symbol warns of possible dangers, which
can lead to death or serious physical injuries!

CAUTION!
Information provided with this heading warns of possible dangers,
which can lead to equipment damage!
Note!
Information provided with this symbol offers application tips and useful information.

Example:
Information provided with this symbol offers practical examples.
Bullet sign (emphasis

Bullet (emphasis).

The operator does not have to adhere to fixed operational sequence or order.

Numbered sequence
1.

Fixes procedure way after the numbers

2.

The operator must adhere absolute to the fixed operational sequence.

3.
Reference to a text at the screen or control panel.
Alarms and Messages are listed throughout the manual in a table, which contains the alarm
class symbol, a description, cause and effect, and troubleshooting information.

operator manual - robot

10

Version: G/11/401/1/11
Sample for error message:

Text of the error message


Reason
impact
removal
In the manuals an alarm list is mentioned in the index directory under Symbols*.

2.1

DIVISION OF SCREEN PAGES


The individual screen pages may vary in length depending on machine configuration. Some
screen pages may have a scroll function. The screen pages are divided into blocks for
functional description.
Screen pages

CAUTION!
The parameters in the illustrations are purely inccidental and should not
be used as a guide for machine set up.

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GENERAL AUTOMATION INFORMATION


Robots are used for part take-off and deposit from the Injection Molding Machine. In the
standard program the Injection Molding Machine and robot operate through a common control
unit and operations occur via the same screen.

Integrated control system


ENGEL robot and ENGEL injection molding machine

Standalone control
ENGEL robot and a non-ENGEL injection molding machine
ENGEL robot in connection with a peripheral unit
ENGEL robot without injection molding machine and peripheral unit

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3.1

Version: G/11/401/1/11

ERC 2X OVERVIEWW

7
8
9
10
5

EUB

[1]

Support mount
For fastening the robot with screws on the stationary mold fixing platen of the injection
molding machine.

[2]

Rotary axes (ABC axes not shown).


Serve to turn and swivel the takeover head.

[3]

Y-axis (Vertical stroke).


Serves in its basic function for moving in and out from the mold area of the injection
molding machine.

[4]

X-axis (Demolding stroke).


Serves the take-off of the parts from the moving or stationary mold fixing platen of the
injection molding machine.

[5]

Support (Option)

[6]

Z-axis (Cross transport).


Serves to move into and move out from the depositing area/take-off area.

[7]

Z-axis motor

[8]

X-axis motor

[9]

Y-axis motor

[10]

Name plate on the robot


Name plate on control cabinet (not shown)
On the inside of the control cabinet there is a name plate, with the electric data of the
robot.

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3.2

ROTARY AXES
The manual axes serve to take off/deposit and/or to manipulate parts (Turning and swivelling).
Here it is distinguished between two types of axes:

Pneumatic axis (Rotary movement occurs via a pneumatic cylinder)

Servomotor axis (Rotary movement occurs via a servomotor)

Pneumatic axes

C Servomotor axes

180

0
above

90

below
B

right

max

middle

180

left
A

90

left

right
middle

max

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SAFETY
Due to the acceleration and force of the robot, always take great care when working in the
robots vicinity.
To protect personnel against potential dangers, robots come equipped with the appropriate
safety equipment.

DANGER!
Safety equipment must not be modified or removed! Before putting the
machine into operation check the safety equipment to ensure it is functioning properly.
[See Function of the safety devices on page 23.]
When a safety equipment defect is detected:
1.

Stop machine operations and switch OFF the motors.

2.

Do not carry out any further activity on the robot.

3.

Immediatly contact in-house personnel responsible for equipment safety.

4.

Resume machine operations only after the functionality of the safety equipment is
guaranteed.

DANGER!
Working and standing below moveable components, floating loads, or
both is strictly forbidden! This applies in all modes of operation, including when the robot is shut down.
Failure to adhere to this warning could result in fatal injuries.
During AUTOMATIC operations do not reach into or enter the robot work
area! When performing work on the Injection Molding Machine, the robot
or inside the guarding enclosure the robot must be moved to a safe
position.

CAUTION!
Caution must be used during machine set-up and operation, as incorrect settings can lead to equipment damage.
Settings must be compatible to the function of the machine, mold, material and peripheral units.

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WARNING!
After a robot collision, every screw in the guide rails, the guide carriage,
the end of arm tooling, and all swiveling axes and torques must be
checked by ENGEL customer service.
ENGEL is not liable in respect to operational errors.
Additional safety hints found throughout this manual must be observed.

WARNING!
Maintenance and repair work on the cell may only be carried out by
trained personnel, who possess comprehensive knowledge of the safety
precautions and operating elements!
The activities and maintenance intervals described in the instruction manual must be
observed.
To ensure personnel and equipment protection all maintenance on the safety devices must
conform to local enforced safety regulations.
Further work on the machine going beyond the described activities may only be carried out by
the ENGEL customer service.

ACCIDENT PREVENTION

Always wear protective clothing when working on the system (safety shoes, protective
gloves, face protector, etc). Observe local safety regulations for the injection molding
machine operations!

Always keep the equipment clean. This contributes considerably to serviceability and
thus to greatest possible safety for the operating personnel.

Do not remove any warning or information signs and markings from the machine or
additional devices!

Observe possible obstacles in the operator work area when stepping through the robot
teach sequence. Ensure the robot does not collide with the downstream equipment or
the Injection Molding Machine!

When working in the vicinity of hot components (barrels, injection molding equipment,
etc.) always wear protective gloves and mask!

Switch off motors during all work carried out in the movement areas of the machine!

The leaning of ladders is not allowed!

Do not turn the control voltage or main voltage OFF during axis movement. This applies
when operating in all modes of operation.

Before turning the pneumatic system OFF, move the robot into the deposit area and
remove any parts from the end of arm tooling. In case pressure is lost, ensure the end
of arm tooling is rotated down to prevent an uncontrolled downward swivel.

Do not exceed the maximum robot payload.

During operation no cleaning and maintenance work may be carried out!

Pay attention to that the control cabinets are always closed. No dust and no humidity
may penetrate.

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Protect all hoses against damage from, for example acids or mechanical abrasion.

Check all pipings for their work-safe state regularly. Switch off the plant immediately
when you detect a leakage, damage or break of a piping.

No access for unauthorized persons on the plant and/or on the robot!

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PICTOGRAPHS
The following section illustrates and describes the safety hazard labels used to address a
potentially dangerous area or situation. Failure to adhere to this safety hazard labels could
result in fatal injuries..

Example:
Engel standard injection molding machine with robot.

At the Y-axis, at the stand or at


the support

At the motors and at the control


cabinet

EE

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Safety hazard labels:

DANGER due to hot surface!

DANGER by electric current!

DANGER of injury to hands!

DANGER by floating loads!

DANGER by wedging / squeezing danger!

DANGER due to pressurized, molten material!

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Signs telling you cant do this:

Admittance for authorized persons only!

Keep off the area!

No admittance for persons with cardiac pacemaker!

Working and standing below moveable components and


floating loads is forbidden! This applies in all modes of
operation, including when the robot is shut down.

At an injection molding machine/safety guarding of a foreign manufacturer this pictograph


must be glued on the presribed points. The pictographs are in the control cabinet.

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Signs giving an instruction:

Read documentation!

Use protection equipment!

Use face shield!

Use lifting point for transport!

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SURVEY SAFETY EQUIPMENT


Example:
Safety equipment on an Engel standard injection molding machine with robot.

EE

12 11

10

[1]

Safety guarding

[2]

Area that can be entered

[3]

EMERGENCY STOP buttons

[4]

Moving/danger area of the robot (work envelope). This is the area the robot, including
the end of arm tooling and molded part can potentially cover.

[5]

Depositing area on conveyor-belt

[6]

Robot

[7]

Injection molding machine

[8]

Injection unit front sliding safety gate

[9]

Stationary mold fixed platen injection molding machine

[10]

Moving mold fixed platen injection molding machine

[11]

Clamping unit front sliding safety gate

[12]

Clamping unit rear sliding safety gate

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FUNCTION OF THE SAFETY DEVICES


Anytime an EMERGENCY STOP button is activated or the safety gate is opened all injection
molding machine and robot movements stop. The respective alarm message is displayed on
the Alarm screen page.

4.1

EMERGENCY STOP BUTTONS FOR CELL SHUTDOWN


Emergency stop buttons are found on the control panel of the injection molding machine and
in the following areas if applicable:

on the rear side of the injection molding machine

on the robot hand-terminal

at the safety guarding access door

mounted inside the safety enclosure

In case of an EMERGENCY STOP actuation the drive motors of the injection molding line and
of the robot are switched off immediately. Message::

EMERGENCY STOP
Reason

An EMERGENCY STOP function is active, e.g. EMERGENCY STOP


button is pressed, rear safety gate is open

impact

The alarm lamp flashes, the current cycle and the motors are stopped
immediately.
All dangerous movements are blocked immediately.
All safety access doors are unlocked.

Robot safety gate <No.> emergency stop unlocking active!


emergency stop acknowledgement required!
Reason

An EMERGENCY STOP function is active.

impact

The alarm lamp flashes, the current cycle and the motors are stopped
immediately.
All dangerous movements are blocked immediately.
All safety access doors are unlocked.
An EMERGENCY STOP acknowledgement is required.

Start-up after an EMERGENCY STOP


1.

Confirm the machine is safe to run and no dangerous situations exists.

2.

Release the EMERGENCY STOP palmbutton by turning it clockwise.

3.

Activate the Program Interruption switch to acknowledge the alarm

4.

Switch on the motors

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Note!
The EMERGENCY STOP function is active in each mode of operation!
When the servomotors are turned OFF the X and Z-axes can be pushed by hand.

4.2

SAFETY GATES INJECTION MOLDING MACHINE


When opening a safety gate, all dangerous movements are blocked and a respective message
appears on the screen.

Clamping unit safety gate x open


Reason

Safety gate has been opened

impact

All machine movements are blocked.

removal

Close the safety gate.

Depending on protection execution the opening of the rear safety gate on the clamping unit
causes an EMERGENCY STOP switch-off or has the same function as the safety gate on the
operator side.

Nozzle safety gate open


Reason

Injection unit safety gate is open

impact

All injection unit movements are blocked and the cycle stops.

removal

Close the injection unit safety gate

Safety distance for tiebarless machine range


When an end of arm tooling, an axis of rotation, or both, are mounted the following items must
be observed:

The end of arm tooling must not consist of sharp-edged and pointed parts

No dangerous movements may be executed with the end of arm tooling (pinching or
shearing points))

The safety distance between the end of arm tooling and the safety device must be
greater than or equal to 120mm (4.72).

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Version: G/11/401/1/11

MM (4,72 in)


Outer contour moving area

BR?

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26

4.3

Version: G/11/401/1/11

ROBOT SAFETY GUARDING


As protection in the danger area a safety guarding is attached on the machine.
At safety guardings with access demand the protection door can only be opened after the key
for access demand has been actuated and the access allowance is granted (Key for access
demand lights).
EMERGENCY STOP button outside
Key with lamp for access demand
EMERGENCY STOP
button inside

Acknowledgement key with key actuation

In automatic mode the operator actuates the key to demand access before opening the safety
guarding door (key flashes). As a result the machine interrupts the cycle after the part has
been taken from the injection mold. In the standard case, the robot stops all movements after
the take-off of the injection molded part (depending on the setting in the sequence editor). The
Access demand keyswitch on the door lights up, indicating that access is allowed and that the
door is unlocked.
On safety guardings without access demands, the protection door can always be opened. As
a result the robot stops all movements immediately.
Before opening the safety guarding door and entering the guarded area, remove the
acknowledgement key and take it with you.

WARNING!
The acknowledgement key must always be with the person who is inside
the safety guarding, in order to prevent any unintentional acknowledgement of the safety guarding and starting of the machine!
The safety guarding may only be acknowledged if all personnel and foreign objects are out of the danger area!
After opening the safety guarding door, all robot movements are blocked.
In set-up mode, up from the access authorization 5, by simultaneous pressing the consent key
and the respective pushbutton on the hand held control unit, the robot movements can be
executed with an open safety guarding door and/or open clamp unit safety gate.

DANGER!
Working below movable components, e.g. the Y-axis, is forbidden!
During robot movements, the work envelope of the robot must not be
entered or reached into!
After leaving the danger area, the operator can acknowledge the safety guarding door with the
key-operated switch, immediately after closing the door. The door is then locked again.

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In automatic mode the next cycle start occurs by actuating the start button on the control panel.
The robot cycle begins with the depositing of parts.

Note!
The safety guarding door is unlocked automatically and can be opened in case of an EMERGENCY STOP.
The protection door can only be acknowledged again when the EMERGENCY STOP condition
has been eliminated.
After switching on the control voltage there must also occur an acknowledgement. As long as
the protection door is not acknowledged, the following message appears:

Open-close-acknowledge robot safety gate <No.>


Robot safety gate <No.> open
impact

All movements are blocked

removal

Open - close safety gate and acknowledge with the key-operated


keyswitch within 5 seconds

The acknowledgement must occur within 5 seconds, but not before 0.05 seconds after closing
the protection door.
The acknowledgement key must not be actuated too long (maximum of 10 seconds) either. If
these conditions are not fulfilled, the corresponding message is displayed:

Robot safety gate <No.>: Acknowledgement key not actuated


too long
Reason

Protection door has not been acknowledged within 5 seconds

impact

Safety guarding door is not acknowledged

removal

Protection door must be opened/closed/acknowledged again

Robot safety gate <No.>: Acknowledgement key actuated too


long
Reason

Acknowledgement key has been actuated longer than 10 seconds

impact

Safety guarding door is not acknowledged

removal

Protection door must be opened/closed/acknowledged again

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Version: G/11/401/1/11

Robot safety gate <No.>: Acknowledgement key actuated too


fast
Reason

Message appears when between closing and acknowledgement of


the protection door less than 0.05 seconds pass. The acknowledgement key has possibly been actuated before the closing of the protection door.

impact

Safety guarding door is not acknowledged

removal

Protection door must be opened/closed/acknowledged again

Lateral take-off with open safety gate


For the lateral take-off of the injection molded part with a robot on injection molding machines
the rear safety gate must remain open. For monitoring the open position a limit switch is
provided.
When the lateral take-off is switched on at the robot, the safety gate must be completely open.
If this is not the case, the following message is displayed:

Clamping unit safety gate 2 not entirely open


impact

A moving of the robot is not possbile. The sequence cannot be run.


The robot motors switch off.

removal

The clamping unit safety gate 2 must be opened completely.

Safety guarding for robot plug-in


At the injection molding machine for the operation without robot the rear safety gate is
executed plug-in. When at robot operation the safety guarding for the robot is not connected,
appears the alarm:

Robot safety gate not connected


Reason

Instead of the safety gate of the robot the rear safety gate of the injection molding machine is connected.

impact

Motors switch off and/or cannot be switched on

removal

Connect safety gate for robot

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5.1

BEHAVIOUR IN CASE OF FIRE


1.

Stay calm

2.

Alert the Fire Department

3.

If possible, switch off the machines main breaker)

4.

Alert all personnel in the immediate area

5.

If possible, close all fire doors

6.

Switch of any venting and/or air conditioning units

7.

As soon as possible, contain the fire with an approved fire extinguisher

8.

Provide assistance and direction to anyone actively involved in fighting the fire

USE AN ABC CLASS FIRE EXTINGUISHER

An ABC Class fire extinguisher is recommended due to its versatility and advantages
over other fire fighting equipment.

Be familiar with the instruction label attached to the fire extinguisher.

Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.

DANGER!
If you use an ABC Class fire extinguisher on an ENGEL molding
machine, keep back a minimum of one meter from the electrical panel
and/or the motor.
The use of water, D powder class or foam is forbidden.
Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:

Contact the nearest ENGEL representative, or

Contact the nearest ENGEL manufacturing plant

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Version: G/11/401/1/11

OPERATION
1

CONTROL PANEL MACHINE


Because the robot and injection molding machine are fully integrated it provides a convenient
platform for operating both components. The common platform for the machine and the robot
offers the same operating elements and sequences, for both.

1.1

CONTROL SYSTEM CC200


Execution with touch-sensitive keys and pushbuttons
Color touch screen

User access authorization card slot


Compact Flash memory card slot
USB interface

Touch keys for manual control of the individual


machine movements.
Touch keys for the robot motor, referencing
and homing

Machine motor and heating switch


Emergency stop button
Control voltage switch
Key-operated safety keyswitch
Program interruption switch
start key

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Execution with pushbuttons


Color touch screen

User access authorization card slot


Compact Flash memory card slot
USB interface

Switch panel for the manual control of the individual machine movements.
Touch keys for the robot motor, referencing
and homing

Switch Motor
Switch cylinder heaters
Switch Mold heating
Emergency stop button
Control voltage switch
Key-operated safety keyswitch
Program interruption switch
start key

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Version: G/11/401/1/11

1.2

CONTROL SYSTEM EC 200

Color touch screen

Switch panel for the manual control of the individual machine movements.

Switch Machine motor


Switch cylinder heaters
Switch Mold heating
Emergency stop button
Control voltage switch
Key-operated safety keyswitch
Program interruption switch
start key
USB interface

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HAND TERMINAL ROBOT KETOP C30E


The standard hand terminal (HT), connected to the control unit by a cable, allows all functions
and axes movements to be executed manually.
In addition, the integrated display offers a multitude of information for robot set-up.
EMERGENCY
STOP button

Display

Second function key


Error acknowlegement and
Pages scroll

Override keys

Motor switch
Homel position
and Referencing

Take over teach and


special teach
instructions

Acknowledge step
and test mode on/
off

Scroll keys

Linear axis keys

Rotary axes keys

Function keys

NOTICE!
The hand control device is equipped with highly sensitive electronics.
Handling tips

Ensure no one can trip over the cable to avoid personnel injury and mechanical
damage.

Place the hand terminal into the designated fixture when it is not being used.

The function of the safety-relevant parts, such as the EMERGENCY STOP and the
Consent switches must be checked periodically to ensure they are functioning correctly.

Never place the control device near a heat source.

Do not expose the device to any mechanical vibrations, excessive dust, humidity or
strong magnetic fields.

To clean the control device use a soft cloth, slightly moistened with water or a mild
cleaning material. Do not use any type of solvent.

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2.1

HAND TERMINAL FUNCTION KEYS


The hand control device has 32 function keys; two functions can be assigned to each key.
The assignment of the keys is preset; however, they can be changed in the Setup Editor.
LED status
1. Function level (Pushbuttons 0 to 31)

2. Function level (Pushbuttons 32 to 63)


You can press the 2nd key to toggle between the two function levels.

Test mode button on


manual mode device

Each function key has a green status LED which indicates the various states of the function in
question. Note that the LED only refers to the active function level.
LED status signals

2.1.1

Solid
Function is executed or key is actuated.

Slow flashing
Indicates that the key should be actuated.

Quick flashing
An alarm was generated during the execution of the function or axis movement.

SAFETY CONTROLS
EMERGENCY STOP button

When the EMERGENCY STOP button is activated the power of the entire system, including
the robot and machine is immediately turned OFF. The control unit remains ON. To reset the
EMERGENY STOP button turn it clockwise.

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Consent keys:

EMERGENCY STOP button


Consent key
(on both sides)

The back of the hand terminal has two consent keys on the left and right-hand sides. The keys
are activated in three stages. To activate the keys ensure both are pressed into the midposition. When the keys are completely pressed in an emergency stop is triggered.

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2.1.2

HAND TERMINAL FUNCTION KEYS KETOP C30E

Key symbol

Key explanation

Motor switch
Switch servomotors on and/or off.
Slow flashing of the LED signals that the motors are ready for switching on. A
quick flashing indicates existing errors which block the switching-on.
Error acknowledgement
Erasure of the displayed error messages. The display display changes to the error
page automatically.
The LED flashes when errors exist.
2nd function
The Second key switches over between the two function levels. The LED lights
when the functions of the second (lower) level can be selected. By pressing a key
(or the 2nd key) it is switched back in the first level automatically.
Increase override
Increases the current speeds of the servoaxes in the automatic mode by a factor
in percent.
The automatic speeds set on the screen pages are valid as maximum (100%).

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38

Key symbol

Version: G/11/401/1/11

Key explanation
Movement to Home position
Starts the normal position run in the manual and/or set-up mode. The key must
remain pressed until reaching the normal position, otherwise the sequence stops.
The LED flashes when the normal position run is possible (Motor switch switched
on, axes referenced).
Step acknowledgement
Serves the stepwise passing of the instructions in the sequence. With switched-on
test mode the consent and step acknowledgement key must be pressed at the
same time in order to process the instructions.
Take over Teach instruction

Decrease override
Reduces the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
Suction/Gripper 1
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll vertically
For information which cannot be represented on the display at once it is possible
to scroll vertically. The function is generally built up as ring. This means, from the
end it is jumped to the beginning of the page again. It is always scrolled page by
page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
Move X-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move X-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Suction/Gripper 2
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll horizontally
For information which cannot be represented once on the display it is possible to
scroll horizontally. The function is generally constructed as ring. This means, from
the end it is always jumped to the beginning of the page. It is always scrolled page
by page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.

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Key symbol

Key explanation
Move Y-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move Y-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Swivel C axis downwards [+]


The movement can only be carried out in the manual and/or set-up mode.

Swivel C axis upwards [-]


The movement can only be carried out in the manual and/or set-up mode.

Conveyor-belt
Steps the conveyor-belt in the manual and/or set-up mode.

Quick position
The robot axes approach the set Quick position directly. The key must remain
pressed, otherwise the movements are stopped.
Move Z-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move Z-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Changing the display page


The display in the display changes from the current page into the next one. After
reaching the last page, the display jumps back to the first page.
Referencing
The referencing sequence of the servoaxes starts. During referencing the key
must be pressed permanently, otherwise the process stops.
The LED flashes when the referencing process is possible (motor switch switched
on) and lights while the referencing is running. The LED goes out when all axes
are referenced.
test mode
Switching-on and/or -off of the test mode.

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40

Key symbol

Version: G/11/401/1/11

Key explanation
Select Teach special instructions

Switch off axis


Switching-on and/or -off of the demolding axis (X- or Z-axis) for the manual displacement of the axis.
Quality part demand
With activated quality part program the deposit of a quality part is requested.

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Version: G/11/401/1/11

2.2

DISPLAY OF THE HAND TERMINAL KETOP C30E


The following information is displayed on the hand control unit display:

2.2.1

Alarm messages

Waiting messages

Teach preview

Axis actual values

Status page

Quick position

DISPLAY AND NAVIGATION


1
Injection active

2
3

2.6
4

[1]

Display information

[2]

Alarm warning
The ! symbol appears when an alarm is generated.

[3]

Vertical scroll bar

[4]

Page information (e.g.: Page 2 of 6)

[5]

Horizontal scroll bar

Navigation
Changing the display page

+
By activating the above keys from the hand terminal, operators are able to move from the
current page to the next. When these keys are pressed from the last screen page the display
jumps back to the first page.
Scrolling
Scroll Vertically

Scroll Horizontally
For information that cannot be displayed simultaneously on the display, you can scroll the
display vertically or horizontally. The function is generally set up as a ring. Thus, jumping to the
start of the page when the end of the page is reached. Scrolling occurs page by page, whereby

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the content is modified to reflect the available space.
The two orientation bars show whether or not scrolling is possible and gage the location of the
present display.

2.2.2

ALARM MESSAGES
The Alarm Screen displays all pending alarms. These alarms are displayed in a list format,
each line containing one alarm message. When no alarm exists, the message No error!
appears on the display.

No error!

1.6

With the exception of the alarm page an exclamation mark ! in the right, upper corner of the
display indicates an alarm at all other pages. By actuating the alarm acknowledgement key the
alarm page is opened automatically and it is tried to acknowledge the alarm.

2.2.3

WAITING MESSAGES
The Waiting Message Screen displays pending wait messages. The messages are displayed
in a list format, each line containing one wait message. When no wait message exists, the
message No waiting message! appears on the display.

Injection active
Wait for injection unit

unit finished

2.6

2.6

Scroll horizontally to read


longer texts.

2.2.4

TEACH PREVIEW
After you have inserted the Teach pointer in the robot sequence, sequence teaching is
enabled. The action performed during teaching is shown on the display and can be transferred
to the sequence.

Robot movement

3.6

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2.2.5

AXIS ACTUAL VALUES


The Actual Axes Value Screen displays the current position of the robot.

X
Y
Z
C1

551,2 mm
360,0 mm
850,5 mm
Above
4.6

These values are consistently updated and only the current position of the robot axes (in a
referenced state) are displayed).

2.2.6

STATUS PAGE
The following information is available via the Status Screen page:

Robot 1 active
Testmode active
Referenced
Mode of operaSpeed

2.2.7

Auto
100%
5.6

Program switch Robot 1 active


Switch robot on or off [See Robot program switches on page 97.]

Testmode active
Switch test mode on or off [See Robot status on page 95.]

Mode of operation
Displays the current mode of operation.

Speed
Display of the preset override speed in %. Pressing the override buttons automatically
opens the status screen on the hand control device.

QUICK POSITION
The quick position page shows the axis position set values of the robot, which are approached
when executing this function.

NOTICE!
The set position is approached directly, therefore be aware of any potential collisions in the work envelope. The set work blocks and prohibited
areas remain valid during the procedure.

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X
Y
Z
C1

330,0 mm
510,0 mm
100,5 mm
Above
6.6

Quick Position key

Press the quick position button to go directly to the position displayed in manual or setup
operations.

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HAND CONTROL DEVICE KETOP C100E


The hand control device (HCD) is a portable operating and display device with an 8.0 touch
screen and the following functions:

Setting and displaying parameters for the injection molding machine and robot.

Robot operations.

Sequence teach and programming function.

EMERGENCY
STOP button
8.0 color touch
screen

Touch-sensitive
keys

Status LEDs

Function

Power

Lit when the connection to the control unit is active.

Motor

Lit when the robot motors are switched on.

RC2

Lit after switching to robot 2 with the toggle robotbutton.

NOTICE!
The hand control device is equipped with highly sensitive electronics.
Handling tips

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3.1

Ensure no one can trip over the cable to avoid personnel injury and mechanical
damage.

Place the hand terminal into the designated fixture when it is not being used.

It is important to check the proper function of safety features such as the EMERGENCY
STOP button and consent key periodically.

Never place the control device near a heat source.

Do not expose the device to any mechanical vibrations, excessive dust, humidity or
strong magnetic fields.

To clean the control device use a soft cloth, slightly moistened with water or a mild
cleaning material. Do not use any type of solvent.

SAFETY CONTROLS
EMERGENCY STOP button

When the EMERGENCY STOP button is activated the power of the entire system, including
the robot and machine is immediately turned OFF. The control unit remains ON. To reset the
EMERGENY STOP button turn it clockwise.
Consent keys

EMERGENCY STOP
button
Consent key
(on both sides)

The hand control device has two consent keys located at both sides of the device. To consent,
you only need to press one of the buttons.
There are three possible positions for the consent key. Press lightly (in the center) to consent.
Do not press, or press down hard (in situations of panic) to enable the Off function.

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3.2

Switch position

Function

Switch contact

Not pressed

Zero position

Off (open)

Pressed

Consent

On (closed)

Panic

Pressed hard

Off (open)

FOIL KEYS ON THE KETOP C100E HAND CONTROL DEVICE


The hand control device has 34 function keys which are implemented as foil keys. You can
select other function keys directly via the screen. You can modify the default key mappings in
the Hand control device Editor or robot setup.
The functions of the green foil keys can always be used for the active robot. The remaining
keys have generic functions and apply to both robots.

Symbol

Key description

Function description

Motor switch

Switch servomotors on and/or off.


A slowly flashing LED indicates that the
motors are ready to be switched on. Fast
flashing indicates an error preventing switching on.

Error acknowledgement

Deleting the error messages displayed. The


display automatically switches to the Alarm
screen.

Movement to Home
position

Starts the normal position run in the manual


and/or set-up mode. The key must remain
pressed until reaching the normal position,
otherwise the sequence stops.
Homing is possible if the motors are switched
on and the axes are referenced.

Referencing

The referencing sequence of the servoaxes


starts. During referencing the key must be
pressed permanently, otherwise the process
stops.

Step acknowledgement

Serves the stepwise passing of the instructions in the sequence. With switched-on test
mode the consent and step acknowledgement key must be pressed at the same time
in order to process the instructions.

test mode

Switching-on and/or -off of the test mode.

Take over Teach


instruction

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Symbol

Key description

Function description

Select Teach special


instructions

Press the button to open a dialog with special


Teach instructions in the sequence editor and
on the hand control device display.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

Freely configurable
keys

The key function is configured to reflect the


requirements for the current machine.

C100 Dialog

Toggles between the standard screens and


the screen for preselecting the function keys.

Start action

Execute the action for the selected function


key on screen.

Toggle robot

Toggles between robot 1 and robot 2 function


keys. The RC2 LED is lit when you toggle to
robot 2.
The functions of the green foil keys can
always be used for the active robot. The
remaining keys have generic functions and
apply to both robots.

Move X axis in [+]


and [-] direction

Movement only possible in manual or setup


mode.

Move Y axis in [+]


and [-] direction

Movement only possible in manual or setup


mode.

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Symbol

B
C

Key description

Function description

Move Z axis in [+]


and [-] direction

Movement only possible in manual or setup


mode.

Rotate A axis right [+]


and left [-]

Movement only possible in manual or setup


mode.

Rotate B axis right [+]


and left [-]

Movement only possible in manual or setup


mode.

Swivel C axis down


[+] and up [-]

Movement only possible in manual or setup


mode.

Freely configurable
keys

The key functions are configured to reflect


the requirements for the current machine.
e.g. for an additional servoaxis.

Quick position

The robot axes approach the set Quick position directly. The key must remain pressed,
otherwise the movements are stopped.

Decrease override

Reduces the current speeds of the servoaxes


in the automatic mode by a factor in percent.
The automatic speeds set on the screen
pages are valid as maximum (100%).

Increase override

Increases the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen
pages are valid as maximum (100%).

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3.3

Version: G/11/401/1/11

SCREEN KEYS ON THE KETOP C100E HAND CONTROL DEVICE


Screen function keys for machine control are also configured on the hand control device.
Press the C100 Dialog foil key to display the keys on screen.
C100 Dialog key on
manual mode device

Actual position
[-]
Robot

Peripheral unit

Note!
Depending on the number of keys, this screen can contain several tabs.
Before you can execute a movement, e.g. move barrel out, first select the key for this
movement on screen. This does not perform an action. The movement occurs when you press
the Execute foil key.
Execute key on
manual mode device

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3.4

HAND TERMINAL FUNCTION KEYS KETOP C100E

Key symbol

Key explanation

Motor switch
Switch servomotors on and/or off.
Slow flashing of the LED signals that the motors are ready for switching on. A
quick flashing indicates existing errors which block the switching-on.
Error acknowledgement
Erasure of the displayed error messages. The display display changes to the error
page automatically.
The LED flashes when errors exist.
2nd function
The Second key switches over between the two function levels. The LED lights
when the functions of the second (lower) level can be selected. By pressing a key
(or the 2nd key) it is switched back in the first level automatically.
Increase override
Increases the current speeds of the servoaxes in the automatic mode by a factor
in percent.
The automatic speeds set on the screen pages are valid as maximum (100%).

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Key symbol

Version: G/11/401/1/11

Key explanation
Movement to Home position
Starts the normal position run in the manual and/or set-up mode. The key must
remain pressed until reaching the normal position, otherwise the sequence stops.
The LED flashes when the normal position run is possible (Motor switch switched
on, axes referenced).
Step acknowledgement
Serves the stepwise passing of the instructions in the sequence. With switched-on
test mode the consent and step acknowledgement key must be pressed at the
same time in order to process the instructions.
Take over Teach instruction

Decrease override
Reduces the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
Suction/Gripper 1
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll vertically
For information which cannot be represented on the display at once it is possible
to scroll vertically. The function is generally built up as ring. This means, from the
end it is jumped to the beginning of the page again. It is always scrolled page by
page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
Move X-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move X-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Suction/Gripper 2
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll horizontally
For information which cannot be represented once on the display it is possible to
scroll horizontally. The function is generally constructed as ring. This means, from
the end it is always jumped to the beginning of the page. It is always scrolled page
by page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.

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Key symbol

Key explanation
Move Y-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move Y-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Swivel C axis downwards [+]


The movement can only be carried out in the manual and/or set-up mode.

Swivel C axis upwards [-]


The movement can only be carried out in the manual and/or set-up mode.

Conveyor-belt
Steps the conveyor-belt in the manual and/or set-up mode.

Quick position
The robot axes approach the set Quick position directly. The key must remain
pressed, otherwise the movements are stopped.
Move Z-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.

Move Z-axis in [-] direction


The movement can only be carried out in the manual and/or set-up mode.

Changing the display page


The display in the display changes from the current page into the next one. After
reaching the last page, the display jumps back to the first page.
Referencing
The referencing sequence of the servoaxes starts. During referencing the key
must be pressed permanently, otherwise the process stops.
The LED flashes when the referencing process is possible (motor switch switched
on) and lights while the referencing is running. The LED goes out when all axes
are referenced.
test mode
Switching-on and/or -off of the test mode.

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Key symbol

Version: G/11/401/1/11

Key explanation
Select Teach special instructions

Switch off axis


Switching-on and/or -off of the demolding axis (X- or Z-axis) for the manual displacement of the axis.
Quality part demand
With activated quality part program the deposit of a quality part is requested.

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USB INTERFACE
The function of the following USB devices is tested and guaranteed by Engel.

Device

Manufacturer

Type

Mouse

Microsoft

Keyboard

Tronix

floppy drive

Mitsumi

D353GUE

Memory stick

Buffalo

RUF-C256M/U2

Memory stick

SanDisk

Cruzer Mini USB 2.0 256 MB

Printer

----->

See Chapter Print

Note!
When using other manufacturers USB devices, possibe problems can arise.

SWITCHING ON THE SYSTEM


WARNING!
Due to pressure build-up, uncontrolled pneumatic cylinder movement
may occur when the air supply is activated; therefore, ensure no personnel are inside the work envelope!
1.

Switch on the control voltage

2.

After the start-up of the control unit check the protection equipment
Check to ensure no personnel are inside the safety guarding enclosure
Open - close - acknowledge the safety guarding access door

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SCREEN STRUCTURE
The clearly constructed Touch Screen of the control system provides operators with a simple
and quick outlet to setup and program the robot.

6.1

TOP LINE
General settings
1

6.2

[1]

Machine number

[2]

Page title

[3]

User name

[4]

User accesss authorization

[5]

Date/time

SCREEN PAGE SELECTION AND FUNCTION KEYS


For user-friendly operation, the following screen page selections and function keys are
available:
Quick Setup, General settings, Status
page, ...
Robot program switches, ...
Take-off
Depositing, Grid
Reject deposit
Quality Control part depositing
Sprue separation
Sprue deposit
Intermediate layers, Previous entry, ...
Grid editor, work area setup, robot
setup, ...
Integrated robot interface
Screen Switchover between robot
and machine

Back to a previous selection


Cycle time analysis, Weekly time
switch
Mold parameters, notepad
Data dialog
Print
Mask editor
Sequence editor
Setup
Help
Alarm page
Scroll keys (faded if not required)

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6.3

ACTUAL AXIS VALUE DISPLAY


Every robot screen shows a display box with the current values for the axes and the set
override speed.
Actual position

The positions of the servoaxes are displayed in millimetres [mm] and/or in degrees [gd].
For the pneumatic rotary axes and swivelling axes the actual status (e.g.: A [ - ], A [ + ]) is
displayed. During axis movement or if no final position is reached, the following onscreen
fields will appear [ - ] start, [ 0 ] start, [ + ] start.
The set override speed is displayed as a percentage and as a bar graph.

6.4

STATUS DISPLAY
The first line displays current messages, warnings and errors generated during operation. The
numeric figure, to the right of the message, indicates the total number of existing messages.
All messages can be viewed on the Error Message Screen page.
The second line displays the active operating states (symbol in color) or inactive states
(symbol in gray).
1
Program interruption key
2

6.5

[1]

Line for messages and alarms

[2]

IMM motor status symbol

[3]

ERC motor status symbol

[4]

Heating

[5]

Data set status symbol

[6]

New message has arrived (see text pages)

[7]

Printer

[8]

Network access

PROGRAM KEYS

Setup

Teach or
Manual

SemiAutomatic

FullyAutomatic

Displays the current mode of operation, which is highlighted in color.

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6.6

Version: G/11/401/1/11

INPUT KEYBOARD
After inserting the authorization card, the corresponding parameters can be selected. The
following input dialogue appears once a parameter field is selected:
Set value

Input field (current value)


Display of possible input values (plausibility)
Previous value entered

intermediate deposit

Cancel key
Increment key (increase value)
Decrement key (reduce value)
Copy key, copies the value from the previous entry to the
input field
Enter key
interruption

Help button for the selected parameter

Press the enter key to store the value in the input field, assuming the value lies within the
possible minimum/maximum values.

Mold number

A virtual keyboard is displayed when parameters are selected that require alphanumeric input.
Special keys
Select all text
Select this key and use the arrow keys to drag the cursor across the required text
Copy the selected text
Insert the copied text

Parameter input process


1.

Insert the magnetic card with the required access authorization level.

2.

Select the corresponding screen page using the screen page selection keys.

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Version: G/11/401/1/11
3.

Choose the set value to be changed.

4.

Type in the value with the numerical keyboard; the value appears in the input field.

5.

Press the cancel key to erase typing errors and re-enter the input.

6.

To store the value press the enter key.


If the entered value is too high or too low, the plausibility display changes color to yellow/
red, as shown below. The control unit will not accept the value.

7.

To copy an existing value:


Select the next set value.
Press the copy key in the input dialogue (takes over the previously typed value from
the previous entry).
Press the enter key to store the value.

Switching programs and functions ON-OFF


When selecting a check box the following input field appears:
Robot main switch

Preview
Switch positon ON

When the enter key is pressed the controller takes over the switch position shown in the
preview.
Selection window (Example: Vacuum/compressed air)
For some settings, a drop-down menu containing different selections is available.

Vacuum
Vacuum
Compressed air
barrel

Dialog window (example: Write data)


For menu functions that require additional inputs there are separate interactive dialogue
windows. The dialogue windows are dependent on the menu function in terms of content, but
the structure is standardized.
Title

Write active parts data on


Available drives
Name
Description

Standard

Contents

Includes standard parts data

Free memory
Process is running, please wait...
Cancel

Help

Write

Interactive messages
Instruction keys

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USER ACCESSS AUTHORIZATION


To change parameters and settings on the machine, technicians must first login with the
appropriate user access authorization. For each available user access authorization an user
name, user level, language preference and unit of measurement is assigned. The higher the
user level the more parameters and settings can be changed.
The control unit records each parameter change with the date, time and user.
Separate user names can be created and administrated.

7.1

USER ACCESS CARD LOGIN


(CC200; RC200 integrated)
The user data are stored on the user access authorization card.

To login with a user access card:


1.

Insert the User access card (writing facing out) into the designated card slot.

2.

Login is successful once the user name and number appear in the top-right corner of the
screen.

Logout
To log out remove the card from the slot.

7.2

PASSWORD LOGIN
(Default for EC200 and RC200 stand-alone; optional for CC200)
To login from the machine using a password:
1.

Access the Setup screen page.


User login
User

Password

Logout

Logout

2.

Select the user from the User drop-down menu.

3.

Enter the correct password in the Password field.

4.

Login is successful once the user name and number appear in the top-right corner of the
screen.

Logout
For logout press the Logout key from the Setup screen page.

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SETUP SCREEN PAGE


On this screen the basic settings for the control unit such as language, date, and time can be
setup
Setup
Settings
Language

German

Date/time

01.05.2005 15:42:15

Unit
ISO

Imperial

Absolute

Relative

User Login
9

User
Password

Logout

Logout

User

Display

System

Lock

Report

Screens

Settings
Through the Settings screen section the language, date, time and unit of measurement can be
changed.

Language
Several different languages are stored in the control unit. Select the required language
from the drop-down menu. Once selected, a status bar appears onscreen to display the
progress of the language switchover.

Date/time
Select this field to open the window displayed below. In this window the time and date
can be changed by pressing the -/+ keys.

Day: 25

Month 6

Year 2005

Hour: 11

Minute 0

Second: 5

Units
To change the units displayed onscreen select one of the options displayed here.
ISO
Displays units in Metric

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Imperial
Displays units in Imperial
Absolute
Displays absolute values
Relative
Displays relative values (percent))
Simple conversion examples

Category

Unit ISO

Unit Imperial

Conversion factors

Stroke

100 mm

3,94 in

100 mm x 0.0394 = 3.94 in

Temperature absol.

100 C

212 F

100 C x 1.8 + 32 = 212 F

Pressure

100 bar

1450.3 psi

100 bar x 14.503 = 1450.3 psi

Weight

100 g

3.53 oz

100 g x 0.0353 = 3.53 oz

Weight

100 kg

220.5 lb

100 kg x 2.205 = 220.5 lb

Force

100 kN

11.24 tf

100 kN x 0.1124 = 11.24 tf

Volume

100 cm

6.10 in

100 cm x 0.061 = 6.10 in

Volume

100 l

58.1 gal

100 l x 0.581 = 58.1 gal

Torque

100 Nm

73.756 lbf ft

100 Nm x 0.7375 = 73.75 lbf ft

User login
To login enter the correct user and password

8.1

USER ADMINISTRATION
Engel supplies the machine with predefined user access authorizations. It is possible to create
additional user access authorizations and to change existing ones.
For creating and changing user access authorizations an user access with administrator rights
is required.

8.1.1

CREATING NEW USER ACCESS AUTHORIZATION


Only user access authorizations that have the same or a lower level than the current user
access can be created.
1.

Access the Setupscreen page?

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Version: G/11/401/1/11
2.

Select the Usertouch key to open a dialogue window.


3
Login Logged on

Administra-

User

Local

Remote

Language

Unit

4
New

Delete

Cancel

Change

Save

Help

Ok

3.

Select the Administrationtab

4.

Press the Newtouch key to access the dialogue window below.


User

5
Name

User

Password confirmation!

Password

Confirmation

Confirmation

Access level on the machine

Local

Access level from network to machine

Remote
Language

Language selection
Unit of measurement selection

Unit
Administrator

6
Cancel

8.1.2

Help

Authorization for new user to create additiona


counts

Ok

5.

In the new window that appears enter the settings for the new user. The chosen
password must be entered a second time in the confirmation field.

6.

Press Ok to load the new settings.

7.

The new user is stored in the control unit.

CHANGING USER ACCESS AUTHORIZATIONS


Only user access authorizations that have the same or a lower level than the current user
access can be changed.
1.

Access the Setupscreen page.

2.

Press the Usertouch-key to open another dialogue window.

3.

In the new dialogue window select the Administrationtab.

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Version: G/11/401/1/11
4.

Select the user access authorization to change. Once selected the user access
authorization is highlighted blue.

5.

Press the Changekey. Another dialogue window appears.

6.

In this dialogue window the settings for the user access authorization can be changed.
The chosen password must be entered a second time in the confirmation field.

7.

Press Ok to save the changes.

DELETING USER ACCESS AUTHORIZATION


Only user access authorizations that have the same or a lower level than the current user
access can be deleted.
1.

Access the Setupscreen page.

2.

Press the Usertouch-key to open another dialogue window.

3.

In the new dialogue window select the Administrationtab.

4.

Select the user access authorization to delete. Once selected the user access
authorization is highlighted blue.

5.

Press the Deletekey.

6.

The following dialog window appears.


Delete?
Cancel

7.

8.1.4

Ok

Press Ok to delete the user access authorization.

SAVING USER ACCESS AUTHORIZATION


On machines with a CC200 control system newly created user access authorizations must be
saved onto the user access cards.
1.

Access the Setupscreen page.

2.

Press the Usertouch-key to open another dialogue window.

3.

In the new dialogue window select the Administrationtab.

4.

Select the user access authorization to save onto the card. Once selected the user
access is highlighted blue.

5.

Press [Save]. Select [OK] from the dialogue window that appears to confirm.

6.

Remove the access card from the slot and insert the new card to write the information
onto.

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8.2

USER LEVEL
User levels and applications
Level

Target group

Applications

Start-up personnel

Start-up and shut down of a preset


machine, with no access to change parameters.

Production personnel

Additional parameter changes for the current production

Setup personnel

Additional parameter changes for standard


programs, read in, write parts data

Reserved

Supervisor

Additional parameters and programs for


optimization, micrograph, QDP, set value
graphics (profile configuration), data dialog,
replacing sequences, heating optimization,
editing screen pages

Reserved

Additional customer-specific configuration

Advanced setup personnel

Additional free programming with graphic


sequence editor settings for heating editor

Reserved

Sequence programmer

Extended commands for sequence programming and more options in condition


editor

10

Customer service technician

Additional parameters for maintenance purposes and service tools for troubleshooting

11

Customer service technician

Additional calibration programs, variables


changes, read, write machine data, secure
USB stick, software update

from 12

ENGEL service technician

Additional functions and settings

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HELP SYSTEM
To access the online help system press the [?] key.

Help
Help

Core moving platen

1
Cores are movable elements inside the mold, which generally move into the mold before
the injection process and move out afterwards.

Injection molded part:


e.g. pipe fitting

Cores
Core movement is enabled when:
the safety gates on the clamping unit are closed,
2 safety switches are actuated,

3
4
Close

6
Back

Next

Contents

[1]

Menu strip with call-up of table of contents, index (alphabetically ordered headwords)
and navigation keys for previous or next page

[2]

Help window

[3]

Scroll keys (can also scroll through the screen text by dragging your finger along the
screen)

[4]

Close and exit help system

[5]

Back to the previous, on to the next description

[6]

Table of contents

The help system is available for the specific screen pages, variables and alarms:

Spezific screen page help: To access, press the [?] key at the bottom right-hand corner
of the screen.
A general description of the functional unit or the program is provided.

Variable help: To access, press the [?] key in the particular input window..
Parameter functional descriptions and setting tips are provided.

Alarm help: To access, select the particular alarm message and press the [Help]key.
Cause of alarm and troubleshooting information is provided.

Programming Help: To access, select a specific instruction in the graphic sequence


editor and press the key [?].

If no help entry is available for the selected page, variable, ..., you can use the table of contents
or index to search the whole machine documentation.

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10

ALARMS AND MESSAGES


Alarms, messages and warnings are displayed onscreen in the following ways:

The first generated alarm is displayed in a red message field, found in the bottom lefthand corner of the screen.

A separate Alarm screen page displays messages chronologically, according to the time
they were generated.

Waiting points are displayed on a separate page, which can be accessed via the class
7 tab, found on the top of the screen page.

Alarms

time

Description

Class
Robot motors switched off
X1 axis not referenced
Y axis not referenced
Z axis not referenced

Robot motors switched off

Acknowledge

Settings

Help

To access alarm-specific help, touch the particular message and press the [Help] key.

Note!
An alarm list can be found in the index directory under *Symbols.

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The symbols beside the alarm texts specifies the alarm level/type:
Class

Reason

Effect

Control unit system errors

Immediate machine stop

Electrical system fault

Immediate machine stop

System fault

Cycle stop

Process malfunction

Cycle stop

Process malfunction

Cycle continues

Information

Alarm light turns ON or screen message


displayed

Waiting points

Waiting points displayed on second tab

Specific effects can be assigned to certain process monitoring features (e.g. cycle stop, reject
sorting, light stack indicator activation or no effect).

WARNING!
Only trained service personnel are authorized to troubleshoot class 1-3
alarms.
10.1

DELETING AND ACKNOWLEDGEMENT OF ALARMS AND MESSAGES


Depending on the alarm class, messages are deleted in the following manner:

After restoring the conditions.

At each cycle start, error messages from the previous cycle are deleted.

Certain alarms also require a manual acknowledgement. To do this either toggle the
Program Interruption switch OFF and ON, or select the message and press the
Acknowledgment key.

Alarms that are not cleared or acknowledged will still cause reactions and related messages.

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10.2

INTERACTIVE MESSAGES
In addition to the generated error messages, interactive symbols are also used in the program
to convey particular information. The following section describes the functionality of each
symbol:

Wait

Wait message for executing an operational step

Information

The message is purely informative without consequences.

Warning

The message represents a warning, which must be acknowledged to execute an action.

Error

Alarm that can be eliminated at the operator level.

Fatal error

Fatal software and/or system error.

At the end of the text, messages can still have another function or link:

The message is backed with a link. By touching the message the target is called
up and displayed.
This symbol is displayed if additional information exists in the online help. Touch
the symbol to access the online help.

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DATA DIALOGUE
The data dialogue serves to store and load data onto the machine and/or onto an external
storage device (i.e. Compact Flash, USB stick, network).
The screen page appears after switching on the control unit and/or after pressing the screen
page selection key.
Data dialogue
\harddisk 0
\harddisk 0

1
3

Training
2

Active parts data set:

Data set attributes

STANDARD+CORE-

Name

STANDARD+CORE-

Author

STANDARD

Production date

STANDARD_Parallel

Change author

STANDARD_SEQUE

Change date

STANDARD+COREFIX

--Description
Machine number
Version

Parts data

[1]

Edit

Setup

View

Data storage device selection


Press the down arrow key to access all possible drive selections.
hard disk0 System Flash card
hard disk1 Flash card inserted in slot at CC200
usbbulk USB memory stick connection
harddisknet Network drive connection

[2]

Status information
Shows the status (symbol) and name of the active data file (Selection key for the display
of the attributes)).

[3]

Setting data sets selection list (Project selection)


Touch the required selection to display the data attributes on the right-side of the screen.

[4]

Data set attributes


Displays all the data for the selected project. This information can be changed when the
correct access authorization is used.
Name Selectable project file name = file name in selection list
Author Name of the creator
Production date
Change date, author Date and name of the user making the latest changes.
Description user defined descriptive text

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[5]

Message window shows dialogs for executed actions, error messages, information
etc. Can be faded out and in in the menu View.

[6]

Instruction menu keys


Parts data with the instructions: Read, Write, Copy, Erase.
Edit with the instruction Erase message.
Setup with the instructions: Backup harddisk, file delivery state, software updating,
licence updating, read machine data, write machine data, display active machine
data.
View with the instructiions: Selection window on/off, message window on/off,
maximizing/minimizing

11.1

STORAGE MEDIA
As input media serve Compact Flash cards or USB storage sticks.
Compact flash card
You can use each commercial Compact Flash card.
USB storage stick
Only use the folllowing USB storage sticks:

Memory stick

Buffalo

RUF-C256M/U2

Memory stick

SanDisk

Cruzer Mini USB 2.0 256 MB

If you select a data carrier with insufficient free storage space, the program will cancel the save
operation and display a message. The message shows which data carrier is full, along with the
last file that was completely stored on the data carrier.

Flash card full X


impact

Cancelling save to data carrier.

removal

Select a data carrier with more free space and try to save again.

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READ DATA SET


A parts data set consists of the sequence and setting data of machine and robot. You can
either read in the whole parts data set or only certain data. When you only read in a certain part
of the parts data, only these change. The other data are preserved.
Parts data
Injection molding maSequence data
Machine settings
Robot
Sequence data
Machine settings

Sequence data
In the sequence data only the machine or robot sequence is stored. When you only read in the
sequence data, only the sequence changes. Parameters such as speeds, pressures,
positions,... do not change.
Machine settings
In the setting data all parameters such as speeds, pressures, positions,... are stored. When
you only read in the setting data, only these parameters change. The sequence does not
change.

Example:
Procedure when loading an existing parts data set from a data carrier.
1.

Switch the machine to manual mode.

2.

Select the data carrier. hard disk1\ is the memory card on the front panel, hard disk0\
is the control-internal memory. usbbulk\ is a connected USB memory stick.

3.

Select the setting data set from the list.


Display of the information in the window Data set attributes

4.

Press Parts data and Read.


A window with a clock is displayed. The control unit loads the chosen parts data set and
overwrites the current machine setting. The manual control keys of the machine are not
active during loading.
If read values are not adjustable (plausible) on this machine, this message is displayed:

Values corrected
impact

Message only

removal

Open the corrected values dialog on the plausibility check screen,


and check which values have been corrected. (See Operator Manual
- Machine)
Acknowledge the message in this window.

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11.3

WRITE A PARTS DATA SET


At the parts data set writing you only store the whole parts data set. It is not possible e.g. to
store only the setting data of the machine.

Example:
Procedure when storing an active parts data set on a data carrier.
1.

Select the active parts data set with the key at the top right of the screen.

2.

Enter name and information in the Data set attributes window.

3.

Select the data carrier. hard disk1\ is the memory card on the front panel, hard
disk0\ is the control-internal memory.

4.

Press [Parts data] and [Write].


The following window is displayed
Write active parts data on
Available drives
Name
Description

Free memory

C:\5632

kBytes

Required memory

C:\231

kBytes

Cancel

5.
6.

11.4

Help

Write

Change the set attributes, when necessary, and confirm with [Write].
The control unit stores the parts data set on the selected drive.
If a data set with the same name already exists on the data carrier, the dialog window

Overwrite ??is displayed. If YES, press [Execute].

COPY PARTS DATA SET


Procedure when copying a parts data set to another data carrier.
1.

Select a storage medium (e.g.harddisk0\).

2.

Touch the required parts data set to select from the list.

3.

Press [Parts data] and [Copy].


A window is displayed, with drive option, name proposal and description.
Copy chosen parts data on
Available drives
Copy 1 of training 4

Name

Parts data set for training


Description
Free memory

Cancel

4.

C:\5632

Help

Copy

Choose a drive and enter requested changes.

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5.

11.5

Press [Copy].

DELETE DATA SET


Procedure when deleting a data set
(from user level 5):

12

1.

From the selection window, choose the drive that contains the data set.

2.

From the directory list, select the data set.

3.

Press [Parts data] and [Delete].


The following data dialog box is displayed Really delete data set? with the name of
the selected data set.

4.

By confirming with the [Execute] key, the data set is deleted.

PRINT
The control unit supports printing from various programs, and of screenshots. The control unit
supports PCL-3 capable printers by vendors that support this specification. To print on-site,
connect a printer to the USB port on the machines front panel.
When the machine is connected to a LAN network, printing to the networked printers is
possible.
The following printer types are tested for the CC200 control unit:
Local printers with USB connection

Manufacturer

Type

Hewlett Packard

HP 880C

Hewlett Packard

HP Deskjet 895C

Hewlett Packard

HP Deskjet 990Cxi

Hewlett Packard

HP Deskjet 995C

Hewlett Packard

HP Business Inkjet 1100D

Hewlett Packard

HP Business Inkjet 1100

Hewlett Packard

HP Deskjet 6840

Network printers (Postscript)

Manufacturer

Type

Hewlett Packard

HP Laserjet 4100dtn

Hewlett Packard

HP Laserjet 4000 PS

The control unit offers the following printing possibilities of screen pages (masks):

a hard copy of the current screen page with screen page selection keys

a graphic printout of the current screen page

several graphic printouts of a selection of screen pages

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textual printout of the current screen page

textual printout of a selection of screen pages

A hard copy as PNG picture and graphic printouts of individual or several screen pages can be
stored in Postscript format as file.
A textual output in file format enables an export function in the data dialog.
Graphic or textual printout of screen pages on a local printer:
1.

Connect a printer with USB cable and switch the printer on.

2.

Choose the printer menu.


Print
Screen page selection
Current screen page
Hardcopy
Text printing
Cancel

3.

Help

Setup

Ok

Press [Setup]
Settings for screen page output

Printer settings
Output on printer
Compress PS

Settings for printing to file


Print to file
Type
Directory
File name

Cancel

Help

OK

4.

Switch on Output on printer . In addition, the selection possibility print to file is


still available. [See Output of the current screen page as hard copy in file format: on
page 76.]

5.

When switching over to Output on printer the printer dialog appears of the currently set
printer. Select the local printer and press [OK].

6.

When you want to have a text printing, switch on Text printing.

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7.

Select Selection of screens and confirm with [Printing].


Screen page selection
0 of 65 selected

Production
Programmable in/outputs
Freely composeable page
Shut-off nozzles
Minicam
Mold close
Set value graphics
Mold height
Mold open

Cancel

Help

Delete

Select all

8.

Select the required screen pages from the selection of screens.

9.

Press [OK] to start the printing process.

Output of the current screen page as hard copy in file format:


1.

Choose the printer menu

2.

Press [Setup]
Settings for screen page output

Printer settings
Output on printer
Compress PS

Settings for printing to file


Print to file
Type
Directory
File name

Cancel

Help

OK

3.

Switch on Print to file .

4.

Select the [Type] of the screen page (File format).

OK

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5.

In [Directory] the output file is fixed.


Save
Selection:

Cancel

Help

Save

6.

The path is filed by [save] and the window is closed.

7.

Enter in the mask Settings for the screen page output a designation in the line
[File name].
With [OK] start the output process to file.

8.

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BASIC ROBOT SETTINGS


The standard pages serve the comfortable operation and control of the robot and the rapid
setting of the predefined sequence variants.

QUICK SETUP
This page contains basic settings and functions of the robot, such as work area settings,
turning limits, swivelling limits, moving limits, group and individual configurations for vacuum/
compressed air.

NOTICE!
These settings must be configured immediately after mounting a mold to
mitigate the danger of collision. To do this, mount the end of arm tooling
that matches the mold!
Work areas for machine, take-off and depositing area
Quick Setup
Actual position

Work area settings


Machine area

Min
Max

Take-off area

Min
Max

Depositing area Z+

Min
Max

Work area settings

Machine area
The machine area is the whole theoretical moving area of the robot within the injection
molding machine. This defined room is switched with a safety condition depending on
the mold position. The machine area defines the whole blocking area of the plant and is
preset on the part of the factory.

Take-off area
Work area in machine area for part take-off. To access a mold without danger of
collision, a take-off area must be defined for each mold. This must be determined with
a completely open mold. Never set values for the take-off area that cause danger of
collision for the mold! The take-off area is thus a mold-driven traversing area for the
robot when the mold is open, and lies within the machine area. This area must be
modified for each new mold you use.

Depositing area Z+
A setting of the work area depositing area Z+ limits the maximum depositing area of the
operator rear side corresponding to the set parameters. The limitation of the depositing
area enables the safeguarding of the whole depositing area with only few work areas.

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Depositing on the operator rear side

[1]

Work area depositing area Z+

[2]

Machine area (= Blocking area clamping unit)

[3]

Take-off area

Note!
To avoid collisions with the robot, you must define the work area and prohibited area for the
take-off and depositing areas. [See Work Areas and Prohibited Areas on page 113.]

Take-off invalid - robot was not in the take-off area


Reason

Take-off area set incorrectly.

impact

Plant will stop after first cycle.

removal

Check take-off area and modify the take-off position.

Closing safety - Robot within machine area


Reason

The robot is within the prohibited area of the machine area.

impact

The requested movement cannot be carried out.

removal

Move robot out of prohibited area.

If a machine movement is cancelled by the robot in manual operations, a Robot interlockalert


occurs. An additional wait-point shows which movement is blocked.

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Robot interlock
Reason

Robot release is not active.

impact

The required machine movement cannot be performed.

removal

Move the robot on the correct release position.

Ejector not retracted


impact

The requested movement cannot be carried out.

removal

Move ejector to ejector retracted position.

Mold not open


impact

The requested movement cannot be carried out.

removal

Open the mold completely.

NOTICE!
The turning, swivelling and movement limits only apply to standard sequences defined by Engel.

Turning, swivelling and moving limits (ENGEL sequences)


Y-position when moving out/in Z
Upper swivelling limit depositing area
Lower swivelling limit depositing area

Turning, swivelling and moving limits (ENGEL sequences)

Y-position when moving out/in Z


Maximum Y position at Vertical take-off when moving the Z-axis out from the machine
area.

Upper - lower swivelling limit depositing area


Y positions in the depositing area within which the manual axes may move.

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Example:
Turning, swivelling and moving limits
Depositing area Z+

Machine area

Y-position when moving out/in Z

Upper swivelling limit


depositing area
Lower swivelling limit
depositing area

NOTICE!
The rotary axis settings for moving into and out of the machine area only
apply to standard sequences defined by Engel.
But the rotary axes settings are not valid for the Engel Teach sample sequences.

Rotary axes moving out to deposit (ENGEL sequences)


Rotary axes movements in machine area

No rotary axes movements

Rotary axes positions moving out Z from machine


Rotary axes priority when moving out
Rotary axes movements to depositing from

Upper swivelling limit depos-

Rotary axes moving out to deposit (ENGEL sequences)

Rotary axes movements in machine area


Selection whether and/or from when rotary axes movements are allowed in the machine
area.
No rotary axes movements in machine area
Before moving out Z
In parallel to Z moving-out

Rotary axes positions moving out Z from machine area


Defines the final position of the rotary axes for moving out Z

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Rotary axes priority when moving out


Defines the order of the rotary axes movement. When several axes are given the priority
1 the movements occur in parallel.

Rotary axes movements to depositing from


Corresponding to the selection Upper swivelling limit depositing area and/or
Machine area max. , rotary axes may start their movement in parallel to the linear axes.
The Y-axis waits until the manual axes have reached their final position on the lower
swivelling limit depositing area and continues the movement only then.

Pneumatic axes

C Servomotor axes

180

0
above

90

below
B

right

max

middle

180

left
A

90

left

right
middle

max

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Rotary axes moving into take off (ENGEL sequences)


Rotary axes position for Z-movement into maRotary axes priority when moving in
Rotary axes movements after depositing - up to

Position before opening

Rotary axes moving into take off (ENGEL sequences)

Rotary axes position for Z-movement into machine area


Defines the final position of the rotary axes for Z moving in

Rotary axes priority when moving in


Defines the order of the rotary axes movement. When several axes are given the priority
1 the movements occur in parallel.

Rotary axes movements after depositing - up to


When moving out from the deposit the rotary axes start moving, from the lower
swivelling limit, in parallel to the linear axes.
The rotaryl axes movement must be finished up to the adjustable selection Upper
swivelling limit depositing area, Machine area max. and/or Position before
opening.
Linear axis movement waits on the set position if rotary axes movement is not
completed.

Group configuration
Take-off vacuum/compressed air circuits
Depositing vacuum/compressed air circuits

Group configuration
Assignment of the vacuum/compressed air circuits in the corresponding groups.
If you need to take-off and deposit a sprue part, you must configure the vacuum/compressed
air circuits with which you will be taking-off and depositing the sprue part in the group
configuration.
You can only configure the group in Teach mode.
When you press the quick select key for the group in question, the group configuration dialog
appears.

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Group configuration - Take-off vacuum/compressed air circuits

Available elements

Selected elements

Vacuum/compressed air 3

Vacuum/compressed air 1
Vacuum/compressed air 2

Cancel

Help

Execute

Using the navigational arrows <<< and >>> you can move the complete content from
Available elements to Selected elements and vice-versa.
You can select an individual vacuum/compressed air circuit, and move it using the navigational
arrows < and > to insert it into Selected elements in the desired order.

Example:
Configure two vacuum/compressed air circuits for take-off.
1.

To configure vacuum/compressed air circuits, you must first change to Teach mode.

2.

Press the appropriate button on the Quick Setup screen for Take-off vacuum/
compressed air circuits screen.
Group configuration
Take-off vacuum/compressed air circuits
Depositing vacuum/compressed air circuits

3.

Use the >>> button to move the vacuum/compressed air circuits to Selected elements.
Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements

Vacuum/compressed air
Vacuum/compressed air

Cancel

Help

Execute

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4.

Use Execute to store the current configuration.


Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements
Vacuum/compressed air
Vacuum/compressed air

Cancel

5.

Help

Execute

This completes the vacuum/compressed air circuit configuration.

Vacuum/compressed air x
Activated
Status marker
Type

Compressed air

Final positions monitoring

Input

Part monitoring

Signal 0 and 1

Vacuum x
Activated
Status marker
Part monitoring

Signal 0 and 1

Vacuum/compressed air x
A strip is available for each vacuum/compressed air circuit.

Activated
Activates vacuum/compressed air circuit x.

Status marker
The flag displays that the equipment is active.

Type
Vacuum/compressed air circuits can be of the following types Vacuum, Compressed
air or Barrel.
Depending on the type setting, final position and part monitoring are configured
automatically.

Final positions monitoring


Activating monitoring by enabling the program switch. The final positions monitoring
setting depends on the selected type, and is set automatically.
Possible settings:
Input - and input +
Both final positions of a barrel are monitored.
Input Monitors the -final position e.g. sprue cutter open.

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Part monitoring
Activating monitoring by enabling the program switch. The part monitoring setting
depends on the selected type.
Selectable settings:.
Signal 0 and 1
Monitors part available/not available.
Signal 1
Monitors part available.

Note!
In the Parameter tab of the robot setup you can specify settings for the vacuum/compressed
air circuits.

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Depositing conveyor-belt x
Depositing conveyor-belt - Cycle when all selected grids are full
Depositing conveyor-belt - Running time

Depositing conveyor-belt x

Depositing conveyor-belt - Cycle when all selected grids are full


If all configured grids are full, the conveyor-belt runs for the preset time. If you cycle the
conveyor belt through the preset cycle in manual or setup mode, by pressing the
Conveyor belt button on the hand control device, the robot will restart depositing in the
grid for the next cycle.
Conveyor belt key on
manual mode device
When you press the quick select key, the group configuration dialog appears for you to
configure the grids used (default setting: Shot grid 1). This is only possible in Teach
mode
Group configuration - depositing conveyor belt 1 - cycle when all selected grid po-

Available elements

Selected elements

Shot grid 2

Shot grid 1

Shot grid 3
Individual part grid 1
Individual part grid 2
Individual part grid 3
Tach grid 1
Tach grid 2
Cancel

Help

Execute

If the robot sequence, e.g. the part sequence Part depositing in individual part grid 1
with conveyor belt is programmed, you must configure individual part grid 1 in the group
configuration dialog. If the wrong grid is configured, the conveyor belt will not cycle, and
the automatic cycle is interrupted.

Depositing conveyor-belt - Running time


Configurable conveyor belt running time. The conveyor belt will run for the configured
running time when all configured grid positions are full.

<Name>grid <No> - Maximum no. of parts exceeded


Reason

The robot was unable to deposit the parts in the grid because the
conveyor belt has not been cycled.

impact

Interrupting automatic cycle.

removal

Check the grid configured for the depositing conveyor belt.

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1.1

ROBOT GENERAL SETTINGS


This page includes basic settings and functions of the robot.
General settings
Actual position

test mode
Testmode active
Testmode speed

test mode

Testmode active

The control unit switches to test mode when you enter changes in the sequence editor,
or press the Test mode button on the hand control device. Press the button once more
to disable Test mode. [See test mode on page 146.]
Test mode button on
manual mode device

Testmode speed
Servo axis speed in test mode.

Home position
Home position

+
Speed to home position
Home position reached

Home position
The home position is the position the robot occupies at the start of an automatic cycle.

Home position
You can move to preset position by pressing the Home position button on the machine
control panel and/or hand control device.
Home position key on
manual mode device

Speed to home position


Speed of the servoaxes moving to the home position.

Home position reached


This flag signals when the home position is reached.
This can be achieved by moving to home position, but also by positioning the axes
individually.

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Movement to home position enabled


Reason

On switching to automatic operating mode, the home position key


was pressed, but the home position was not reached.

impact

Switchover to automatic mode not possible.

removal

Execution of the home position run until the position is reached completely.

Quick positioning
Quick position

+
Quick position speed
Position reached

Quick positioning
The program is used for faster positioning of the robot at a predefined position.

Quick position
You can move to the preset position by press the Quick positioning button on the hand
control device.
Quick position key on the
manual mode device

Quick position speed


Speed of the servoaxes moving to the quick position.

Position reached
The active marker signals that the preset quick position has been reached.

Quickpos still active


Reason

On switching to automatic operating mode, the quick position key


was pressed, but the quick position was not reached.

impact

Switchover to automatic mode not possible.

removal

Perform quick position move until the position is fully reached.

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Park position
Move to park position during production without robot
Park position

Speed to park position


Park position reached

Park position (optional)


The program serves to automatically position the robot at a predefined position e.g. for
changing the end of arm tooling or for production without robot.

Move to park position during production without robot


For Production without robot in automatic operations, if this switch is enabled, the robot
will move to park position after injecting.

Park position
Park position for all axes adjustable on screen.

Button on hand control device for moving to park


position

Speed to park position


Speed of the servo axes moving to the parking position.

Park position reached


This flag signals when the park position is reached.

Park position sequence still active


Reason

On switching to automatic operating mode, the park position key was


pressed, but the park position was not reached.

impact

Switchover to automatic mode not possible.

removal

Perform park position move until the position has been fully reached.

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QUICK SETTING OF ROBOT POSITION


For all position input fields (e.g.: home position, take-off position, ...) there is a quick set key on
screen.
The QuickSet/QuickPosdialog appears when you press the button.
QuickSet/QuickPos
QuickPos

QuickSet

All axes

Axes

Cancel

Help

Execute

QuickPos
Serves to specify the current position for the selected robot axis as the Quick position
on the General settingsscreen.

QuickSet
Used to for quick collection of position information for the selected robot axes at the
current position.

Example:
Apply current values for the robot axes for Position before opening .
1.

Select the take-off screen.

2.

Press
quick set
keyopening
for Position before opening.
Speedthe
to position
before
Position before opening

3.

Select QuickSet and All axes.


QuickSet/QuickPos
QuickPos

QuickSet

All axes

Axes

Cancel

Help

Execute

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4.

Press Execute to use the current robot axis values as the Position before opening.
Take-off
Actual position

Take-off Standard
Position before opening = Home position
Speed to position before opening
Position before opening

Example:
In manual operations, the robot will stop at Position before opening and should be moved
directly to the take-off position.
The mold is completely open, and the basis is the simple robot sequence with 2 move-in
positions.
1.

Select the take-off screen.

2.

Press the quick set key for Take-off position - XYZ.


Take-off speed
Take-off position - X Y Z
Waiting time before take-off
Mold pause time

3.

Select QuickPos and All axes.


QuickSet/QuickPos
QuickPos

QuickSet

All axes

Axes

Cancel

Help

Execute

4.

Press Execute to assign the take-off position to the quick position.

5.

When you press the quick position button on the hand control device, the robot travels
from the Position before opening directly to the take-off position. The robot does not
move to the preset moving-in position.

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Sequence sketch

[1]

Position before opening

[2]

Moving-in position 1

[3]

Moving-in position 2

[4]

Take-off position

NOTICE!
The positions are approached directly, pay attention to possible collisions.

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1.3

ROBOT STATUS
The status page provides information about general robot and sequence states.
Status page
Actual position

General
All motors switched on
All axes referenced
All axes in Home position
Hand terminal Consent key active
Testmode active
Override speed
Cycle counter

General

All motors switched on


Indicates when all servocontrollers are supplied with voltage.

All axes referenced


Indicates when all servo axes are referenced.

All axes in Home position


Indicates when all axes are in home position.

Hand terminal Consent key active


Indicates if the consent key on the hand terminal is pressed.

Testmode active
Indicates whether the test mode is activated.

Override speed
Actual value for current override speed.
You can press the Increase override/reduce override buttons on the hand control
device to increase/reduce the current servoaxis speeds by a percentage factor in
automatic operating mode. The automatic speeds set on the screens represent the
maximum (100%).
Reduce override button on
hand control device

Increase override button on


hand control device

Cycle counter
Actual value counter for executed robot cycles. The counter can only be reset by
pressing Rbutton.

Example:
Override speed
If the Speed to depositing position is set to 70%, and the override speed is 50%, the robot
will move to the depositing position at 35% speed.

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closing release
Electric mold closing release
Program mold closing release

General mold closing release

closing release
These flags show the states of the closing releases.
Vacuum/compressed air
Vacuum/compressed air - output +
Vacuum/compressed air - output -

Vacuum/compressed air - input +


Vacuum/compressed air - input Vacuum/compressed air - input part monitoring
Vacuum/compressed air - input vacuum monitoring

Vacuum/compressed air
The flags show the states of the digital outputs for the pneumatic valves with the appertaining
monitoring inputs. The green checkmarks indicates that the hardware is okay.
Swivelling cyl. CD1
C-axis - Swivelling cyl. CD1 - Output +

C-axis - Swivelling cyl. CD1 - Output C-axis - Swivelling cyl. CD1 - Input +
C-axis - Swivelling cyl. CD1 - Input -

Swivelling cyl. CD1


These flags show the states of the digital outputs for the pneumatic valves with the
appertaining monitoring inputs.
Output-/Input-: C-axis above
Output+/Input+: C-axis below
Locking cylinder CD2
C-axis - Locking cylinder CD2 - Output +
C-axis - Locking cylinder CD2 - Output -

C-axis - Locking cylinder CD2 - Input +


C-axis - Locking cylinder CD2 - Input -

Locking cylinder CD2


Output-/Input-: Locking cylinder unlocked
Output+/Input+: Locking cylinder locked

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ROBOT PROGRAM SWITCHES


The program switch page includes the most important configuration possibilities for the robot
and its sequences.
Robot 1 program switch
Actual position

Robot
Robot main switch
Home position movement with parts
ERC SIP3 Vertical

Equipment type

Robot

Robot main switch


Switches the robot on or off. When the switch is off the robot sequence is ignored. For
the operation of the injection molding machine it must be paid attention to that the
closing safety for the mold is given.

Home position movement with parts


With switched-on program switch the outputs of the vacuum/compressed air do not
switch off at the movement to home position if these should still be active. E.g. at inserts.

Equipment type
The configured safety package and the take-off sequence are displayed here.
This field is factory set and is for information purposes only.

Take-off movement
The following program switches can be set as a function of the constructional plant execution,
of the configured safety package and of the allowed take-off type. The chosen setting
influences the work areas and the robot standard variants (Take-off, depositing,...).
Take-off movement
Allowed take-off movement

Vertically and horizontally

Take-off movement

Vertical

Vertical
The robot moves into and out of the mold from above = vertically (e.g.: injection molding
machine with tiebars).
The closing release for the mold is given when the Y-axis is above (Y-reference switch
or Y-waiting position switch actuated).

Horizontal
The robot moves into and out of the mold laterally = horizontally (e.g.: tiebarless
injection molding machine).
The closing release for the mold is given when the robot has left the take-off area (Zreference switch not actuated and/or Z-position >= home position).

Vertically in/Horizontally out


The robot will move from the top (vertically) into the mold, and to the side (horizontally)
out of the mold (can save cycle time, depending on your application).
The closing release occurs like at Take-off horizontal.

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Horizontally in/Vertically out


The robot moves into the mold laterally (horizontally) and moves out vertically.
The closing release occurs like at Take-off vertical.

Vertical take-off

Horizontal take off

Robot <-> machine


Communication settings between robot and injection molding machine
Robot <-> machine
Production without robot
Robot test run without machine
Block movements on the clamping unit at automatic start
Early start
Minimum mold position for early start and intermediate stop
Early start position
Mold open on early start position
Take-off with mold intermediate stop
Mold intermediate stop position

Production without robot


If the program switch is enabled, the robot will complete the current cycle and then wait
at its home position. The injection molding machine will then go on producing without
the robot, until the switch is disabled. The switch can also be actuated in automatic
mode.

Robot test run without machine


When the program switch is activated, the roboter sequence is started without the
injection molding machine sequence when the start key is pressed either in semi or fully
automatic mode.
On the injection molding machine, the mold must be open, the ejector retracted, and
any cores moved out.
At the test run the mold remains open and the required signals of the cores, ejector etc.
are simulated.

Block movements on the clamping unit at automatic start


If the program switch is activated when you switch to semi-automatic or fully automatic
mode, all mold, ejector, core movements, and air valve functions are locked. Individual
releases must be programmed in the robot sequence.

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Early start
Activates early start in the take-off sequence. The program switch and the early start
position are queried by the Wait for part acceptance releasesequence. To avoid
collisions, the sequence waits for Mold open , before accessing the take-off position
(the default is to wait until move-in position 2 has been reached). Moving-in positions 1
and 2 must be set to avoid collisions between the end of arm tooling and the mold.

Minimum mold position for early start and intermediate stop


This mold position limits the early start and intermediate stop position and therefore, is
a safety limitation for the mold area.

Early start position


The robot enters the machine area from this position onward.

Mold open on early start position


The active flag signals when the early start position is reached.

Take-off with mold intermediate stop


When this field is selected the mold intermediate stopp is activated. This is possible
after inserting the sequenz step Form open at robot start position in the machine
sequence.

Mold intermediate stop position


At this position mold opening stops to allow molded part take-off by the robot.

Robot test run without machine active


Reason

Program switch Robot test run without machine is activated.

impact

In automatic mode no machine movements occur.

removal

Deactivating program switch Robot test run without machine.

Relocate pre-molded part


Program for pre-molding part take off with inserting into another cavity (e.g. Combimelt
machines).
Relocate pre-molded part
Take-off/re-locate pre-molded part
Take-off for pre-molding cycle
Current premolding cycle
Number of premolding cycles

Take-off/re-locate pre-molded part


If this program switch is activated, the robot receives the pre-molding part take-off
release signal in the set pre-injection cycle (and/or with the Wait for part acceptance
releasesignal).
If the program switch is deactivated, the robot will not move in until the pre-molding
cycles have been completed.

Take-off for pre-molding cycle


In the pre-molding cycle the robot moves into the mold, e.g. to transfer the pre-molding
part to the cavity for finished part molding.

Current premolding cycle


Actual value display.

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Number of premolding cycles


Pre-set pre-molding cycles for injection molding machine.

Depositing variants
Program switch for enabling or disabling various depositing areas.
Reject deposit - 1 position
Program switch reject depositing

Quality Control deposit - 1


Program switch Quality Control depositing

Sprue depositing - 1 posiProgram switch Sprue depositing

Rotary axes
Program switch for enabling or disabling rotary axes.
Rotary axes
B-axis - Activated
C-axis activated

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POWERING UP THE ROBOT


WARNING!
Due to pressure build-up, uncontrolled pneumatic cylinder movement
may occur when the air supply is activated; therefore, ensure no personnel are inside the work envelope!
1.

Switch on the control voltage

2.

Check the protection equipment


Ensure no personnel are inside the safety guarding enclosure
Open - close - acknowledge the safety guarding access door

3.

Switch on the robot main switch form the Robot 1 program switch screen

4.

Switch on compressed air at the maintenance unit; operating pressure 6 bar (87 psi)

5.

Switch the robot motors on form the hand terminal or the injection molding machine
control panel.

Robot motors switched off


Reason

The robot motors are not yet switched on or have been switched off
by the appearance of an alarm (see alarms on the screen).

impact

Prevents switchover to automatic mode

6.

If the safety gates are not closed, appears the message:

Enable robot setup operations; robot motor in setup operations


as of level 5
impact

In Level 5 or higher, robot motors can be actuated in setup mode by


holding down the consent key despite the safety gates being open.

removal

Switch on set-up. For confirmation appears the message: Robot setup mode activated.

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SERVO AXES REFERENCING


Each time the control voltage is switched on the servo axes must be referenced in order to
reach the absolute positions.

NOTICE!
Pay attention that there are no obstructions in the robots way during referencing.
The referencing sequence and the referencing order are set in the sequence editor.
The order of the individual axis referencing sequences determines the referencing order.
Standard referencing sequence:
Robot sequence
Referencing

Instructions:
Robot
Peripheral unit

Referencing

Injection molding ma-

Reference robot axis (Y-axis)

Sequence control

Reference robot axis (X-axis)

Grid
Sequences
structure instructions

Reference robot axis (Z-axis)


Referencing

Referencing process:
1.

Switch to manual or set-up mode.

2.

Use the referencing key on the hand control device or injection molding machine
operating panel to reference the robot axes. The robots linear axes will move slowly in
fixed order (Y>X>Z) to fixed referencing positions.
Referencing key on
manual mode device

3.

Hold the key down until referencing is complete and the robot stops.

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When an axis is not referenced, the following message appears:

<Name>-Axis not referenced


impact

Automatic mode is not possible and the alarm lamp flashes. The axis
can only be referenced or moved with the hand terminal touch keys.
The set work area data is not considered!

removal

Carry out referencing

NOTICE!
When the robot is not referenced it means no final positions are defined;
therefore, the respective axis moves until the EMERGENCY STOP!
The following message is displayed:

<Name>-Axis axis emergency stop +/-, automatic start not possible


impact

The robot motor is switched off.

removal

Move out the axis from the EMERGENCY STOP position, carry out
referencing

The following alarm messages could occur during referencing:

Axis zero impulse statistics omitted; ofs=x; val=x; num=x; min=x


Reason

There are less than two statistically valid values in the zero impulse
history.

impact

No statistics check. Axis is not referenced

removal

Repeat referencing process until at least two valid values exist.

Parameters

ofs= set zero impulse offset (0/180)


val= current zero impulse angle
num= Number of the existing values in the zero impulse history
min= Number of the necessary values (2)

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Axis zero impulse statistics warning; ofs=x; val=x; avg=x; dev=x


Reason

The current zero impulse angle is outside the statistically calculated


tolerance (3x standard deviation). The zero position of the axis can
be displaced due to a mechanical tolerance.

impact

Axis is not referenced

removal

Eliminate mechanical problem. Measure axis newly.

Parameters

ofs= set zero impulse offset (0/180)


val= current zero impulse angle
avg= calculated mean value from the zero impulse history
dev= statistically calculated standard deviation

Axis zero impulse distance too small; ofs=x; val=x;


Reason

The current zero impulse angle lies in the range +/- 45. The zero
position of the axis can be displaced by a motor revolution.

impact

Axis is not referenced

removal

Deactivate the program switch Confirm change of the zero impulse


displacement In the robot setup for the displayed axis. Start the referencing process anew.

Parameters

ofs= set zero impulse offset (0/180)


val= current zero impulse angle

Axis reference switch defective


Reason

The digital input signal of the reference switch did not have the correct status on the switching position within the monitoring tolerance.

impact

The robot motors switch off. Automatic cycle is interrupted.

removal

Check electric input signal and/or parametrization of the reference


switch.
Check monitoring tolerance and monitoring speed.

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3.2

NORMAL POSITION (BRING ROBOT IN NORMAL POSITION)

NOTICE!
Danger of collision with peripheral unit, sprue cutter or support etc.
1.

Press the Homing key on the hand control device or on the injection molding machine
operating panel.
Home position key on
manual mode device

2.

3.3

Hold the key down until the robot has reached the home position.

MOUNT TAKEOVER HEAD

DANGER!
Working or standing below moving components is prohibited! The robot
must be at an accessible position that does not endanger the user.
Before the parameter settings a takeover head suitable for the injection mold must be
mounted.

Example:
End of arm tooling with four spring-loaded suction pads and a sprue cutter.

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ROBOT WORK AREAS


1

WORK AREA SETUP


The work area setup serves to define the work areas and prohibited areas for the robot. A work
area is an area in which the robot is allowed to move A prohibited area is an area in which a
robot is not permitted to move; it can be located within a work area. Undefined areas are
always prohibited areas.
Work area setup
Robot1

Work Areas and Prohib-

Settings

3D view

Overview

Robot
Work area above

Work area above


Work area clamping
Prohibited area

Work area rear safety


Work area above deWork area depositing
Work area above deWork area depositing
In machine data
In parts data
Work

Edit

View

[1]

Status line for work area data


Selection window for the available robots.

[2]

Setting and visualization area

[3]

Instruction menu keys

[4]

Selection tree for listing up the available areas, subdivided in:

Robot
Predefined work and prohibited areas from machine constants, take-off areas and
depositing areas.
In machine data
User-defined work and prohibited areas for storing in the machine data set.
In parts data
User-defined work and prohibited areas for storing in the parts data set.

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SETTINGS ROBOT
In order to change the robot settings, select the robot folder from the selection area, as shown
below.
Work area setup
Robot1
Work Areas and ProhibRobot
Work area above
Work area above
Work area clamping

Settings

3D view

Overview

Machine area
Min
Max

Take-off area

Prohibited area
Work area rear safety
Work area above deWork area depositWork area above deWork area deposit-

Min
Max

Work area depositing area ZMin


Max

Work area depositing area Z+

In machine data

Min

In parts data

Definition of the machine, take-off and work area deposit areas:


The Machine, take-off and work area depositing areas must be setup when powering-up
the cell or when using a new mold. This data and the maximum axes lengths allows the control
unit to calculate the individual work area and prohibited areas.
Robot work areas

[1]

Work area depositing area Z+ (Operator rear side)

[2]

Machine area = prohibited area clamping unit. Blocks all work areas in the machine area
with mold not open.

[3]

Take off area

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Option: Dual-side deposit

1.2

[1]

Work area depositing area Z+

[2]

Machine area = prohibited area clamping unit;

[3]

Take-off area

[4]

Work area depositing area Z-

SETTINGS WORK AREAS


In order to change the settings for an area, select the designated submenu from the robot
folder.
Work area setup
Robot1
Work Areas and ProhibRobot

Settings

3D view

Overview

Element attributes

Work area above


Work area above
Work area clamping

Name

Work area above machine

Type

Work area

Min

Prohibited area
Work area rear safe-

Max
Activation switch

Work area above de-

Active

Work area depositing

Visible

Work area above de-

Filled

Work area depositing


In machine data
In parts data

Description

System name

Element attributes

Name
Freely selectable name of the area

Type
Fixing of the area type (Work area or prohibited area)

Min/Max
Area coordinates for the respective area

Activation switch
Program switch for enabling or disabling area

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Active
Status flag (green = area active)

Visible
When this field is switched Off the work or prohibited area is not displayed on the 3D
view window; however, the functionality of the area is maintained.

Filled
When this field is switched Off the work or prohibited area is displayed on the 3D view
window, as an outlined red box and when switched On the area is filled in as a solid.

Description
Field for a short description of the room

System name
Clear designator for the control unit (cannot be changed)

Robot assigned
Assignment of the area to the corresponding robot

3D VIEW
The 3D view window displays the arrangement of the work and prohibit areas. Different colors
and line strengths are used to differentiate between the various areas and the status.
The 3D view window provides the following features
Work area setup
Robot1
Work Areas and Prohib-

Settings

3D view

Overview

Robot
Work area above
Work area above

Work area clamping


Prohibited area

Work area rear safeWork area above de-

Work area depositWork area above deWork area depositing


In machine data
In parts data

[1]

Starting point coordinates (Zero point)


The starting position is marked with a yellow crosshair.

[2]

Filled representation.
The side edges of the room are represented with black lines and the area of the room
are filled out with the color of the area type.

[3]

Line representation.
Only the side edges of the area are represented with the corresponding color of the
selected area.

[4]

Reset key
This function resets the graphic to its fixed starting position.

[5]

Vertically rotation keys


The graphics turns around the vertical axis.

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[6]

Horizontal rotation keys


The graphics turns around the horizontal axis.

[7]

Zoom In/Zoom Out


These keys allow the graphic window area to be increased (+) or decreased (-).
The focus is dependent on the preceding processing of the graphics.
When the graphic has not been changed or has only been rotated using the Rotation
keys, the zoom is focused in on the middle of the screen.
When the graphic has been manually displaced, the zoom is focused in on the yellow
crosshair/starting point.

Work/Prohibited area color definitions


Only one area can be selected at a time from the available onscreen selections. To identify the
selected work area the edges of the graphic are bolded. Using color coding the state of the
work area can be identified.

Work area

Active

Inactive

Selected

Not selected

Work area

blue

violet

thick line and/or.


edge

thin line and/or.


edge

Prohibited
area

red

pink

thick line and/or.


edge

thin line and/or.


edge

Collision area
When in the automatic mode a work area error appears, the robot movement stops with the
following message:

Robot synchronous axes work area error: <No.> <Name> [Pos1 > Pos2]
Reason

The next robot movement would collide with a prohibited area.

impact

The robot axes are stopped.

Parameters

<No.> Robot number.


<Name> room name at which the collision has appeared.
Pos1 starting position of the robot movement.
Pos2 Final position of the robot movement.

The 3D view window displays the collision point with a crosshair and a warning symbol. A
dialog shows the data of the collision position.

Collision point

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1.4

OVERVIEW
The Overview window displays a listing of all the areas within the selection.
This window provides a quick overview of the most important work area data.
Work area setup
Robot1

Work Areas and ProhibRobot


Work area above
Work area above
Work area clamping
Prohibited area
Work area rear safety
Work area above deWork area depositing
Work area above deWork area depositing
In machine data

Settings

3D view
Name

Overview

Start point (X/Y/Z) End point (X/Y/Z)

Work area above machine


Work area above clamping
Work area clamping unit
Prohibited area clamping
Work ara rear safety gate
Work area above depositWork area depositing area
Work area above depositWork area depositing area

In parts data

[1]

Listing of the area in the main node

[2]

Start and end point of the listed areas

[3]

Status marking of the areas (green = active)

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1.5

WORK AREAS AND PROHIBITED AREAS


The work areas listed underneath the Robotnode are calculated by the control unit using the
data of the min./max. axes lengths, lower swivelling limit depositing area, switching position of
the Y-waiting position and the settings of the individual areas.
The node In machine data means that all work and prohibit areas are saved with the machine
data. When require, this must also be set by the operator.
The node In parts data means that all work and prehibit areas are saved with the parts data
set. When require, this must also be set by the operator.
Work area setup
Robot1

Work Areas and Prohibited Areas


Robot
Work area above machine
Work area above clamping unit
Work area clamping unit
Prohibited area clamping unit
Work area rear safety gate
Work area above depositing area Z +
Work area depositing area Z +
Work area above depositing area Z Work area depositing area Z In machine data
In parts data

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Work area above machine

Moving area over the machine, with mold closed or without.

Min.

Axis position min.

Axis position -0.3mm

Axis position min.

Max.

Axis position max.

Machine area min.

Machine area max.

Work area above clamping unit

Moving area over the mold (with Y-waiting position switch).

Min.

Work area take-off


area min.

Machine area min.

Work area take-off area


min.

Max.

Work area take-off


area max.

Machine area min. With


waiting position switch up
to Y waiting position

Work area take-off area


max.

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Work area clamping unit

Take-off area with mold open.

Min.

Work area take-off


area min.

Work area take-off area


min.

Work area take-off area


min.

Max.

Work area take-off


area max.

Work area take-off area


max.

Work area take-off area


max.

Prohibited area clamping unit

Prohibited area with mold not open.

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Min.

Prohibited area
machine area min. 0.045mm (in)

Y-Waiting position switch


Work area take-off area
max.
Prohibited area machine
area min.

Prohibited area machine


area min. -0.045mm (in)

Max.

Prohibited area
machine area max.
+0.045mm (in)

Prohibited area machine


area max. +0.045mm (in)

Prohibited area machine


area max. +0.045mm
(in)

Work area rear safety gate

Moving area within the rear safety gate area. The work area is activated and/or deactivated in
relation to the take-off type (horizontal/vertical).

Min.

Work area take-off


area min.

Prohibited area machine


area min.

Work area take-off area


max.

Max.

Work area take-off


area max.

Work area take-off area


max.

Prohibited area machine


area max.

Work area above depositing area Z+

Maximum moving area in the operator rear-side deposit area, up to the lower swivelling limit
deposit area.

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Min.

Axis position min.

Axis position min. 0.3mm

Prohibited area machine


area max.

Max.

Axis position max.

Lower swivelling limit


depositing area

Axis position max.

Work area depositing area Z+

Maximum movable deposit area on the operator rear-side, from the lower swivelling limit
deposit area.

Min.

Work area operator


rear side min.

Lower swivelling limit


depositing area

Work area operator rear


side min.

Max.

Work area operator


rear side max.

Work area operator rear


side max.

Work area operator rear


side max.

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Work area over depositing area Z- (Only for dual-side deposit)

Maximum moving area in the operator side deposit area, to the lower swivelling limit deposit
area.

Min.

Axis position min.

Axis position min.


-0,3mm

Axis position min.

Max.

Axis position max.

Lower swivelling limit


depositing area

Prohibited area machine


area min.

Work area depositing area Z- (Only for dual-side deposit)

Maximum deposit area on the operator side, from the lower swivelling limit deposit area.

Min.

Work area operator


side min.

Lower swivelling limit


depositing area

Work area operator side


min.

Max.

Work area operator


side max.

Work area operator side


Ymax

Work area operator side


max.

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TAKE-OFF-DEPOSITING VARIANTS
Engel variants are preprogrammed sequences which can be included in the graphical
sequence. The parametrization occurs on the screen pages provided for this purpose.
The corresponding screen page is generated automatically after the change and storage in the
sequence editor.

ENGEL - TAKE-OFF VARIANTS


At all Engel variants the function Early start is possible. If the robot has parts on the takeover
head, it deposits at first the parts before the take-off (not at the Teach sample sequence!).
The following take-off variants

are preprogrammed:

Take-off Standard
This variant is preset at the delivery of the robot. It is an universal variant for many
application cases. Several program switches enable a simple and comfortable cycle
time optimization.
Moving in via 2 separate intermediate positions
Take over parts
Moving out via 2 separate intermediate positions

Take-off 6 positions
This variant is the same as the take-off standard, but does it not include any switches
for cycle time optimization.

Take-off 3 positions
This variant is for the most simple type of the take-off. Only the moving-in position
before opening and the take-off position must be set.
Moving in with Z > Y > X individual axis movements on take-off position
Take over parts, ejector returns in parallel with X take-off stroke
Moving out with X > Y > Z individual axis movements on position before opening (the
same path as moving in).

Take-off Teach sample sequence


Moving in via an intermediate position, moving out via 2 intermediate positions. This
take-off variant serves as model for a Teach sequence without screen switch.
CAUTION: At the Teach sample sequence Quick Setup settings for rotary, swivelling
and moving limits as well as settings for rotary axes are without effect when moving out
from the machine area and moving into the machine area!

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TAKE-OFF STANDARD
The standard take-off variant covers a majority of most different take-off requirements for
injection molded parts. It is programmed with two intermediate positions for moving-in and -out
and a demolding position. For the cycle time optimization program switches are provided.
Take-off
Actual position

Take-off Standard
Cycle time
Last cycle time
2nd to last cycle time
Take-off time
Last take-off time
2nd to last take-off time
Moving-in with ejector advanced
Switch on suction pad

after ejector advanced

Close sprue gripper before ejector advancing ejector


Move out as soon as part monitoring
Moving-out without ejector positioning

Take-off Standard

Moving-in with ejector advanced


When switched on, the ejector advances in parallel to the moving-in of the robot.

Switch on suction pad


Switch on selection for sucker before or after the ejector is in front or when the robot
moves in.

Close sprue gripper before ejector advancing ejector


Allows the closing of the sprue gripper still before the ejector is advanced.

Move out as soon as part monitoring


Allows the moving-out of the robot still before the expiry of the demolding time when the
part monitoring gives the release.

Moving-out without ejector positioning


When switched on, the ejector returns in parallel to the moving-out of the robot.

Position before opening = Home position


Speed in take off area
Position before opening

Take-off position - ABC

Take-off Standard

Position before opening = Home position


If the program switch is activated, the position parameters for Home position are
automatically set equal to the parameters for Position before opening [See Robot
general settings on page 89.]

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This causes the robot to wait at its home position for the mold to open before taking off
a part.
If the switch is disabled, the robot waits at the Position before opening. When
automatic operations start, the robot moves from home position to Position before
opening.

Speed in take off area


Speed of the robot axes for moving to the position before opening.
The adjustable speed for the robot movement on the respective position is always valid
for the axis which runs the longest way. The other axes move correspongingly slower in
order that they reach the position at the same time.

Position before opening


Robot waiting position before opening the mold. On this position the robot wait for the
opening of the mold before the take-off of parts.

Take-off position - ABC


Position of the manual axes of the robot for take-off.

Moving in via 2 intermediate positions


Moving-in position speed 1
Moving-in position 1
Moving-in position speed 2
Moving-in position 2

Moving-in position speed 1


Speed of the servoaxes to moving-in position 1.

Moving-in position 1
Robot position which is approached from completely open mold in order to move around
obstacles (tiebars, mold guides).

Moving-in position speed 2


Speed of the servoaxes to moving-in position 2.

Moving-in position 2
Robot position which is approached after the moving-in position 1 in order to move
around obstacles (tiebars, mold guides).

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Sequence sketch

Mold completely open

[1]

Position before opening

[2]

Moving-in position 1

[3]

Moving-in position 2

[4]

Take-off position

Subsequence: Moving-in standard


The robot moves to the take-off position via two moving-in positions. Depending on the
condition fulfilled for the If structure commands, the commands Ejector enable advance and
Take-off vacuum/compressed air circuits [ON] without monitoring are either started in the
sequence or skipped.

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Moving-in standard
If
Moving-in with ejector advanced
Ejector
enable advance

Moving-in position 1
If
Switch on the suction pad {after ejector advanced} = at moving-in position 1
Take-off vacuum/compressed air circuits
[ ON ] without monitoring

Moving-in position 2
Wait until
Mold open
Take-off position - XYZ

Moving-in standard
Take-off
Take-off speed
Take-off position - X Y Z
Waiting time before take-off
Time for part removal

Take-off speed
Speed of the servoaxes to take-off position.

Take-off position - X Y Z
At this position the molded part is taken over by the robot by means of vacuum/
compressed air.

Waiting time before take-off


Waiting time before ejector advance and activation of the vacuum/compressed air
circuits.

Time for part removal


Delay in take-off time for takeover of molded part.
The ejector is then retracted and vacuum/compressed air monitoring is enabled. The
robot then moves to moving-out position 1.

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Moving out via 2 intermediate positions
Speed for move-out position 1
Moving-out position 1
Speed for move-out position 2
Moving-out position 2

Speed for move-out position 1


Speed of the servoaxes to moving-out position 1.

Moving-out position 1
The robot position accessed after the take-off position to avoid obstacles (tie-bars, tool
guides).

Speed for move-out position 2


Speed of the servoaxes to moving-out position 2.

Moving-out position 2
The robot position accessed after the take-off position 1 to avoid obstacles (tie-bars, tool
guides).

Sequence sketch
Depositing area

Machine area

6
1

3
5
Mold completely open

[1]

Position before opening

[2]

Moving-in position 1

[3]

Moving-in position 2

[4]

Take-off position

[5]

Moving-out position 1

[6]

Moving-out position 2

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Subsequence: Moving-out standard


The robot moves via two moving-out positions to either the Position before opening or the
Machine area - Max - Z position. The position the robot accesses depends on the condition
fulfilled in the If structure command.
The rotary axes movements follow the Quick Setup settings.

Moving-out standard
Moving-out position 1
Moving-out position 2
Rotary axes movement moving out from machine area
Speed for move-out position 2 = 100
Stop when safety gate requested
If
Moving-in/out horizontally
Position before
Machine area - Max - Z

Moving-out standard

<Name> part lost


Reason

Part monitoring is still inactive after the monitoring time expired.

impact

Automatic cycle is stopped until the monitoring input is enabled.

removal

Check and set part monitoring or modify the automatic sequence.

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ENGEL DEPOSITING VARIANTS


The following depositing variants are preprogrammed:

Part depositing with/without grid and conveyor-belt


Part deposit in shot grid 1 with/without conveyor-belt
Part deposit in individual part grid with conveyor-belt
Part deposit in Teach grid 1/2 with conveyor-belt
Part deposit Teach sample

Reject deposit - 1 position


Reject deposit - 3 positions
Reject deposit Teach sample

Quality Control deposit - 1 position


Quality Control deposit - 3 positions
Quality Control deposit - Teach sample

Sprue depositing - 1 position


Sprue depositing - 3 positions
Sprue depositing Teach sample

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2.1

PART DEPOSITING IN SHOT GRID WITH CONVEYOR-BELT


This variant is preset at the delivery of the robot. The depositing variant enables a simple grid
depositing of the parts on a conveyor-belt.
depositing
Actual position

Part deposit in shot grid 1 with conveyor-belt


Speed in depositing area
Speed to depositing position
Shot grid 1

Shot grid 1
Waiting time before depositing
Depositing time
Speed from depositing position
Depositing conveyor-belt - Activated
Depositing conveyor-belt - Running time

Part deposit in shot grid 1 with conveyor-belt

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed of servoaxes from the lower swivelling limit to the depositing position.

Shot grid 1
Select this key to tell the control unit to open the shot grid. [See Grid editor on
page 195.]

Waiting time before depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing the molded part.

Speed from depositing position


Speed of servoaxes from the depositing position to the lower swivelling limit.

Depositing conveyor-belt - Activated


Program switch for enabling or disabling the conveyor belt.

Depositing conveyor-belt - Running time:


Running time for the depositing conveyor-belt. The running time starts when the grid is
full (last part deposited). After the conveyor-belt cycle the grid is reset.

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Example:
Shot grid 1

Depositing area Z+

Machine area

Y positon when
moving out/in Z

Upper swivelling limit


depositing area
Lower swivelling limit
depositing area

Grid editor
Robot

Grid

At-

Parame-

Intermediate

Shot grid
Shot grid 1
Shot grid 2
Shot grid 3
Individual part grid
Tach grid

[1]

Position over depositing

[2]

Calculated depositing position in the shot grid.

Simulation Production

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2.2

REJECT DEPOSIT
This depositing variant enables, in case of a rejects recognition, the depositing of the parts on
a separate rejects depositing position.

Reject deposit
Actual position

Reject deposit - 1 position


Program switch reject depositing
Rejects request active
Speed in depositing area
Speed to depositing position
Reject depositing position

Waiting time before depositing


Depositing time
Speed from depositing position

Reject deposit - 1 position

Program switch reject depositing


Program switch enables or disables rejects depositing sequence.
The appertaining flag displays that the rejects depositing sequence is processed.

Rejects request active


The flag signals rejects depositing and is active until a good part is taken out.

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed of servoaxes from the lower swivelling limit to the depositing position.

Reject depositing position


Defines the depositing position for rejects depositing.

Waiting time before depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing the reject molding.

Speed from depositing position


Speed from the depositing point up to the lower swivelling limit.

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QUALITY CONTROL PART DEPOSITING


The depositing variant enables, at an automatic and/or manual request, the depositing of test
parts on a separate test part depositing position.
You can request a quality control part manually by pressing the quality control part request
button on the hand control device.
process malfunction
Actual position

Quality Control deposit - 1 position


Program switch Quality Control depositing
Quality Control necessary
Production cycles before Quality Control part depositing
Production cycles before Quality Control depositing - actual value
Reset counter after manual request for Quality Control part
Quality Control parts - set value
Quality Control parts - actual value

Quality Control deposit - 1 position

Program switch Quality Control depositing


Program switch enables or disables quality control part depositing sequence.
The appertaining flag displays that the test part depositing sequence is processed.

Quality Control necessary


The flag signals that the injection molding machine is producing a quality control part.

Production cycles before Quality Control part depositing


The entered number indicates after how many cycles the depositing of test parts is
started.

Production cycles before Quality Control depositing - actual value


The counter counts the cycles since the last quality control part was deposited. If the
value matches the Production cycles before quality control part depositing count,
a quality control part is deposited in the next cycle. Press the Rbutton to reset the
counter manually.

Reset counter after manual request for Quality Control part


When the program switch is activated, the Production cycles before quality control
parts counter is reset, after depositing a quality control part, when you press the quality
control part request button on the hand control device.
Quality control part request button
on
manual mode device

Quality Control parts - set value


Specifies the number of successive cycles to be deposited as quality control parts.

Quality Control parts - actual value


Actual value counter for quality control part depositing. The value is automatically reset
when it reaches the Quality Control parts-set value . Press the Rbutton to reset the
counter manually.

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Speed in depositing area


Speed to depositing position
Quality Control depositing po-

Waiting time before depositing


Depositing time
Speed from depositing position

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed of servoaxes from the lower swivelling limit to the depositing position.

Quality Control depositing position


Defines the depositing position for the test part depositing.

Waiting time before depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing quality control part.

Speed from depositing position


Speed from the depositing point up to the lower swivelling limit.

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SPRUE DEPOSIT
The sprue depositing function allows separate depositing of injection molded parts and sprue
parts at separate positions.
Sprue deposit
Actual position

Sprue depositing - 1 position


Program switch Sprue depositing
Speed in depositing area
Speed to depositing position
Sprue depositing position

Waiting time before depositing


Depositing time
Speed from depositing position

Sprue depositing - 1 position

Program switch Sprue depositing


Program switch enables or disables sprue depositing sequence.
The appertaining flag displays that the sprue depositing sequence is processed.

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed from the lower swivelling limit up to the depositing position.

Sprue depositing position


Defines the depositing position for the sprue depositing.

Waiting time before depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing the sprue part.

Speed from depositing position


Speed from depositing position to lower swivelling limit.

<Name> Part not deposited


Reason

Part monitoring is still enabled although the function is switched off


after the depositing time expires.

impact

Automatic cycle is stopped until the monitoring input is disabled.

removal

Check and set part monitoring or modify the automatic sequence.

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2.5

INTERMEDIATE LAYERS
The intermediate layer program serves to separate individual grid layers using intermediate
layers (e.g. cartons). The parameters for picking up intermediate layers can be set in the
intermediate layer screen page. Settings for depositing intermediate layers can be set in the
Grid editor, intermediate layer tab. [See Tab - Intermediate layer on page 198.]
Intermediate layers
Actual position

Intermediate layers standard


Program switch Intermediate layers
New search necessary
Speed in the intermediate layers area
Search start position

Magazine moving-in speed


Speed intermediate layer search
Search area before last saved position
Maximum search position

Intermediate layers standard

Program switch Intermediate layers


Program switch for enabling or disabling intermediate layer sequence.
The corresponding flag shows that the intermediate layer sequence is being processed.

New search necessary


The flag is lit when it is uncertain if the stored position is correct when a malfunction or
system restart has occurred. You need to redetermine the pick-up position in this case.

Speed in the intermediate layers area


Speed from lower swivelling limit to Search start position.

Search start position


Starting at this position the robot travels at Speed intermediate layer search until the
stack height has been determined. After determining the stack height, the robot travels
away from this position at Magazine moving-in speed in the subsequent cycles.

Magazine moving-in speed


Speed from Search start position to pick-up position of the last intermediate layer,
minus Search area before last saved position.

Speed intermediate layer search


The robot travels away from Search start position at the speed set here to determine
the initial pick-up position.
In ongoing production, the robot will then move at this speed from the pick-up position
of the last intermediate layer minus Search area before last saved position.

Search area before last saved position


The value is subtracted from the last known pick-up position. Starting at this calculated
position, the search move to the next intermediate layer starts.

Maximum search position


This parameter delimits the search movement of the axis applying the set value. If this
value is overstepped, the robot stops and issues an error message indicating that the
magazine is empty.

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Sequence sketch: Pick up first intermediate deposit

Speed in the intermediate layers area


2

Speed intermediate layer search


3

Maximum search position


[1]

Lower swivelling limit

[2]

Search start position

[3]

Pick-up position of first intermediate layer determined

Sequence sketch: Pick up another intermediate deposit

Speed in the intermediate layers area


2
5

Magazine moving-in speed


3

Speed intermediate layer search


4

Maximum search position


[1]

Lower swivelling limit

[2]

Search start position

[3]

Current pick-up position minus Search area before last saved position

[4]

Pick-up position of first intermediate layer determined

[5]

Search area before last saved position

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Pick up time
Speed intermediate layer lifting
Speed move out magazine

Speed to depositing position


Waiting time before depositing
Depositing time
Speed from depositing position

Pick up time
After activating the vacuum/compressed air circuits, the robot waits at the pick-up
position for the specified time.

Speed intermediate layer lifting


Slow speed for picking up the intermediate layer up to the calculated position (current
pick-up position minus Search area before last saved position).

Speed move out magazine


After reaching the calculated position (current pick-up position minus Search area
before last saved position), the robot travels at this speed to the lower swiveling limit
depositing area.

Speed to depositing position


The robot travels at the speed set here from the lower swiveling limit to the depositing
position.

Waiting time before depositing


Waiting time after reaching the depositing point.
While the time is running the flag is active.

Depositing time
Waiting time after depositing the sprue part.
While the time is running the flag is active.

Speed from depositing position


Speed from the depositing point up to the lower swivelling limit.

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Sequence sketch: Move from intermediate layer pick-up to depositing position

Speed to depositing position


Speed move out magazine

4
2

Speed intermediate layer lifting


1

Maximum search position


[1]

Pick-up position of first intermediate layer determined

[2]

Current pick-up position minus Search area before last saved position

[3]

Lower swivelling limit

[4]

Search area before last saved position

Example:
Pick up intermediate layer from a stack and then deposit after a Y layer on the depositing grid.

[1]

Reception of the intermediate layer.

[2]

Move from intermediate deposit to depositing grid.

[3]

Depositing the intermediate layer on the depositing grid.

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SET UP ROBOT ON INJECTION MOLD


DANGER!
During the robot movement by no means enter the moving area of the
robot and do not reach into it!
Pay attention to possible collisions.
The following procedure only refers to the program Take-off 3 positions with vertical take-off:
1.

On the injection molding machine switch on the set-up mode and at least access
authorization 5

2.

At the injection molding machine the mold must be open with not demolded injection
molded part(s). Pay attention to the correct opening, ejector and core position(s).

3.

At the robot switch on vacuum / compressed air (screen page Quick Setup).

4.

Place robot on the move-in position. Bring X- and Z-axis in position so that no collision
with the injection mold arises when moving in the Y-axis.

5.

Move-in with the Y-axis into the open injection mold. When for reasons of the exact
positioning movements with open safety gate of the injection molding machine must be
run, then press the consent key on the hand control device in addition to the pushbutton.

6.

Place machine ejector on handing-over position (rear and/or in front)

7.

Set robot axes on takeover position so that the part can be taken over.

8.

Switch on sucker or gripper on the hand control device.

9.

Set and/or take over position of the axes on screen page Take-off at Take-off position
- XYZ.

10.

Set required speeds for later automatic mode

11.

Move Y-axis so that a collision-free moving-out from the mold with injection molded
part(s) is possible.

12.

Move Y-axis out from the mold on position 0 so that a collision-free closing of the
injection mold is possible. When necessary, also change the Z position.

13.

Enter axis positions on the screen page Take-off under Position before opening .

14.

Set release for manual axis (axes).

15.

Set times (takeover delay, takeover time, ejector delay).

16.

Move out from the mold.

17.

Move to depositing position.

18.

Move all axes into the position where the part will be deposited.

19.

Select screen page Grid editor and Parameters.

20.

Enter actual position in the Starting position.

21.

Enter speed (V=10%).

22.

Set swivelling limit.

23.

Set parameters for C-axis (and/or A- and B-axis).

24.

Set times (depositing delay time, depositing time, running time depositing conveyorbelt).

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GRAPHIC SEQUENCE EDITOR


The sequence editor is used to create and modify sequence programs for the complete
production machine. It visualizes the program sequences graphically from top to bottom and
is subdivided into subsequences to give operators a better overview.
In Teach mode , sequences/subsequences (= variants) can be replaced as of user level 5,
and created, modified or taught as of user level 7. Machine and robot movements occur at
reduced pressure and speed in this mode.
Engel defined sequences/subsequences are available for various applications. There is only
one user defined sequence/subsequence for every sequence/subsequence.
Robot sequence

Robot sequence

Instruc-

Robot

Robot sequence - user

Peripheral unit

Execute as long as
Automatic mode of operation ac-

Injection molding ma-

Take-off 6 positions

Sequence control

Sprue depositing - 1 position

Grid

If
Reject deposit
Reject deposit
1 Position

Sequences
structure instructions

If
Test part depositing
process malPosition

Part deShot grid

Robot sequence - user

Variants

Program

Edit

View

[1]

Selection window
Structured listing of the equipment components, sequence variants and programming
instructions.

[2]

Sequence selection
Switchover to machine sequence, robot sequence, etc.

[3]

Status line
Displaying the current axis values.

[4]

Sequence window
Graphical display of the selected program sequence with short description. The window
can be scrolled horizontally and vertically.

[5]

Instruction menu keys

[6]

Switchover key
Switching between variant exchange mode and sequence programming

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SEQUENCES
The whole sequence of an automated injection molding unit comprises a number of program
sequences. Sequences can be separated to achieve better readability for complex programs.
The robot sequence, teach sequence and machine sequence all start at the same time when
the start button is pressed.
Sequence selection
Robot sequence
Home position
Park position
Referencing
Robot sequence
Teach sequence
Machine sequence

Robot sequence
The following Engel-defined robot sequences are available:
Robot - Simple - sequence
Variant for standard applications with screen switch for sequence selection. In the
standard case it includes take-off, sprue depositing, reject depositing, test part
depositing and depositing of parts in the grid on the peripheral unit.
Robot - Complex sequence
This also includes the program for intermediate layers, sprue separation and
intermediate deposits.
Robot Teach sample sequence
Simple variant without screen switch for creating special Teach sequences (screen
switches are without effect).
Robot empty sequence
Creating a completely new robot sequence. The robot is provided with a convenient
programming tool (Teach pointer). The last action to be performed using the manual
controller is automatically transferred to the sequence. This can be robot movements
and functions (e.g. vacuum/compressed air, barrel functions).
Ejector and core releases are also automatically programmed if you perform the
corresponding movement on the injection molding machine, and then transfer it to
the manual control unit.

Home position
Moves the robot from the depositing or take-off area with a separate pushbutton
start position.

to

Park position (optional)


Moves the robot to a predefined parking position.

Referencing sequence
Serves to reference the robot axes after switching on the control unit with a separate
pushbutton
.

Teach sequence
Empty sequence for peripheral units or special applications not covered by the standard
program. The Teach sequence starts parallel to the robot sequence. This can occur in
manual mode or via a programmed pushbutton while the robot is in the home position.

Machine sequence
Includes the injection molding machine sequence with closing, injection and opening
sequence.

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READING OF A ROBOT SEQUENCE


The graphic program sequence consists of serial and parallel steps as well as conditional
branches and repeat loops. Each function step is represented as symbol with short text.
When you touch a command in the sequence, the long description appears and the command
is selected in the selection box.

Example:
Robot - Simple - sequence

Robot - Simple - sequence


Execute as long as
Automatic mode of operation active
Take-off Standard
Sprue depositing - 1 position
If
Reject deposit

If
Test part depositing active

Rejects deposit1 Position

process malfuncPosition

Part depositing in
Shot grid 1 with

Robot - Simple - sequence

The robot sequence mainly comprises a take-off sequence and conditional part depositing
sequences (rejects depositing, quality control part depositing, and part depositing). The
subsequences are processed step by step from the top down.
At the structure instruction If corresponding to the condition it is branched downwards or to
the right. The instruction Execute as long as automatic mode of operation active causes a
new start of the robot sequence as long as the automatic mode is active.
Disabled programs are crossed out in red in the sequence and are skipped.
Reject deposit - 1 position
Individual subsequences are indicated by an icon with a bold border, and can be opened by
pressing the + symbol. These subsequences can be broken down into further subsequences
and individual commands.

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Example:
Take-off sequence with subsequence Move-in 3 positions.
1.

Select the command Take-off position - Z.


Take-off
Moving-in 3 positions
Take-off position - Z
Take-off
Moving-in 3 positions

Take-off position - Y
Wait until
Mold open
Take-off position - Y
Moving-in 3 positions

Take-off
2.

The selected step is highlighted in red and a text window with the complete description
appears.
Take-off position - Z
Z=0
Individual axis movement
Speed in take off area=100
Start

3.

If you touch the Take-off position - Z command again, a dialog box appears where you
can read and set the individual parameters.
Individual axis movement
Type

Start
Take-off position - Z

Position

Name

Take-off position - Z
Display on screen page
Speed

Take-off 3 positions

Speed in take off area

Name

Speed in take off area


Display on screen page
Cancel

Take-off 3 positions
Help

Execute

Multiple selection
Touching 2 commands in a sequence selects these two commands and any commands
between them. If you make a multiple selection, the selection is discarded the next time you
select a command in the sequence. Touching an area outside the sequence discards all
selections.

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Display pointer
A green step pointer shows the sequences, subsequences and instructions that are currently
being processed in semi-automatic and fully-automatic operations.
You can activate or deactivate the step pointer in the Sequence Editor using the menu keys
View and Step counter.
Take-off Standard

Background color for instructions

Symbol

Color

Type

Function

yellow

Move instructions - To position

The next instruction starts after reaching the position.

yellow

Release to machine and


wait for final position

The next instruction starts after reaching the final position.

yellow

Switch function on/off and


wait for final position

The next instruction starts after reaching the condition of the final position
or the vacuum switch.

green

Move instructions - Start

The move instruction starts and the


program immediately jumps to the
next instruction. If the next instruction
is also a move instruction, the robot
will not move precisely to this position, but use a smoothing radius
defined in the robot setup.

green

Release to machine

The machine movement is released


by the robot, however, the program
immediately jumps to the next instruction for parallel execution.

green

Switch function on/off

The function starts and the following


instruction is executed immediately.

turquoise

General release or block in


both directions

This instruction takes effect immediately, and the following instruction is


executed immediately.

orange

structure instructions

Structure commands typically contain


conditions. The next instruction is
executed after evaluating the conditions.

Example:
A Goto positionmove instruction, is followed by another Goto positionmove instruction.
Move instruction P3 starts when the robot has moved exactly to position P2 prior to this.

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P3
P1
P2
P3

P1

P2

A Goto position (P1)move instruction, is followed by a Start (P2)move instruction, and then
a move instruction Goto position (P3).
After reaching P1, the move to P2 and the move to P3 instructions immediately start. Position
P2 is approximated.
P3
P1
P2
P3

P1

P2

The ball shows the overgrinding


radius

A Goto position move instruction is followed by a Function.


The vacuum/compressed air function will not start until the robot position has been reached.

A Start move instruction is followed by a Function.


The vacuum/compressed air function starts parallel to the move instruction. They can be
programmed sequentially or preferably in parallel within the sequence.

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EDITING A ROBOT SEQUENCE


The sequence processing can occur in three levels

Exchange variants (as of user access authorization 5).

Teach-In, edit sequence with restricted command set, inserting additional sequences
(as of user level 7).

Editing sequences with full command set (as of user level 9).

Teach operating mode is always required.

NOTICE!
Due to the freely programmable nature of the sequence editor, it is very
easy to make setting mistakes. Pay close attention to the settings
because incorrect settings can lead to equipment damage.
How to switch into Teach mode of operation
1.

Finish any automatic cycle that is running.

2.

Press the Manual program key

3.

Press the Teach program key

During the switchover into the mode of operation Teach the background of the sequence editor
changes from gray to white. It appears the message:

Editiermodus aktiv
impact

Machine and robot movements occur with reduced pressures and/or


speeds.

removal

Switch to manual mode.

NOTICE!
Danger of collision!
In the mode of operation Teach the safety conditions of the sequence
set last for machine and robot are effective.
The new safety conditions only become effective after storing the
changed sequence.

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3.1

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STORING THE SEQUENCE


When you save a sequence, the control unit configures the screens and calculates the
required safety conditions. You must save every sequence change you make.
There are two ways to save the sequence.
1.

Saving by pressing the keys Program + Save.


The control unit stays in Teach operating mode.

2.

Saving by exiting Teach mode.


By pressing the Manual program key Teach mode is exited. The following dialog window
is displayed.
Save sequence
Do you want to save the sequence changes?
Cancel

Help

Undo

Execute

Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
Teach mode is exited. No sequence changes are saved.
Execute
Teach mode is exited, the changes to the sequences are saved.

Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.

3.2

TEST MODE
When test mode is activated, you can step through the instructions in the sequence, e.g. to
test the sequence step by step after programming.
Test mode is activated by

making changes in the Sequence Editor and then quitting Teach mode.

Pressing the Test mode key on the hand control device.

Test mode button on


manual mode device
Pressing the Testmode key again deactivates test mode.
Test mode can be activated at any point in the sequence in automatic mode. Any servoaxis
motions that have been started are completed, and you keep the consent button pressed and
start the next instruction using the acknowledge step button.
If the system is in manual mode when you enable test mode, you must first switch to automatic
mode, and then press the start key. You can then step through the commands in the sequence.
To do so, you must press the Acknowledge step button on the hand control device along with
the consent key.

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Acknowledge step button


on
manual mode device
When you release the consent key, all servoaxis movements are stopped, and you need to
press the consent key again to continue. All servoaxes move at the preset test mode speed.

NOTICE!
A pneumatic axis or function that has already started will not stop when
you release the consent key!

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EXCHANGE VARIANTS
Engel defined sequences/subsequences, referred to as Variants are available for various
applications. You can modify these sequences to reflect your requirements. A modified Engel
defined variant cannot be overwritten, but you can store it as a User defined variant.
If you modify an Engel defined variant, the user-defined variant of every modified sequence/
subsequence is overwritten.
You can only store one user defined sequence for each sequence/subsequence.
For applications such as sprue separation or intermediate deposit, a fully Engel defined Robot
sequence is available. These variants require corresponding hardware signals for monitoring.
The signals are optionally available as interface packages.
After inserting a variant of this type into the sequence, and then storing, the control unit will
display the corresponding setting parameters on the screen pages.
You can replace a variant and then store the sequence to display the modified sequence and
corresponding screen.

Note!
In the Variants view you can only select sequences/subsequences, but not commands.
Tab - Sequence
Robot sequence
Robot sequence

Take-off can be switched

Move in via Z, Y, X take-off position....


Se-

Subse-

Subsequence properties

Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)

Sequence

Robot - Simple - sequence


Execute as long as
Automatic mode of operation active
Take-off Standard
Moving-in/out via 2 intermediate positions
Take over parts
Check function switches on screen for
cycle time optimization
Reject deposit
Reject deposit
1 Position

Program

Edit

Quality Control depositing


process malpart dePosition
Shot grid

View

Variants can only be replaced in the Variants view (light blue background) in Teach mode.
Press the Sequence menu key to change to the Sequenceview where you can only replace
programming sequences but no variants. [See Programming Sequences on page 152.]

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Tab - Subsequence
Se-

Subse-

Subsequence properties

Take-off Standard
If
Take-off vacuum/compressed air circuits one or
Move out without part take-off
Jump to sequence end

Move to position before mold opening

Each sequence comprises a number of subsequences. The subsequence variant selected in


the selection box (e.g. take-off standard,..) is displayed in this tab. This gives you the ability to
view Engel or user-defined subsequences before they are transferred to the sequence.
Tab - Subsequence properties
Se-

Subse-

Subsequence properties

Element attributes
Name

Take-off Standard

Description

Moving in/out via 2


intermediate positions
Take over parts
Check function switches on
screen for
cycle time optimization

Element attributes
Name and short description for selected part depositing (e.g. take-off standard). Which you
can only modify for user-defined variants.

Example:
Replacing the Take-off standard with the Take-off 3 positions variant.
This is based on the Robot sequence simple.
1.

Switch to Teach mode.

2.

Select the robot sequence.


In level 5 the Variant view is automatically enabled (light blue background).
In level 7 or higher, you need to switch to the Variant view using the Variants menu key
in the sequence editor.
Teach pointer
Take-off position - XYZ
Variants

Program

Edit

View

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3.

Select Take-off standard in the sequence.


The available Engel and User-defined sequences are displayed in the selection box.
Robot sequence
Robot sequence

Move in via Z, Y, X take-off position....

Take-off can be switched

Se-

Subse-

Subsequence properties

Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)

Robot - Simple - sequence


Execute as long as
Automatic mode of operation active
Take-off Standard
Moving-in/out via 2 intermediate positions
Take over parts
Check function switches on screen for
cycle time optimization
Reject deposit
Reject deposit
1 Position

Quality Control depositing


process malpart dePosition
Shot grid

4.

Select the Take-off 3 positions variant in the selection box.


You can view the sequence in the Subsequence tab and read the variant properties in
the Subsequence properties tab.

5.

Select Accept to transfer the new variant to the sequence.


Robot sequence
Robot sequence

Move in via Z, Y, X take-off position....

Take-off can be switched Se-

Subse-

Subsequence properties

Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)

6.

Robot - Simple - sequence


Execute as long as
Automatic mode of operation active
Take-off 3 positions
Move in via Z,Y X take-off position
Take over parts for 3/6 position take-off
Move out the same path as move in
If
Reject deposit
Reject deposit
1 Position

If
Quality Control depositing
process malpart dePosition
Shot grid

To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel

Help

Undo

Execute

Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.

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Execute
Teach mode is exited, the changes to the sequences are saved.
7.

The control unit will apply your settings after you save the sequence.
The control unit configures the screen page and calculates the corresponding safety
conditions.

8.

Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]

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3.4

Version: G/11/401/1/11

PROGRAMMING SEQUENCES
This refers to changing Engel and/or user-defined variants or programming of new sequences.
Sequence programming is only possible in the Sequence view which has a white background
in Teach mode.
A modified Engel defined variant cannot be overwritten, but you can store it as a User defined
variant.

Note!
Only one user-defined variant exists for each sequence. In other words, you must store each
user-defined sequence in a part record of its own. The sequence data can be loaded separately from the settings.
There are 2 basic types of sequence programming

Simple programming with the Teach pointer


If you perform a movement or action with the manual control unit, the corresponding
command is displayed on the manual control unit as a preview. The action is transferred
to the sequence when you press the
Transfer Teach command key on the
manual control unit. The Teach pointer automatically proceeds to the next step.
You can use the Teach pointer to program ejector and core movements as release
signals for the sequence.
When you quit Teach mode, the Teach pointer is automatically removed from the
editor.

Programming by manual command insertion


To program a sequence, select a command in the selection box and then insert the
command at the required position into the sequence.
You can insert any commands from the selection box into the sequence.

Note!
If you program a robot movement (linear and rotary axis) with the Teach pointer, a complete
robot position is always inserted, even if only one axis is moved. The control unit assumes the
current position for any axes which are not moved.
You may need to manually optimize the transition between one robot movement and the next,
as well as any parallel functions.
Various approaches to sequence programming

Extending an existing variant


Open the subsequence in question in the sequence editor and use the Teach pointer to
add additional commands at the desired position.
Or open the subsequence in question in the sequence editor and manually select the
commands in the selection box that you would like to insert at the required position.

Modifying an existing sequence


Open the subsequence in question in the sequence editor, delete any commands you
do not need and use the Teach pointer to insert the new commands.

Programming an empty sequence


Instead of an existing sequence, insert an Empty subsequence from the sequence
pool into the robot sequence and program this sequence to suit your requirements. You
can then name the sequence in the Sequence properties tab.

Creating and programming a new Teach variant


Insert a new Teach variant you have created into the sequence and then program the

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subsequence.
When you create a new variant, you can select an icon to match the variant.

3.4.1

USING THE TEACH POINTER TO INSERT THE ROBOT POSITION


Example:
This is based on the Robot Teach sample sequence.
Use the teach pointer to insert Moving-in positions 2 + 3 after Moving-in position 1.
The moving-in points and speeds should be displayed on the take-off screen.
1.

Switch to Teach mode.

2.

Commands can only be inserted in the Sequence view (white background).

3.

In the selection window, select the structure command Teach pointer and insert it into
the sequence below Moving-in position 1.
Robot sequence
Robot sequence

Sequences
structure instructions
Teach pointer
Execute as long as
Repeat until
If

Robot Teach sample sequence


Execute as long as
Automatic mode of operation active
Home position - XYZ
Take-off Teach sample sequence

Parallel open

Take-off position -ABC

Parallel closed
Waiting time
Wait for time or
Wait until

Wait until part take over allowed


Moving-in position 1
Teach pointer

Comment

4.

Move the robot axes to the next desired moving-in position.

5.

The accomplished action is shown in the turquoise field in the Sequence Editor and in
the C30 hand control device display.

Robot movement (Move Job


3/6

6.

Press the

Accept Teach instruction key on the hand control device.

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7.

In the sequence, robot position 2 is created using the current axis positions and a new
speed.
The Teach pointer automatically moves to the next step.
Robot sequence
Robot sequence

Sequences

Robot Teach sample sequence

structure instructions

Execute as long as
Automatic mode of operation active
Home position - XYZ

Teach pointer
Execute as long as
Repeat until

Take-off Teach sample sequence

If

Take-off position -ABC

Parallel open
Wait until part take over allowed

Parallel closed

Moving-in position 1

Waiting time

Robot position 2

Wait for time or


Wait until

Teach pointer

Comment

8.

Double click on the robot position x you just inserted to open a dialog where you can
enter settings for this position.

9.

In the dialog box, click on the Name button for the position and change the name
created by the system to Moving-in position x.
Click the Name speed button, and change the name created by the system to Speed
for moving-in position x. This will help you distinguish the speed for the moving-in
position easier.
Robot movement
Type

On position

Position

Robot position 6

Display on screen page


Speed

Name

Take-off Teach sample...


Name

Speed 6

Speed 6
Display on screen page
Cancel

Take-off Teach sample...


Help

Execute

10.

If you want to display the position and speed on the corresponding screen, additionally
enable the selection boxes Display on screen.

11.

Select Execute to transfer the robot movement changes to the control unit.
The parameter lines with the position and speed are displayed on the Take-off screen
when you store the sequence.

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12.

To insert a second position repeat steps 4 through10.


There is no need to remove the Teach pointer because it is automatically removed from
the sequence on saving.

13.

To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel

Help

Undo

Execute

Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.
Execute
Teach mode is exited, the changes to the sequences are saved.
14.

After saving the sequence the position and speed parameter lines are displayed on the
Take-off screen.
You can use the screen editor to move these parameters to the correct position on the
screen page to reflect the take-off sequence.
[See Moving variables and strips on page 222.]
Moving-in position 2
Moving-in position speed 2
Moving-in position 3
Moving-in position speed 3

3.4.2

15.

In the Variant view, Subsequence properties tab, you can assign a unique name to userdefined sequences and create a short description.

16.

Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]

INSERT ROBOT POSITION MANUALLY


Example:
This is based on Robot simple sequence and Take-off 6 positions.
To reach the take-off point, insert an additional linear axis movement with the name moving-in
position 3 after moving-in position 2. The movement type must be On position.
The speed name should be Speed for moving-in position 3.
1.

Switch to Teach mode.

2.

Commands can only be inserted in the Sequence view (white background).

3.

Open the Robot, Move commands branch in the selection dialog.

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4.

Select the move job Linear axes movement and insert it into the sequence by clicking
on the corresponding insert point below Moving-in position 2.
Robot sequence
Robot sequence

+
Instructions:

Moving-in 6 positions

Robot

Moving-in position 1

Move commands

Moving-in position 2

Individual axis
Wait until
Mold open
Take-off position - XYZ

Linear axes
Rotary axes
Robot movement

Moving-in 6 positions

Multi-position lin-

5.

Dialog window for Linear axes movement opens automatically.


Robot sequence
Robot sequence

Instructions
Robot
Move commands
Individual axis
Linear axes

Moving-in 6 positions
Moving-in position 1
Linear axes movement
Type

On position

Position

Linear axes position 3

Name

Rotary axes
Robot move-

Display on screen page

Multi-position

Speed

Relative move-

Moving-in position speed 3

Stop movement

Display on screen page

Take-off 6 positions

Moving-in position speed 3

Name

Take-off 6 positions

Reference robot
Position check

Cancel

Help

Execute

6.

Use the dialog box to enter settings for the linear axes movement.

7.

Enter a meaningful text as Name for the inserted position and speed. The Display on
screen page switch adds the position at the bottom of the Take-off screen page.

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8.

Press Execute to insert the linear axis movement into the sequence.
Robot sequence
Robot sequence

Instructions

Moving-in 6 positions

Robot

Moving-in position 1

Move commands

Moving-in position 2

Individual axis
Moving-in position 3

Linear axes

Linear axes movement


Speed for moving-in position 3 =50
On position

Rotary axes
Robot moveMulti-position

Moving-in 6 positions

Relative move-

9.

St

To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel

Help

Undo

Execute

Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.
Execute
Teach mode is exited, the changes to the sequences are saved.
10.

After saving the sequence the position and speed parameter lines are displayed on the
Take-off screen.
You can use the screen editor to move these parameters to the correct position on the
screen page to reflect the take-off sequence.
[See Moving variables and strips on page 222.]
Moving-in position 3
Moving-in position speed 3

11.

Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]

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3.4.3

Version: G/11/401/1/11

INSERT SEQUENCE
In the Sequence view you can insert sequences/subsequences besides individual
commands.

Example:
You have removed the complete robot sequence and now want to insert the Robot complex
sequence.
1.

Make sure you are in Teach mode.

2.

You cannot switch to the Variants view because the robot sequence is empty.
Robot sequence
Robot sequence

InstrucRobot
Peripheral unit
Injection molding maSequence control
Grid
Sequences
structure instructions

3.

In the selection box below Sequences, select Robot complex sequence from robot
sequence and add it to the sequence.
Robot sequence
Robot sequence

Intermediate layRobot sequence


Reference -

Robot - Complex sequence


Engel standard sequence, with additional
sprue separation, intermediate deposit and intermedi-

Referencing
Home position Home position
Robot - Empty
Robot - Simple Robot empty seRobot - Complex
Robot Teach

4.

You can now switch to the Variants view.

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3.4.4

CREATE TEACH VARIANT


You can use this function to create sequences/subsequences for peripheral units or special
applications. Every new Teach variant is stored in the Sequences tree below User-defined
sequence.

Example:
You want to create a special subsequence, insert the subsequence into the robot sequence
and then program the sequence.
The basis for this is the Simple robot sequence which is located in the Sequence view (white
background).
1.

You need at least user level 9.

2.

Switch to Teach mode.

3.

Click onj the menu gbuttons Program and Create Teach variant.
Automatic mode of operation active

Sequence control
Grid
Sequences

Take-off Standard
Create Teach variant
Delete user sequence

structure instructions

Delete variables

part deShot grid

Deactivate
Print sequence
Save
Variants

Program

Edit

View

4.

In the dialog window Create variants , enter a name and if needed a short description
for the variant.

5.

Select the icon in the dialog box.


Create variants
Name

Reject molding lamp

Description

Symbol
Cancel

Help

Execute

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6.

The dialog box Icons appears.


Select an icon for the new variant you are creating in the Predefined ODS pool.
Symbols
Display file name

Symbols

Malfunction alert lamp

Predefined ODS

Cancel

Help

Execute

7.

Use the Execute menu button to use the selected icon.

8.

Use Execute to apply your settings.


Create variables
Name

Reject molding lamp

Description

Symbol
Cancel

Help

Execute

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9.

A new User defined sequence branch, where you can access the sequence, is created
in the selection box in the Sequences branch.
Robot sequence
Robot sequence

Intermediate layers
Robot sequence
Robot - Simple - sequence

Park position
intermediate de-

Execute as long as
Automatic mode of operation ac-

Quality Control de-

Take-off Standard

Reject deposit

Sprue depositing - 1 position

Sprue deposit

If
Reject deposit
Reject deposit
1 Position

Tach grid 1
Tach grid 2

If
Quality control part depositing
process malPart deShot grid
Position

User-defined seReject molding


structure instructions
Robot - Simple - sequence

10.

Select the new sequence and insert the sequence at the required position in the
sequence.
Open this sequence and program the required actions.
Robot sequence
Robot sequence

Instruc-

Robot sequence simple - user


Execute as long as
Automatic mode of operation ac-

Robot
Peripheral unit
Injection molding maSequence control
Grid
Sequences
structure instructions

Take-off
Standard
Part deposit
Shot grid

Reject molding lamp


Execute as long as
Automatic mode of operation acWait until
Rejects counter ->
User package 1 output
Set

11.

Finally, store the sequence.

12.

All commands for which Display on screen has been enabled, are automatically
displayed on the Robot parameters screen after saving. This is assigned as a
subscreen to the program switch screen.
Robot 1 program switch
Actual position

+
Robot main switch

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Version: G/11/401/1/11

REMOVING VARIANTS
You can only remove user-defined variants that are not used in the sequence. You cannot
remove Engel-defined variants.
You can remove user-defined variants in the Teach sequence in the Variants view (light blue
background).

Example:
Removing a user-defined variant from the Teach sequence.
1.

Switch to Teach mode.

2.

In the sequence selection dialog, change from Robot sequence to Teach sequence.

3.

Use the Variantmenu button to switch to the Variants view. The sequence is displayed
on a light blue background.

4.

Open the User-definedbranch.

5.

Select the sequence you wish to delete.

6.

Click Program and Delete user sequence.


Robot sequence
Teach sequence

weigh scale

Robot sequence

Se-

Subse-

Subsequence properties

Engel
Teach variant
User-defined (2)

Teach variant

Reject molding lamp


weigh

Create Teach variant


Delete user sequence
Delete variables
Deactivate
Print sequence
Save

Variants

7.

Program

Edit

View

Accept

This removes the scale sequence from the variant pool User-defined sequences.

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3.4.6

DELETE VARIABLES FROM USER-DEFINED SEQUENCES


During programming each new variable you create is stored below User-defined sequence .
The pool may contain a number of variables which are not used by the current sequence.
These variables can be removed from the variable pool using the Remove variables function.
Before you remove the variables, you must save the current sequence. This tells the control
unit which variables you need in the sequence.
Procedure
1.

Switch to Teach mode.

2.

Click on the menu buttons Program and Delete variables.


Robot sequence

Robot sequence
Robot sequence simple - user

Instruc-

Execute as long as
Automatic mode of operation ac-

Robot
Peripheral unit
Injection molding ma-

Take-off
Standard

Sequence control

Reject molding lamp

Create Teach variant

Grid
Sequences

Delete user sequence

structure instructions
Delete variables
Deactivate
Print sequence
Save
Variants

Program

Edit

View

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SEQUENCE INSTRUCTIONS
In the selection window the necessary instruction groups are available for the following
functions:

4.1
4.1.1

Robot
Robot move commands, position checks, special instructions, vacuum/compressed air,
cylinder, outputs.

Peripheral unit
Depositing conveyor-belt, standard interface, reject request, cylinder, outputs.

Injection molding machine


Enabling signals for machine functions,
Enabling signal for robot Wait until part take over allowed,
Rejects.

Sequence control
Stop sequence, stop when safety gate requested.

Grid
Shot grid, individual part grid.

Sequences
All sequences and subsequences which are used in the standard sequences.

structure instructions
Teach pointers, branchings, waiting instructions, assignments etc.

ROBOT
ROBOT MOVE INSTRUCTIONS
Robot movements can occur with individual axes or parallel with several axes. There are 2
movement types:

On position
The position is approached exactly and afterwards the next instruction is executed
(Symbol with yellow background)

Start
The movement starts and the next command is performed(icon with green background).
Servoaxes smoove the movements from one position to the next.

NOTICE!
Danger of collision!
By changing a position instruction to a start instruction the following
movements or actions can be released early in parallel.
Parallel linear axis movements (X, Y, Z) always run so that they reach the set position at the
same time. The adjustable speed is always valid for the axis which moves the widest way. The
other axes move correspondingly slower.

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Symbol

4.1.2

Name

Function

Individual axis movement

The selected linear axis moves on the set


position.

Linear axes movement

All 3 linear axes (X,Y,Z) move parallel on the


set positions.

Rotary axes movement

All rotary axes (A,B,C) move parallel on the


set positions.

Robot movement

All robot axes (X,Y,Z,A,B,C) move parallel on


the set positions.

Multi-positionLinear axes movement

All 3 linear axes (X,Y,Z) move parallel on different positions which are selected in the condition editor (e.g. Y-on upper swivelling limit
depositing area, X and Z-on depositing position).
As an example this instruction is used for
moving only 2 axes.

Relative movement

The selected linear axis moves by the set


value in plus or minus direction.

Stop movement

The preceding move instruction


is stopped, e.g. after switching a key limit
switch on the takeover head. The move
instruction must be configured as Start.

Reference robot axis

This is only used in the Referencing


sequence.

ROBOT POSITION CHECKS

Symbol

Name

Function

Check current position


within range

Checks whether the current linear axes position is


in the defined area. A status marker is set when the
linear axes are in the area.

Check current position


to set position

Checks whether the current linear axes position is


on the defined position. A status marker is set when
the current linear axes position is equal to the
defined position.

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Example:
Check current position within range
In the movement to home position sequence, a range is queried and a marker is set to true if
the linear axes are within the range. The branch is queried by the If structure command and
an X single axis movement, which is only executed in this case, is inserted.
Check current position within range
Range 1
If
Range 1
Movement from area 1 - X

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4.1.3

ROBOT SPECIAL INSTRUCTIONS

NOTICE!
Danger of collision!
When removing manual axes macroinstructions settings on the Quick
Setup screen page become ineffective.

Symbol

Name

Function

Switch off axis

The instruction Switch off axis start switches


the X- and/or Z-axis powerless. This may only
occur when the robot axes stand still. While
an axis is powerless, no moving instruction
with that axis may be programmed.
The instruction Switch off axis stop switches
the power for the corresponding axis on
again.

Start
Stop

Rotary axes movements


moving out from machine
area (Quick Setup)

Rotary axis macro-instruction used in Engeldefined sequences/subsequences. Takes


rotary axes positions, priorities and any parallel movements on Z move out of machine
area into consideration. Parameter setting in
Robot Quick Setup tab Rotary axes on moving out in depositing direction.

Rotary axes movements


before depositing (Quick
Setup)

Rotary axis macro-instruction used in Engeldefined sequences/subsequences. Takes the


settings in the robot Quick Setup tab Rotary
axes on moving out in depositing direction,
parameter Rotary axes to deposit from.

Rotary axes movements after


depositing (Quick Setup)

Rotary axis macro-instruction used in Engeldefined sequences/subsequences. Takes


rotary axes positions, priorities and any parallel movements on Z move in to machine area
into consideration. Parameter setting in the
robot Quick Setup tab Rotary axes moving in
take-off direction.

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Example:
Switch off axis
You need to transfer an injection part to a negative mold mounted on the end of arm tooling.
The Softservo program is not available. The end of arm tooling is robust enough to allow it to
be retracted by an ejector movement.
Take over parts standard user
Take-off vacuum/compressed air circuits
[ON] without monitoring
Switch off axis - Start
X - axis
Ejector
advance
Switch off axis - Stop
X - axis
Mold pause time
Time = 0,3

Ejector
retract

Move out position 1 - X

Example:
Rotary axes movements moving out from machine area (Quick Setup)
Moving-out standard
Moving-out position 1
Moving-out position 2
Rotary axes movement moving out from machine area
Speed for move-out position 2 = 100
Stop when safety gate requested
If
Moving-in/out horizontally
Position before

Moving-out standard

Machine area - Max - Z

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Example:
Rotary axes movements before depositing (Quick Setup)
Moving-in shot grid 1 with conveyor-belt
Position over depositing

Lower swivelling

Wait until
Special instructions rotary axes movement
Shot grid 1 - depositing position screened

Depositing conveyor-belt 1 - Wait depositing allowed


Shot grid 1 - depositing position screened
Moving-in shot grid 1 with conveyor-belt

Example:
Rotary axes movements after depositing (Quick Setup)
Move from depositing area to machine area
If
Not in the depositing area - over upper swivelling limit
Upper swivelling limit depositing area

Wait until
Special instructions rotary axes movement

Wait until
in the depositing area -

If
Moving-in/out vertically ->
Position before
Home position - XYZ

Manual position

Wait until
Special instructions rotary axes movement after depositing completed before
Move from depositing area to machine area

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Version: G/11/401/1/11

ROBOT FUNCTION INSTRUCTIONS


There are 2 instruction types

With monitoring or up to final position


The sequence is only continued after reaching the vacuum / final positions switch
(symbols with yellow background).

Without monitoring or start


Action is started and the sequence is continued without waiting for the vacuum / final
positions switch (symbols with green background)

Symbol

Name

Function

Vacuum/compressed air

Switching-on-off of a vacuum/compressed air


circuit and/or group (group configuration in
the Quick setup) with or without monitoring.

Vacuum/compressed air
group
barrel
Cylinder group
outputs

Activation of a barrel function or all barrels


(barrel group) in the robot and/or peripheral
unit node in + / - direction as appropriate and
with or without monitoring.
Setting or resetting robot or peripheral unit
outputs.

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4.2

PERIPHERAL UNIT
Additional functions are activated/deactivated, switched on/off or interrogated.

Symbol

Name

Function

Depositing conveyor-belt

The conveyor belt program itself is not visible. These commands prevent a collision
between the end of arm tooling and the conveyor-belt. In Engel depositing sequences
with conveyor-belt, the commands Wait until
depositing allowed and Part deposited are
programmed.
For special applications the instructions
Stepping and Action are available.
Stepping actuates the depositing conveyorbelt once for the depositing conveyor-belt
running time.
Action switches the conveyor-belt to permanent operation, time-controlled, clearing
or off.

Sequence instructions
Wait until depositing
allowed
Part deposited
Stepping
Action

Standard interface
Depositing instructions
Wait until depositing
allowed
Part deposited
Pick-up commands
Wait until pick-up allowed
Part picked up
Reject request
Request

Option, used in partial sequence Intermediate layer. In the robot setup for this purpose
2 in/outputs each are configured.
Parts are deposited e.g. in an imprinting
machine ( Wait depositing allowed).
Robot moves on waiting position (Part
deposited).
When printing is finished (Wait until pick-up
allowed), the robot moves to the pick-up
position and picks up the parts.
Following this, the printing machine receives
a signal indicating that the Part has been
picked up.

In a test peripheral unit e.g. good parts and


rejects are separated.
The Request must be programmed before
the part sequence rejects depositing and
sets the internal rejects marker.

barrel

Activation of a robot or peripheral unit barrel


function in the appropriate direction, + / -,
with or without monitoring.

outputs

Setting or resetting robot or peripheral unit


outputs.

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INJECTION MOLDING MACHINE


Instructions for the communication between robot and injection molding machine.
There are 2 instruction types:

Relase and waiting


After the release the execution of the movement is waited for and afterwards the next
instruction is executed (symbols with yellow background).

Only release
After release, the cycle does not wait for the movement to be executed, but continues
with the next command (icons with green background).

NOTICE!
Danger of collision!
Modifying a yellow wait command to a green release command can trigger the subsequent movements or events too early in parallel.

Symbol

Name

Function description

Mold

Mold movement close, open or release/block in both


directions. Clamping force build-up/reduction is not
released/blocked.

Block clamping force


build-up-/reduction

In machines without tie-bars, clamping force build


up causes the C frame to expand which in turn displaces depositing/pick-up positions. To allow for
easy depositing/pick-up of parts, clamping force
build-up/reduction has to be blocked.

Enable clamping force


build-up/reduction

This instruction releases clamping force build-up/


reduction.

Ejector

Ejector movement forward, back or release/lock in


both directions.

Cores

Core moving in, moving out or release/lock in both


directions.

Air valves

Enable air valve, wait for blowing time, do not wait


for blowing time, lock.

Wait until part take


over allowed

Waiting for part injection, mold opening or early start


position has been reached (if early start is configured).
Caution: You can use this only once in a cycle.

Part is reject

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Core not moved in


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Core not moved out


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Mold not open


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Mold not closed


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

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Mold not open at intermediate position


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Mold not closed at intermediate position


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Ejector not in front


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Ejector not retracted


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

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Ejector not advanced at intermediate position


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

Ejector not retracted at intermediate position


Reason

The function is not at the position set in the sequence.

impact

Automatic start is not possible.

removal

Set the position correctly in manual mode.

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4.4

Version: G/11/401/1/11

SEQUENCE CONTROL
Instructions for automatic sequence

Symbol

4.5

Name

Function

Stop sequence

Stops automatic sequence.

Stop when safety gate


requested

The sequence stops if the opening of the safety gate


is requested.

GRID
These functions must be used for the depositing of parts. They refer to shot grid and individual
part grid.

Symbol

Name

Function

Shot grid

At the shot grid (standard depositing) the following instructions can be used:

Increase
Delete

Individual part grid


Increase
Delete
Switch off vacuum/compressed air
Determine the next depositing position
Movement to Y-moving
height

At Increase the shot grid is incremented.


At Delete the shot grid is deleted.

At the individual part grid (special depositing


of each individual part) these instructions
are programmed.
At Increase the individual part grid is
increased by one shot.
At Delete this grid is deleted.
Select Switch off vacuum/compressed air
to switch off vacuum/compressed air in the
configured order (individual parts grid x vacuum/compressed air circuits).
The instruction Determine next depositing
position calculates the next position in the
individual part grid automatically.
At Movement to Y moving height the Y-axis
is moved to the chosen moving height (Grid
editor - Individual part grid - parameters).
Selection: Lower swivelling limit depositing
area, Y moving position absolute or Y moving position relative

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4.6

SEQUENCES
A pool of all sequences/subsequences for insertion into the robot sequence.
You can replace complete sequences/subsequences in the Variants view. [See Exchange
variants on page 148.]
You can insert or delete complete sequences/subsequences in the Sequence view. [See Insert
sequence on page 158.]
Additional sequences

Symbol

Name

Function

Intermediate layer

Serves to take up intermediate layers or trays from a


magazine in the depositing area. For this purpose
also a button switch on the takeover head is necessary.
They are deposited on the depositing grid (see Grid
editor - Intermediate layer)

Park position

The robot moves to its own park position, e.g. when


changing the end of arm tooling or for production
without robot.

intermediate deposit

Serves the intermediate depositing of parts, e.g. on


a peripheral unit or for gripping before depositing.

Sprue separation

Serves to separate the sprue from the part, e.g. with


sprue separation nippers.

Tach grid

For special depositing requests. The sequence must


be programmed by the user.

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4.7

Version: G/11/401/1/11

STRUCTURE INSTRUCTIONS
Special instructions for programming the robot sequence.

Symbol

Name

Function description

Teach pointer

This instruction is inserted into the sequence at the


position where you wish to execute a move or function. In combination with the Accept Teach instruction key on the hand control device, this is
transferred and inserted into the sequence.

Execute as long as

The instructions in the Execute as long as loop are


repeated until the programmed condition is no
longer fulfilled. The next instruction in the sequence
then starts. If the condition is not fulfilled when the
sequence reaches the Execute as long as condition, the sequence flow moves on to execute the
next instruction.

Repeat until

The instructions in the Repeat until loop are


repeated until the programmed condition is fulfilled.
The next instruction in the sequence then starts.
The instructions in the Repeat until loop are executed at least once, whether or not the condition is
fulfilled.

If

When condition {TRUE}, then branch I.


When condition {FALSE}, then branch 0.

Parallel open branch

In case of parallel open branch, the sequence does


not wait for the end of the parallel sequence.

Parallel closed branch

The parallel closed branch must be completed to be


able to start with the next sequential instruction in
the sequence.

Waiting time

Waits for available times from the robot or separate


time modules.

Wait for time or marker

Waits for available times from the robot, separate


time modules or markers.

Wait until

Waits until the condition is fulfilled.

Comment

A text comment does not influence the sequence


but it makes the sequence more readable.

Assignment

Assigns a certain value to a variable.

Jump to sequence end

The execution flow immediately jumps to the end of


the sequence/subsequence in which the instruction
is programmed.

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Symbol

Name

Function description

Alarm

Setting of different alarm classes. Also a separate


text message can be added.

Delete alarm

Command deletes alerts.

Set position

Existing or user-defined positions are used for robot


positions programmed in the sequence.

Copy actual position to

A current robot position is used for the robot position


programmed in the sequence.

Increase

Increments a counter or a position by a specific


value).

Decrease

Decrements a counter or a position by a specific


value).

Check whether intermediate layer possible

Checks whether there are still parts on the takeover


head.

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4.7.1

Version: G/11/401/1/11

TEACH POINTER
Used for quick programming of a Teach sequence for special applications. Set the Teach
pointer at a position in the sequence where you need to perform a special sequence or a
specific movement. [See Programming Sequences on page 152.]

4.7.2

EXECUTE AS LONG AS
The instructions in the Execute as long as loop are repeated while the programmed condition
is fulfilled. If the condition is not fulfilled when the program flow reaches the Execute as long
as condition, the instruction that follows the sequence starts immediately.

Example:
In an automatic sequence, you wish to repeat the additional peripheral unit subsequence until
Input 1 of User Package 1 is no longer active.

Robot sequence simple- user


Execute as long as
Automatic mode of operation active
Take-off Standard
Execute as long as
User package 1 Input 1 {FALSE}
Additional peripheral

Part deposit in shot grid 1 with conveyor-belt

Robot sequence simple- user

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4.7.3

REPEAT UNTIL
The instructions in the Repeat until loop are repeated until the programmed condition is
fulfilled. The next instruction in the sequence then starts. The instructions in the Repeat until
loop are executed at least once, whether or not the condition is fulfilled.

Example:
In an automatic sequence, you wish to start the additional peripheral unit subsequence at
least once, and then repeat the subsequence until Input 1 of User Package 1 is active.

Robot sequence simple- user


Execute as long as
Automatic mode of operation active
Take-off Standard

Additional peripheral
Repeat until
User package 1 Input 1 {FALSE}
Part deposit in shot grid 1 with conveyor-belt

Robot sequence simple- user

4.7.4

IF
In the sequence one or several conditions are interrogated. These must be selected by the
operator before.
If the condition is {TRUE} the main branch is continued to be processed.
If the condition is {WRONG} the alternative branch is processed.

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Example:
If parts are located at the end of arm tooling after the movement to home position (e.g.: program switch Movement to home position with parts) is activated, the cycle continues at the
end of the sequence.
Take-off Standard
If
Take-off vacuum/compressed air circuits Monitoring of parts active {TRUE}
Move out without part take-off
Jump to sequence end

4.7.5

PARALLEL OPEN BRANCH


You can use the parallel open branch to execute instructions in parallel.
In contrast to the Parallel closed branch, the movements in the Parallel open branch do not
need to be completed in order to start the next step in the Sequence Editor.
This instruction is cycle-overlapping.

Example:
After depositing the part on the conveyor-belt, the Y axis must have reached the lower swivelling limit. The peripheral unit must be stepped without waiting in the sequence.
Wait until
Lower swivelling limit depositing area reached

Upper swivelY=0

Peripheral unit cycle


User package 1 - output 1
Set
Clock time
Time=5
User package 1 - output 1
Reset
Peripheral unit cycle

Move out from depositing with conveyor-belt

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4.7.6

PARALLEL CLOSED BRANCH


You can use the parallel closed branch to execute instructions in parallel.
To allow the next step in the sequence editor to start, all movements in the Parallel closed
branch must be completed.
You can program a Parallel closed branch only within a sequence.

4.7.7

WAITING TIME
These times can be used as often as required in the sequence as delays or waiting times. You
can create a time block in a dialog box and display the block on the screen. It is also possible
to use existing robot times.

Example:
After the depositing of parts on the conveyor-belt it must be waited for 0.5 seconds in order to
reduce the vacuum.
Shot grid part deposit 1
Waiting time before depositing
Time=

Depositing vacuum
[OFF] without moni-

Depositing
Time=0,5

Shot grid 1 - Increase

Shot grid part deposit 1

4.7.8

WAIT FOR TIME OR MARKER


The sequence either waits for a time or a marker before continuing. If the time elapses before
the marker receives the signal, the sequence continues.

Note!
If the time = 0, the command is processed and the sequence continues.

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4.7.9

Version: G/11/401/1/11

WAIT UNTIL
In the sequence it is waited until one or several conditions are fulfilled. It can be waited for
counters, markers, actual positions, set positions, values, etc. The conditions must be
programmed by the operator.

Example:
It shall be checked whether parts are still on the takeover head after depositing. The Y-axis
must have reached the lower swivelling limit.
Move out from depositing with conveyor-belt

Lower swivelling
Y=0
Upper swivelling
Y=0

Wait until
Lower swivelling limit depositing area
reached {FALSE}
[OFF] with monitoring
Depositing conveyor-belt - Part deposited

Move out from depositing with conveyor-belt

4.7.10

COMMENT
To make programmed robot sequences more intelligible, operators can add Comments ,
which have no effect on the sequence.

4.7.11

ASSIGNMENT
With this instruction it is possible to assign a value to markers, values, program switches, set
positions manual axes, set positions servoaxes and counters.
This value must be interrogated in the sequence again with certain structure instructions such
as If and Wait until.

Example:
See condition editor

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4.7.12

JUMP TO SEQUENCE END


This command goes to the end of the sequence that includes the command. It is also possible
to use this command in other sequences.

Example:
The automatic cycle is started and if e.g. at the movement to home position still molded parts
are on the takeover head, these shall be deposited on the conveyor-belt.
Take-off Standard
If
Take-off vacuum/compressed air circuits one or several with monitoring
Move out without take-off of parts
Jump to sequence end

Move to position before mold opening


Wait until part take over allowed
Moving-in standard
Take over parts standard
Moving-out standard
Take-off Standard
Sprue depositing - 1 position
If
Reject deposit

If
Test part depositing

Reject deposit
1 Position

Quality Control
Position

Depositing of parts in shot grid


Conveyor-belt

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4.7.13

Version: G/11/401/1/11

ALARM
When this command is reached in a robot sequence, the selected alarm action becomes
active. The alarm screen displays the alarm text you created previously. Alarm actions can be
set from Immediate system stop to Info.

Example:
For an additional peripheral unit for insert parts, you need to query a signal to determine if
insert parts exist. If the peripheral unit is almost empty, you want to issue an alert for information purposes only. The message text is: Caution! Insert parts for machine xxx running null!
If
User package 1 Input 1 = true
Information
Caution! Insert parts for machine xxx running null!

4.7.14

DELETE ALARM
This command deletes any alarm messages you programmed previously.

4.7.15

SET POSITION
Existing or user-defined positions are used for robot positions programmed in the sequence.

4.7.16

COPY ACTUAL POSITION TO


A current robot position is used for the robot position programmed in the sequence.

4.7.17

INCREASE
Incrementing a counter or a position by a specific value.
You can use existing counters and positions or create new ones.
This instruction lets you add a stroke to a position, or increment a counter.

4.7.18

DECREASE
Decrementing a counter or a position by a specific value. The functionality is the same as for
Increase.

4.7.19

CHECK WHETHER INTERMEDIATE LAYER POSSIBLE


If you use the intermediate layers program, the sequence is queried with this command to
determine whether the end of arm tooling contains parts.

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CONDITION EDITOR
The condition editor serves to create logic condition expressions.
For a structure command such as If, Wait until etc., you need at least one condition, which
is programmed in the condition editor.
If you insert the If structure command into a sequence, or you double click on an If condition,
the condition editor is launched.
Two variable types are distinguished by the condition editor

5.1

Boolean variables
These are markers, program switches or digital inputs and outputs.
In case of Boolean variable types, only the states true and false are distinguished.

Non-Boolean variables
These are counters, current or set positions and values and they expect a number as
their parameter.

DIALOG WINDOW
Depending on which user level you log in, the Condition Editor dialog box has a variety of
functions.

User accesss authorization 7


Operators can only program a single condition.
Condition editor - If

Type

TRUE

Test signal of digital inputs


Element
Robot

FALSE
CLR

Number
Cancel

Help

DEL.

Execute

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As of user level 9
Operators can program AND/OR operations.
The dialog box is extended to reflect this ability.
Condition editor - If

Type

Test signal of digital inputs


Element

Robot
Name

Display on screen page

TRUE

XOR

NOT

OR

AND

FALSE

Text

MOD

Number

Cancel

Help

CLR

Execute

DEL.

[1]

Display of the created condition


The selected condition is displayed in the selection boxes Type and Element.

[2]

Arrow left / right


Navigates in the condition to the left/right, but only if a condition part is marked.

[3]

Instruction menu
The created condition can be inserted into the sequence by pressing Execute.

[4]

Structuring and processing functions for the condition

[5]

Assignment functions for variables and functions


Buttons are only active if the corresponding function for the selected condition is
possible.

[6]

Display on screen page


If the program switch is activated, the selected condition is displayed on the screen
(depending on the sequence in which the structure command is inserted).

[7]

Name
Renaming of marked user variables.

[8]

Element
Selection tree of all available elements of the selected type.
For each type the user can createuser-defined variables. Those should be named
intuitively to make the sequence clear and easier to read.
Standard system variables cannot be renamed.

[9]

Type
Selection tree for variable types (e.g. markers, counters, digital inputs and outputs, etc.).

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Type
Test signal of digital inputs
and outputs

The hardware modules for the inputs/outputs supply a


hardware check signal which can be queried to determine
if the status is valid. Possible use in safety-critical
sequences.

Marker

10 Machine markers and Markers created by the user


are available as elements. These can be used freely in the
sequence.
The machine markers 1 and 2 can be described in the
machine sequence and they can be interrogated in the
robot sequences.

Digital in and outputs

In structure instructions such as If, Wait until, Execute


as long as, Repeat until the status of in/outputs can be
interrogated correspondingly.

Program switch

It is also possible to create a program switch which is


saved under the node User-defined sequence.

Status marker

For each robot position, function, in/output and machine


state it is described via the status markers whether a state
is True or False.
With the structure instruction If a status is interrogated
and the program sequence is branched correspondingly.

Counter

In structure instructions such as Increase, If, Wait until,


Assignmentcounters created by the user can be interrogated and/or assigned.

Rotary axes set positions

In structue instructions such as Ifthe machine settings of


rotaryl axes can be interrogated correspondingly.

Actual positions rotary axes

In structure instructions such as Ifactual values of rotary


axes positions can be interrogated correspondingly.

Values

In structure instructions such as Increase, If, Wait until,


Assignmentcreated Values by the user can be interrogated and/or assigned.

Servoaxes set positions

In structure instructions such as Ifthe machine settings of


servoaxes can be interrogated correspondingly.

Servoaxes actual positions

In structure instructions such as Ifactual values of servoaxes positions can be interrogated correspondingly.

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Assignment functions
TRUE

Assigns the boolean value TRUE (1) to the expression.

FALSE

Assigns the boolean value FALSE (0) to the expression.

Text

Opens the input dialog and supports string input).

Number

Opens the input dialog and enables the input of numbers.

Structuring and processing functions


XOR

logic XOR for boolean data types

NOT

logic NOT for boolean data types

OR

logic OR for boolean data types

AND

logic AND for boolean data types

()

Brackets for structuring expressions

Division

Multiplication

Subraction

Addition

<

smaller

>

larger

<=

less than or equal to

>=

greater than or equal to

equal

<>

not equal

MOD

Modulo (delivers an integral rest of a division) e.g.: 5 mod


2 = 1, (5/2=2 rest=1)

CLR

deletes the whole condition

<-

deletes the element inserted last

DEL

removes a marked element

Use of brackets for operations with non-Boolean variables


If you link a non-Boolean variable and another condition with an AND/OR operation, the nonBoolean variable must be enclosed in brackets.
If you do not use brackets at the start of the expression, the keys for the AND, OR, etc.
operations will not be active (black key label).

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Condition editor - If
(Rejects counter
> 10)
AND rejects depositing rejects request active

Type

TRUE

Test signal of digital inputs


Element

XOR

NOT

OR

MOD

CLR

AND

FALSE

Robot
Name

Text

Display on screen page

Number

Cancel

Help

DEL.

Execute

Example:
Add structure command Assignment to robot sequence. For the assignment command, create a variable with a Part 1 deposited marker, and set the TRUE condition.
1.

In the selection window, select the Assignment structure command and insert it into the
sequence at the required position.
Assignment

2.

The Assignment dialog box automatically appears.

3.

Click Selection.
Assignment
Selection:

variable
value

Name

No condition

Cancel

Help

Execute

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4.

Another Assignment dialog box appears.


variable
Selection:
Marker
Counter
Values

Create

Cancel

Help

Execute

5.

Select the Selection icon and then the Create menu button.

6.

The Create variables dialog box appears.


Create variables
Name

value 1

Type

Values
Cancel

Help

Execute

7.

Change the basic type to Marker and the name to Part1 deposited.

8.

Press Executeto transfer the variable to the Assignmentdialog box.

9.

Click on the text box to open the Condition editor.


Assignment
Name

Part 1 deposited

variable
Display on screen page

Robot sequence

value

Cancel

Help

Execute

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10.

Insert a true condition, and apply by pressing Execute.


Condition Editor - Assignment

TRUE

Type
Digital in and outputs

TRUE

XOR

NOT

OR

AND

Element
FALSE

Robot
Name
Display on screen page

Text

Number

MOD

Cancel

11.

Help

DEL.
Execute

Enable the program switch to display the parameter on the screen.


Assignment
Part 1 deposited

variable
Display on screen page

value

Robot sequence

TRUE

Cancel

12.

Name

Help

Execute

Use the Execute menu button to insert the assignment into the sequence.
Assignment
Part1 deposited {TRUE}
TRUE

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GRID EDITOR
The Grid editor is a tool for creating depositing or take-off grids. In these grids the robot can
either deposit injection molded parts, or pick-up insert parts.
Grid editor
Robot

Grid

At-

Shot grid

Parame-

Intermediate

Simulation Production

Starting position

Shot grid 1
Shot grid 2

Shot grid 3
Individual part grid

Grid parameters

Individual part grid

Grid type

Individual part grid

Deposit grid

Distance

Tach grid

Number

Tach grid 1

Priority

Subgrid 1

Shot set

Shot 1

Actual shot

Grid

Edit

Parts sequence

[1]

Status line
Displaying the current axis values.

[2]

Selection tree
Listing of the available grids.

[3]

Setting and simulation area


Machine settings and/or display for selected tab above

[4]

Instruction menu keys

View

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GRID TYPES
3 shot grids, 2 individual part grids and 2 Teach grids are available

1.1

SHOT GRID
The robot deposits all parts for a shot simultaneously, that is, all deposit vacuum/compressed
air circuits are switched off on the corresponding grid depositing positions.
Corresponding to number, distance and priority the shot grid arises from several cycles
(shots).

Example:
The robot uses separate vacuum/compressed air circuits to pick up both parts from a mold
with 2 cavities, and deposits the parts in the shot grid at the same time. In a grid layer the
robot deposits four shots with two parts each.

Z-

X+

2
1

[1]

1.1.1

Calculated depositing position for the fourth shot.

SETTING AND SIMULATION AREA


Tab attributes
Grid editor
Robot

Grid

At-

Parame-

Intermediate

Simulation Production

Shot grid
Shot grid 1
Shot grid 2
Shot grid 3

Element attributes
Name

Shot grid 1

Description

Individual part grid

Element attributes
Freely selectable name and short description for the selected element (e.g. Shot grid 1) in the
selection tree.

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Tab parameters
At-

Parame-

Intermediate

Simulation Production

Starting position

Grid parameters
Grid type

Deposit grid

Distance
Number
Priority
Shot set
Actual shot

Starting position
Depositing or pick-up point for first part on grid. Using the starting position and the Grid
parameterssettings, the control unit calculates the depositing position for the individual shots.
Grid parameters

Grid type
Selecting Deposit grid or Pick-up grid.
For a deposit grid the sign for the Y distance is automatically set to minus.

Distance
Distance between shots on the grid for linear servoaxes (X,Y,Z).
A positive value moves in the positive axis direction from the starting point, and a
negative value moves in the negative axis direction. The sign for the Y distance is set
automatically by the grid type.

Number
Number of shots the robot deposits/picks up in each axis direction.

Priority
Specifies the axis order in which the shots are deposited/picked up on the grid. The axis
with 1 has the highest priority.

Shot set
The set value is calculated by reference to the grid number values. You can change the
value manually to deposit/pick up a defined number of shots. The value must be smaller
than the calculated value. After reaching the set value, the grid is reset.

Actual shot
Actual value for shots deposited/picked up on the grid.

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Example:

-d
is
ta

nc
e

Y - distance

Starting position and grid spacing for part depositing.

Z
ta
is
-D

e
nc

4
2

[1]

Starting position

Tab - Intermediate layer


At-

Parame-

Intermediate

Simulation Production

Used magazine
Magazine sequence

Intermediate layers de-

Thickness of intermediate layers

Intermediate layer
Intermediate layer
Number of layers before intermediate

Special layer
Top layer
Bottom layer

Starting position bottom layer

Intermediate layers are carton, plastic plates or trays which are inserted between the Y grids
(Y layers). The robot can deposit an intermediate layer as a bottom or Top layer.
The parameters for picking up intermediate layers must be set on the Intermediate layers
screen page. [See Intermediate layers on page 133.]
Used magazine

Magazine sequence
In the standard case only Intermediate layers depositing is available. Selection is

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provided for options.
The intermediate layers program will not work if you select No sequence.

Thickness of intermediate layers


Defines the thickness of the intermediate layer. The value is necessary for the
calculation of the Y grid positions.

Intermediate layer

Intermediate layer
Program switch for enabling or disabling intermediate layers. Bottom/covering layers
can still be deposited.

Number of layers before intermediate layer


The value indicates after how many part layers an intermediate layer is placed.

Special layer

Top layer
Program switch for enabling or disabling covering layer. After the last parts layer,
another intermediate layer is deposited as a Top layer.

Bottom layer
Program switch for enabling or disabling bottom layers. Before the first parts layer, an
intermediate layer is deposited as a bottom layer.

Starting position bottom layer


X Y Z A B C - Starting position for bottom layer

Example:

Thickness of
intermediate

Y - distance

Shot grid with bottom and covering layers and two intermediate layers.

Starting position for first grid layer

2
3
4

[1]

Top layer

[2]

Intermediate layer

[3]

molded part

[4]

Bottom layer

Starting position bottom layer

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Tab - Simulation/Production
This is a visualization of the set grid. The settings for the grid can be checked immediately
using the simulation program. You can query the current grid status during production in the
Production tab.
At-

Parame-

Intermediate

Simulation Production

2
3

[1]

Representation of the shot grid with the shot number.


Depositing direction and priority evolve from the shot arrangement.
The Y grid layers and intermediate layers appear in X and Z displaced, but lie exactly
one on top of each other.

[2]

Intermediate layers (in this case as bottom and intermediate layers without covering
layer) are depicted as white rectangles.

[3]

Limiting values of the depositing/take-off positions from the first and last shot in X, Z and
Y direction.

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1.2

INDIVIDUAL PART GRID


The robot can use multiple vacuum/compressed air circuits to deposit individual shot parts at
separate depositing positions.
The number of depositing positions is derived from the number of vacuum/compressed air
circuits selected in the configuration.

Example:
A robot will use separate vacuum/compressed air circuits to pick up each part from a mold
with 2 cavities. Each part is deposited on its own depositing position on the individual parts
grid to ensure optimum use of space. In a grid layer the robot deposits four shots with two
parts each.
Advantage: No Teach grid required. The individual parts grid is simple to configure.

Z-

X+

2
2
1

[1]

Calculated depositing position for vacuum/compressed air circuit 1

[2]

Calculated depositing position for vacuum/compressed air circuit 2

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SETTING AND SIMULATION AREA


Note!
The following section describes those tabs for the individual parts grid that differ from the shot
grid.
Tab parameters
Attributes Parame-

Positions

Intermediate

Sim

Y-moving height
Moving

Lower swivelling limit depos-

Lower swivelling limit depositing area


Y-moving position absolute
Y-moving position relative

Grid parameters
Grid type

Deposit grid

Distance
Number
Priority
Shot set
Actual shot
Actual parts

Y-moving height

Moving height
At the selected moving height, the robot moves along the X and Z axes from the
previous to the next depositing position.
That is: The robot moves its Y axis from the current depositing position at the set Y
movling height, then it moves along X and Z axes on the Y plane to a position above the
next depositing position. When the robot is above the depositing position, the Y axis
moves to this position.
The following parameters are available:
Lower swivelling limit depositing area
Y-moving position absolute
Y-moving position relative

Lower swivelling limit depositing area


You can change this value on the Quick Setup screen page.

Y-moving position absolute


This is a Y axis position. You can change this position if it is set as a moving height.

Y-moving position relative


The stroke of the Y axis in the set direction (+/-). You can change this position if it is set
as a moving height.

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Example:
Sketch of Y moving height

Y move height

[1]

Depositing position for vacuum/compressed air circuit 1

[2]

Depositing position for vacuum/compressed air circuit 2

Tab - positions
At-

Parame-

Positions

Intermediate

Sim

Vacuum/compressed air
mm

mm

mm

mm

mm

Vacuum/compressed air
mm

Vacuum/compressed air x
Starting depositing position for vacuum/compressed air circuit x. The robot moves to the
depositing positions Vacuum/compressed air 1 and Vacuum/compressed air 2 in the order
specified here.
Using the starting position and the Grid parameterssettings, the control unit calculates the
depositing position for parts in the individual shots.

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Example:

-d

is
ta
nc
e

Y - distance

Starting positions for two vacuum/compressed air circuits and grid distances.

Z
e
nc
ta
is

-D

[1]

Depositing starting positions vacuum/compressed air circuit 1

[2]

Depositing starting positions vacuum/compressed air circuit 2

Configure vacuum/compressed air circuit


The depositing starting positions for the vacuum/compressed air circuits are displayed in the
order of dialog box Group configuration - Vacuum /compressed air circuits.
On the Grid Editor screen, the dialog is opened in Teach mode when you press the Grid and
Configurebuttons.
Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements
Vacuum/compressed air
Vacuum/compressed air

Cancel

Help

Execute

Using the navigational arrows <<< and >>> you can move the complete content from
Available elements to Selected elements and vice-versa.
You can select an individual vacuum/compressed air circuit, and move it using the navigational
arrows < and > to insert it into Selected elements in the desired order.

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Note!
You can also configure vacuum/compressed air circuits on the Quick Setup screen page in
the group configuration for Individual part grids - Vacuum/compressed air circuits. [See
Group configuration on page 84.]

Example:
Creating 2 depositing positions for the individual part grid 1.
You need to configure vacuum/compressed air circuits 1 and 2 for this.
1.

To configure vacuum/compressed air circuits, you must first change to Teach mode.

2.

On the Grid Editor screen page select the required individual parts grid in the selection
tree.
Grid editor
Robot

Grid

At-

Parame-

Positions

Intermediate

Sim

Shot grid

Vacuum/compressed air

Individual part grid

mm

Individual part grid 1

mm

mm

Individual part grid


Tach grid

3.

Vacuum/compressed air

Press the menu buttons Grid and Configurationto display the Group configuration Vacuum/compressed air circuitdialog box.
Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements

Vacuum/compressed air
Vacuum/compressed air

Cancel

Help

Execute

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4.

Select Vacuum/Compressed air circuit 1 and use the > key to move it to Selected
Elements.
Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements

Vacuum/compressed air
Vacuum/compressed air

Cancel

Help

Execute

5.

Select vacuum/compressed air circuit 2 and move it to the right using the > key.

6.

Use Execute to store the current configuration.


Group configuration - Vacuum/compressed air circuits

Available elements

Selected elements
Vacuum/compressed air
Vacuum/compressed air

Cancel

7.

Help

Execute

The starting positions are now set in the Positions tab.


Grid editor
Robot

Grid

At-

Parame-

Positions

Intermediate

Sim

Shot grid
Individual part grid
Individual part grid 1

Vacuum/compressed air
mm

mm

mm

mm

mm

Individual part grid


Tach grid

Vacuum/compressed air
mm

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Tab - Simulation/Production
This is a visualization of the set grid. The settings for the grid can be checked immediately
using the simulation program. You can query the current grid status during production in the
Production tab.
Parame-

Positions

Intermediate

Simulation Pr

[1]

Depositing position number for an individual shot (red number in white box). The exact
positions are shown in the Positions tab.

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Version: G/11/401/1/11

TACH GRID
Teach grids are the most flexible grids; two are available. A Part sequence is programmed to
reflect the requirements for each part (the smallest element on the Teach grid). This allows the
robot to deposit each part at a different position.
In standard a Teach grid has the following structure
Tach grid 1
Subgrid 1
Shot 1
Part 1

1.3.1

Teach grid x
Consists of a subgrid, of a shot and of a part.
Operators can extend the structure by creating subgrids, shots, or parts.
The depositing order can be modified directly in the structure tree using Edit, Move in
the instruction menu.

Subgrid x
Several subgrids can be created in the Teach grid x.

Shot x
Several shots can be created in the Subgrid x.

Part x
Several parts can be created in the Shot x.
The depositing sequence for a part can be programmed individually in Part sequence

CONFIGURE TEACH GRID


You can add several subgrids, shots and parts to the Teach grid as required.
Before you can configure the Teach grid you must change to the Teach mode.
You can select Create, Delete and Move in the command menu Grid and Edit . The command
keys are only active if the command in question can be performed for the element selected in
the selection tree (subgrid, shot or part).
Instruction keys

Create
Creates a new subgrid, shot or part.

Delete
Removes a selected subgrid, shot or part.

Move
Change of the Teach grid structure, of subgrid, shot or part. Push marked element in the
selection tree upwards and/or downwards

Note!
Delete all subgrids, shots and parts you do not need for part depositing in the Teach grid from
the selection tree.

Example:
Adding a subgrid to Teach grid 1.

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1.

Before you can configure the Teach grid you must change to Teach mode.

2.

On the Grid Editor screen page select the required individual Teach grid in the
selection tree.
Grid editor
Robot

Element attributes

Grid
Shot grid

Name

Part 1

Individual part grid


Description

Tach grid
Tach grid 1
Subgrid 1
Subgrid 2

3.

Press the Grid and Createmenu buttons to display the Create new subgriddialog box.
Create new subgrid
Subgrid name

Subgrid 2

Shot name

Shot 1

Parts name

Part 1

Cancel

4.

Help

Execute

Use the Execute menu button to insert subgrid 2 into Teach grid 1.
Grid editor
Robot

Element attributes

Grid
Shot grid

Name

Individual part grid


Tach grid

Part 1

Description

Tach grid 1
Subgrid 1
Subgrid 2
Shot 1
Part 1

5.

Tach grid 2

Save the configuration by quitting Teach mode.

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PARTS SEQUENCE
In the Teach grid sequence you can program an individual part sequence for each part in a
shot.
The first instruction in the part sequence starts when the sequence reaches the Teach grid x
instruction in the robot sequence.
You must use the Robot movement with grid move instruction for the depositing position in
the part sequence. This tells the robot to rasterize this position only when depositing injection
molding parts as specified in the Grid Editor. Do not use this instruction for any other
movement, unless you want to rasterize these positions too.

Symbol

Name

Function

Robot movement - grid

All robot axes (X,Y,Z,A,B,C) move in parallel


to the preset positions, and are rasterized
based on the Grid Editor settings.

Example:
In each cycle the robot deposits two parts at different positions. To do this, two parts
sequences have been programmed in the Teach grid sequence.
After the Position before opening or Machine area - Max - Z the robot moves to Linear axes
position 2 . After completing the part sequence for part 1, the part sequence for part 2 starts.
After depositing both parts, the robot continues with the instructions in the robot sequence.

1
If
Moving-in/out horizontally
Position before
Machine area - Max - Z

Part 1
Linear axes position 2
Depositing position 1
Vacuum/compressed air 1
[OFF] with monitoring
Depositing time
Time=1
Lower swivelling limit depositing area

Moving-out standard
Take-off Standard
Part depositing on Teach grid 1 on the conveyor-belt
Depositing conveyor-belt 1 Wait depositing allowed
Tach grid 1

3
Part2

Depositing conveyor belt 1 - Part deposited


Part depositing on Teach grid 1 on the conveyor-belt

Linear axes position 3


Depositing position 2
Vacuum/compressed air 2
[OFF] with monitoring
Depositing time
Time=1
Upper swivelling limit depositing area

[1]

Robot sequence

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[2]

Part sequence for part 1

[3]

Part sequence for part 2

Note!
Double click the Teach grid x instruction in the robot sequence to open the Grid Editor
screen.
Programming the Part Sequence
1.

Switch to Teach mode and select a Part in the selection tree on the Grid Editor screen
page.

2.

Selecting the Parts sequencemenu button takes you from the Grid Editor screen to the
Teach grid sequence.

3.

Select a part and confirm by pressing Close.


Teach grid parts
Grid
Tach grid
Tach grid 1
Subgrid 1
Shot 1
Part 1
Part 2
Shot 2
Tach grid 2

Help

Close

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4.

In the Teach grid sequence, you can program the sequence for a part, or modify an
existing sequence. The Grid Editor menu key lets you go back to the Grid Editor.
Teach grid sePart 1

Instructions:

Part 1

Robot
Peripheral unit
Injection molding maSequence control
Sequences
structure instructions

Grid editor

5.

Program

View

To change from the Teach grid sequence for Part 1 to Part 2 , click on the Part
1selection box.
Teach grid sePart 1

Edit

Instructions:
Robot
Peripheral unit
Injection molding ma-

Part 1

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6.

The Teach grid parts dialog box appears.


Teach grid parts
Grid
Tach grid
Tach grid 1
Subgrid 1
Shot 1
Part 1
Part 2
Shot 2
Tach grid 2

Help

7.

Close

Select Part 2 and confirm by pressing Closein the Teach grid parts dialog box to display
the sequence for the part 2.
Teach grid sePart 2

Instructions:

Part 2

Robot
Peripheral unit
Injection molding maSequence control
Sequences
structure instructions

8.

Quit Teach mode to save.


Press the Manual program button to quit Teach mode. The Save robot sequencedialog
appears.
Save robot sequence
Do you want to save the sequence changes?
Cancel

Help

Undo

Execute

Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
Teach mode is exited. No sequence changes are saved.
Execute
Teach mode is exited, the changes to the sequences are saved.

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Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.

1.3.3

SETTING AND SIMULATION AREA


Note!
The following section describes those tabs for the Teach grid that differ from the shot grid and
individual parts grid.
Tab - Simulation/Production
Grid

At-

Shot grid
Individual part grid
Tach grid
Tach grid 1
Subgrid 1
Shot 1
Part 1
Tach grid 2

Simulation Production

Intermediate

Parame-

Processing
Shot

Subgrid 1

Part

Last Subgrid 1

Shot 1

Part 1

Actual Subgrid 1

Shot 1

Part 2

Next Subgrid 1

Shot 1

Part 1

Depositing staParts total

Act

Set
X

Act

Y
Set

Act

Set

Act

Set

Tach grid 1
Subgrid 1

There is no graphical simulation for a teach grid. The depositing order for subgrids, shots and
parts is displayed in tabular format. You can query the current grid status during production in
the Production tab.
Processing
The subgrid, shot and part for the previous, current and next cycle are shown in the
programmed order.
Depositing status
The current / set number of total parts for all grids is shown.
Below this you can see the current / set numbers juxtaposed for the programmed Teachgrids
and Subgrids in X, Y and Z direction.

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Example:
A robot will use separate vacuum/compressed air circuits to pick up each part from a mold
with 2 cavities. To save space, each part is deposited at a separate depositing position.
A grid layer always contains four parts. The parts from shot 2 are displaced by the Z distance
= 300mm (11.81 in) with respect to the parts from the first shot.
In the subgrid is a shot with 2 parts configured.

Grid editor
Robot

Grid

At-

Parame-

Shot grid

Intermediate

Grid parameters

Individual part grid

Grid type

Tach grid

Deposit grid

Distance

Tach grid 1

Number

Subgrid 1

Priority

Shot 1

Shot set

Part 1
Part 2

Z-

Tach grid 1
Subgrid 1
X+

Shot 2

Shot 1

2
1

Z - Distance

[1]

Part 1

[2]

Part 2

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Example:
A robot will use separate vacuum/compressed air circuits to pick up each part from a mold
with 2 cavities. To save space, each part is deposited at a separate depositing position.
A grid layer always contains four parts at different positions.
Two subgrids with one shot and two parts each are configured for the Teach grid.

Grid editor
Robot

Tach grid

At-

Tach grid 1
Subgrid 1
Shot 1
Part 1
Part 2
Subgrid 2
Shot 1

Parame-

Intermediate

Simulation Production

Grid parameters
Grid type

Deposit grid

Distance
Number
Priority
Shot set

Part 1
Part 2

The robot deposits the parts from the first cycle in subgrid 1, and the parts from the second
cycle in subgrid 2.
Z-

Tach grid 1
Subgrid 2
X+

Subgrid 1

Shot 1
1

Shot 1

2
1

[1]

Part 1

[2]

Part 2

[3]

Part 3

[4]

Part 4

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SCREEN PAGE EDITOR


The screen page editor enables screen pages to be created and edited.
You can also change standard screen pages. However you can only add screen lines and
variables or erase added screen lines and variables.
How to start the screen page editor
1.

Change to the screen page which you want to edit.

2.

Press the screen page selection key Screen page editor.

3.

The following dialog window appears.


What do you want to do?
Create new screen
Delete this screen
Edit this screen page
Cancel

Help

Execute

Create new screen


Opens the screen page editor for creating a new screen page.
Delete this screen
Erases the page to which you have changed. You can only erase user-defined
screen pages.
Edit this screen page
Opens the screen page editor for editing the screen page to which you have
changed. Only the addition of lines and variables is possible on standard screen
pages.
4.

Choose the requested action and press Execute. When you have chosen Create new
screen or Edit this screen page , the screen page editor starts.

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Example page
Screen page

2
Properties

Strips 1

View

Properties

Speed

Example page

Name

Position

Key

Position
Time

Version

Strips 2

Symbol

Comment

Screen

Edit

Finish

View

[1]

Structured view of the current screen page

[2]

Properties
Shows the parameters of the element selected in the structure view.

[3]

View
Preview window for the chosen screen page.

[4]

Instruction menu key

COMPONENTS OF SCREEN PAGES


The structure of a screen page is built up as follows:
Screen page

Properties

View

Strips 1

Strips 1

Actual value
Set value

Speed

flag
flag
Strips 2
Comment
Time

Strips 2
Comment

A Screen page consists of one or several strips.


In the strips you can insert variables . There are several variants of variables. For example:
Actual value, set value, markers, switches, etc.

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STRIPS
There are three types of stripes. Depending on the stripe type you have different processing
possibilities.

Standard stripes (only injection molding machine)


You cannot add or remove any variables to these stripes. You cannot erase or displace
these stripes either. You can insert user stripes on a mask only after the last standard
stripes.

User-defined stripe
When you add a stripe, this is always a user stripe. You can add and remove variables
to these stripes. You can also displace and erase this stripe.

Conditional stripe (only robot)


When you program a sequence in the robot sequence, after the storage the
corresponding variables appear in conditonal stripes on the respective screen pages.
You can add and remove variables to this stripe. You can also displace and erase this
stripe.

EDIT SCREEN PAGES


You can adapt the screen page Freely composeable page to your requirements.
How to edit a screen page
1.

Change to the screen page which you want to edit. In this case to the Freely
composeable page.

2.

Press the key Screen page editor.

3.

In the dialog window choose Edit this screen page and press Execute.

4.

The screen page editor starts. In the screen page editor you change the settings for this
screen page
Example page
Example page

Properties

View

Properties
Name

Example page

Quick call-up key


Screen authorization
Symbol

Name
Designation of the screen page. This name is displayed in the top line.
Quick call-up key
Assign a position to the quick call-up key of the new page. You can choose between
machine and robot quick access. You can assign the quick call-up key only to a
position which is marked with unoccupied.
Screen authorization
Set the user level from which the new screen page can be edited.
Symbol
Select a symbol for the quick call-up key of the screen page.

PASTE OF EXISTING STRIPS


You can insert strips from existing screen pages into another screen page.

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Inserting an existing strip:


1.
2.

Press the menu key New and Strips from screen.


A dialog window appears with a selection of the screen pages.
Select screen
Machine screens

Robot screens

Robot screens
Quick Setup
General settings
test mode
Home position
Quick positioning
Park position
Status page
Torque monitoring

Cancel

Help

Execute

3.

Select the required strip. In this case the Home position strip on the General
settingsscreen.

4.

Press Execute.

Now you have inserted the strip into your screen page.

PASTE NEW STRIPS


Besides the existing strips you can also insert new user-defined strips into the screen page.
Inserting a new strip:
1.

Press the menu key New and Strips.

2.

A new strip has been inserted into the screen page.

3.

Name the strip according to your requirements at Name.


Screen page
Strips 1

Properties

View

Name

Actual value right side

Actual value centered

Strips 1

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Now you have inserted a new strip into the screen page.

PASTE VARIABLES FROM OTHER SCREEN PAGES


You can insert variables into your screen page which are in use on other screen pages.
How to insert variables from other screen pages into your screen page.
1.

Choose the strip into which you want to insert the variable.

2.

Press the menu key New and Variable from screen.

3.

A dialog window appears in which you can select the requested variable.
Select screen
Machine screens

Robot screens

Status page
Torque monitoring
Robot 1 program switch
Robot
Take-off movement
Robot <-> machine
Reject deposit - 1 position
Program switch reject depositing
Quality Control deposit - 1 position

Cancel

Help

4.

Choose the requested variable.

5.

Press Execute.

Execute

Now you have inserted a variable from an existing screen page into your screen page.

PASTE VARIABLES FROM A LIST


You can insert variables from a defined list into your screen page.
How to insert variables from other screen pages into your screen page.
1.

Choose the strip into which you want to insert the variable.

2.

Press the New and Variable from listbuttons.

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3.

A dialog window appears in which you can select the requested variable.
Choose variable from list
System list

Teach Control list

%firmware
%KEOPS
%resource 1
%resource 2
AnalogCoordination
Analog
AnaolgResource1
AutoprotectInj1
AutoSequence1

Display text
Cancel

Help

4.

Choose the requested variable.

5.

Press Execute.

Execute

Now you have inserted a variable from a list into your mask.

PASTE A COMMENT
Comments give you the possibility to insert a freely defineable text line into the screen page.
Inserting a comment:

1.

Choose the stripe into which you want to insert the comment.

2.

Press the menu key New and Comment.

3.

You have added the comment to the stripe.

4.

Enter the requested text into the line Comment.

MOVING VARIABLES AND STRIPS


You can sort individual variables and strips on a screen page by using the Screen Editor.
Do this to move a variable.
1.

Select the variable you want to move.

2.

Press the menu keys Edit and Move.

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3.

A dialog box appears where you can move the selected variable.
Move
to top
Up
Down
to bottom
Close

4.

After moving the variable to the required position, press Close.

You have now moved the variable to the required position on the screen.
You can move a strip in the same way.

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OPTIONS
1

USER PACKAGE
Consists of 2 cylinders with 4 digital inputs and outputs and 4 freely programmable digital
inputs and outputs. Activation of a cylinder function from the node Robot and/or Peripheral unit
in the corresponding direction + / -, with and/or without monitoring.
barrel

STANDARD INTERFACE
The peripheral unit Standard interface is used in the intermediate layerpart sequence. 2
inputs/outputs each are configured for this purpose in the robot setup.
Parts are deposited e.g. in an imprinting machine (Wait depositing allowed).
Robot moves on waiting position (Part deposited).
When imprinting finished (wait Pick-up allowed), the robot moves on the take-up position and
takes up the parts again.
Following this, the imprinting machine receives a signal indicating that the Part has been
picked up.

Symbol

Name
Standard interface
Depositing instructions
Wait until depositing
allowed
Part deposited
Pick-up commands
Wait until pick-up allowed
Part picked up

TAKE-OFF STROKE CORRECTION


This is used to correct the take-off position for the robot in case of mold opening position
deviation.

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Example:
In the Moving-in standard subsequence, the special robot instruction Take-off stroke correction - start is inserted before the take-off position. The X axis is corrected to reflect the current
mold stroke position.
After the Take-off position the robot special instruction Take-off stroke correction stop is
inserted.
Take-off stroke correction - start
Take-off position - XYZ

Take-off stroke correction - stop


Moving-in standard

MOLD SYNCHRONIZATION
The early start program switch must be enabled.
From the early start position the robot moves into the mold. The takeover head approaches the
mold up to a safety distance and follows the mold opening synchronously. When the mold has
reached the opening stroke, the demolding position is approached by the robot. ENGEL
sequence variant is available.

Example:
Moving in with mold synchronization
Mold synchronization - Start
Take-off safety position
Take-off safety position
Wait until
Mold open
Mold synchronization - Stop
Take-off position - XYZ

EJECTOR SYNCHRONIZATION
The takeover head moves synchronously with the ejector movement. When the X-axis can no
longer follow the ejector speed, the ejector is stopped.

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Example:
Special instruction Ejector synchronizations - Start is inserted before the release instruction
Ejector advance . The x-axis will now move back synchronously with the Ejector advance
movement. Ejector synchronization is stopped at the Ejector advanced.
Take over parts with ejector synchronization
Ejector synchronizations - Start
Take-off position
Ejector
advance

Mold pause time


Time=0

Take-off vacuum
[ON] without moni-

Ejector synchronization - stop

SOFTSERVO
Serves to demold, insert and take up parts with an adjustable torque.

Example:
The ejector presses the molded part on the takeover head at the advance and pushes the Xaxis back. When the ejector is advanced, softservo is deactivated again.
Take over parts
Softservo - start
Torque demolding = -0,8
Move out position 1 - X
Ejector
advance
Softservo - stop

Move out position 1

Ejector
retract

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POSITION COMPENSATION FOR TIEBAR-LESS MACHINES


With tiebar-less injection molding machine the depositing and pick-up positions are displaced
on clamping force build-up by C frame expansion. This can cause issues with the robot on
depositing or picking up parts.
The following two sample sequences give you an easy solution to the problem using the
Sequence Editor.

Example:
Picking up insertion parts with built-up clamping force and relative positions.

Position over pick-up position


X=300 Y=0 Z=1200
Wait until
Mold standstill
Mold
block
Block clamping force build-up/reduction
If
Mold clamping force built up
Pick-up insertion part - Pick-up position - Y
Linear axes relative
Y=600
X= -3
Linear axes relative position 1 - Z
Z=0
Set individual axis position (of/on)
Pick-up insertion part - Pick-up position - Y
Increase position (by)
Memory position - Y
Memory position - Y
Y=0

After Position over moving-out position the mold and the clamping force build-up/reduction
are both locked.
The condition in the If command causes the robot to move to the Pick up insertion part Pick-up position - Y if clamping force is not built up.
If clamping force is built up, the robot moves in X and Z direction by a relative position. The
Insert part pick-up - pick-up position - Y is copied to Memory position - Y , and increased
by the value set in the Increment position (from/by) parameter.
The robot then moves to the calculated Memory position - Y.

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Pick-up insertion parts - Pick-up delay


Time=0,2
Vacuum/compressed air 1
[ON] without monitoring
Pick-up insertion parts - Pick-up time
Time=0,5

Lower swivelling
Y=400

Wait until
Lower swivelling limit depositing area reached

Manual position 1
C=[ - ]

Mold
enable

Upper swivelling
Y=0

Enable clamping force build-up/reduction

The Delay time for pick-up starts when the robot reaches the pick-up position. After the delay
has elapsed, the part is picked up.
After the pick-up time has elapsed, the robot moves to the lower swiveling limit. After this, the
mold, and clamping force build-up/reduction are released.

Example:
Picking up insertion parts with built-up clamping force and absolute positions.

Position over pick-up position


X=300 Y=0 Z=1200
Wait until
Mold standstill
Mold
block
Block clamping force build-up/reduction
If
Mold clamping force built up
Pick-up insertion part - Pick-up position - Y
Pick-up insertion
Y=600
X=297
Pick-up insertion parts - Pick-up position for clamping force
Z=1202
Pick-up insertion parts - Pick-up position for clamping force
Y=605

After Position over moving-out position the mold and the clamping force build-up/reduction
are both locked.

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The condition in the If command causes the robot to move to the Pick up insertion part Pick-up position - Y if clamping force is not built up.
If clamping force is built up, the robot first moves to the X and Z pick-up positions and then to
the Y pick-up position.

Note!
You can program the sequence for pick-up parts, release mold and clamping force build-up/
reduction like in the first example.

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SPRUE SEPARATION
With the insertion of a sprue separation sequence to the robot sequence a separate sprue
separation position can be set for the molded part with 2 moving-in and -out positions.
Sprue separation
Actual position

Sprue separation
Program switch Sprue separation
Speed to moving-in position 1
Moving-in position 1

Speed to moving-in position 2


Moving-in position 2

Sprue separation

Program switch Sprue separation


The program switch acivates and/or deactivates the program Sprue separation.

Speed to moving-in position 1


Speed of the servoaxes to moving-in position 1.

Moving-in position 1
Robot position accessed first in Depositing area Z+ to avoid obstacles for sprue cutter.

Speed to moving-in position 2


Speed of the servoaxes to moving-in position 2

Moving-in position 2
Robot position accessed after moving-in position 1 to avoid obstacles for sprue cutter.

Speed to sprue separation position


Sprue separateion position

Delay time
Sprue separation time

Speed to sprue separation position


Speed of the servoaxes to sprue separation position.

Sprue separateion position


After reaching this position, the subsequence for Separate sprue starts in the robot
sequence.

Delay time
After reaching the sprue separation position, the sprue cutter waits for this time before
closing.

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Sprue separation time


After this time has expired, the sprue cutter opens.

Speed to moving-out position 1


Moving-out position 1

Speed to moving-out position 2


Moving-out position 2

Speed to moving-out position 1


Speed of the servoaxes to moving-out position 1.

Moving-out position 1
Robot position which is approached after the sprue separation position in order to drive
round obstacles.

Speed to moving-out position 2


Speed of the servoaxes to moving-out position 2.

Moving-out position 2
Robot position which is approached after the moving-out position 1 in order to drive
round obstacles.

Example:
The robot travels via two move-in positions to the sprue separation position where the cutter
separates the sprue from the molded part. After separating the sprue, the robot travels
towards the depositing position via two moving-out positions.

Depositing area Z+

Upper swivelling limit


depositing area

Machine area

1
3
6

5
4

Lower swivelling limit


depositing area
7

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[1]

Move-in position 1 for sprue separation

[2]

Move-in position 2 for sprue separation

[3]

Sprue separateion position

[4]

Move-out position 1 for sprue separation

[5]

Move-out position 2 for sprue separation

[6]

Position over depositing

[7]

Depositing of parts on conveyor-belt

Subsequence: Sprue separation - user


Sprue separation - User
Moving-in 2 positions - User
Sprue cutters
[ - ] up to final position
Moving-in position 1
Moving-in position 2
Sprue separateion position

Moving-in 2 positions - User


Separate sprue
Delay time
Time = 0,5
Sprue cutters
[ + ] up to final position
Sprue separation time
Time = 0,5
Sprue cutter
[ - ] up to final position
Separate sprue
Move out 2 position
Moving-out position 1
Moving-out position 2
Move out 2 position
Sprue separation - User

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INTERMEDIATE DEPOSIT
Intermediate depositing is often used when molded parts have to be rehandled before
depositing on a conveyor-belt or in cartons. Optional hardware, comprising digital I/Os as
interfaces for the individual signals is required.
intermediate deposit
Actual position

intermediate deposit
Program switch - Intermediate deposit
Speed in depositing area
Speed to depositing position
Depositing position

Delay time depositing


Depositingtime
time
Depositing
Speed from depositing position
Waiting position

intermediate deposit

Program switch - Intermediate deposit


Program switch enables or disables the intermediate deposit program.

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed of servoaxes from the lower swivelling limit to the depositing position.

Depositing position
Position accessed first by the robot in Depositing area Z+.

Delay time depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing the molded part.

Speed from depositing position


Speed of the servoaxes from the depositing position to the waiting position.

Waiting position
Waiting position for robot until molded part pick-up is released.

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Speed to the reception position


Pick-up position

Delay time reception


Pick up time
Speed after pick-up position

Speed to the reception position


Speed of the servoaxes from the waiting position to the pick-up position.

Pick-up position
Robot position to which the robot moves to pick-up molded parts again.

Delay time reception


Waiting time after reaching pick-up position.

Pick up time
Waiting time after picking up a molded part.

Speed after pick-up position


Speed of servoaxes on leaving the pick-up position and moving to the lower swivelling
limit.

Example:
The molded part is deposited on the rotary station. After depositing the part, the robot moves
to its waiting position. While the robot is waiting at the waiting position, the peripheral unit
rotates the molded part through 90. After the peripheral unit has rotated the part, the Pick-up
part released signal is sent to the robot. The robot then moves to the pick-up position to pickup the molded part that has been rotated by the peripheral unit.

3
1

[1]

Depositing position

[2]

Waiting position

[3]

Pick-up position

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WEIGH SCALE INTERMEDIATE DEPOSIT


This option also gives you the opportunity to check the weight of injection molded parts during
production. The robot can automatically separate out reject moldings and deposit them at a
reject molding position. This ensures that the good part depositing area will only contain parts
whose injection weight is within weight tolerance. This removes the need to check the weight
of molded parts manually.
Weigh scale interActual position

Weigh scale intermediate deposit


Program switch - Intermediate deposit on weigh scale
Speed in depositing area
Speed to depositing position
Delay time depositing
Depositing position

Depositing time
Speed from depositing position
Waiting position

Delay time weighing

Weigh scale intermediate deposit

Program switch - Intermediate deposit on weigh scale


Program switch enables or disables the intermediate deposit on weigh scales program.

Speed in depositing area


Speed of the servoaxes in the depositing area (above the lower swivelling limit).

Speed to depositing position


Speed of servoaxes from the lower swivelling limit to the depositing position.

Depositing position
Position accessed first by the robot in Depositing area Z+.

Delay time depositing


Waiting time until depositing position reached.

Depositing time
Waiting time after depositing the molded part.

Speed from depositing position


Speed of the servoaxes from the depositing position to the waiting position.

Waiting position
Waiting position for robot until molded part pick-up is released.

Delay time weighing


Waiting time for weighing the molded part after depositing.

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Speed to the reception position


Delay time reception

Pick-up position

Pick up time
Speed after pick-up position

Speed to the reception position


Speed of the servoaxes from the waiting position to the pick-up position.

Delay time reception


Waiting time after reaching pick-up position.

Pick-up position
Position to which the robot moves to pick-up molded parts.

Pick up time
Waiting time after picking up a molded part.

Speed after pick-up position


Speed for leaving pick-up position.

weigh scale
Weight actual value
Weight within tolerance

Weight set value


Negative tolerance
Positive tolerance

weigh scale

Weight actual value


Weight of current sample.

Weight within tolerance


This flag shows if the measurement is within the tolerance.

Weight set value


Set value for molded part.

Negative / positive tolerance


The tolerance specifies the amount by which the weight of the molded part is allowed to
deviate. If the weight deviation is too large the molded part is sorted out as a reject
molding.

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Quick Setup
Actual position

weigh scale
Weigh scale activated
Weight actual value
Weight within tolerance
Weightset value
Negative tolerance
Positive tolerance
Zero tolerance

weigh scale

Weigh scale activated


Program switch enables or disables the Scale program.

Weight actual value


Weight of current sample.

Weight within tolerance


This check mark shows if the measurement is within the tolerance.

Weight set value


Set value for molded part.

Negative / positive tolerance


The tolerance specifies the amount by which the weight of the molded part is allowed to
deviate. If the weight deviation is too large the molded part is sorted out as a reject
molding.

Zero tolerance
Zero tolerance indicates by what extent the weight of the empty scales is allowed to
deviate. Weight fluctuations of the weighing scales can be caused by vibrations, for
example.
Keep the zero tolerance as low as possible. Reason: If the empty scales show a weight
of 5 grams, and zero tolerance is set to 7 grams, the 5 grams are not deducted but
added to the weight of the molded part. This falsifies the results by 5 grams. This means
that a molded part with a weight of 1 kg will be shown as 1.005 kg on the scales.

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Example:
The robot deposits a molded part on the scales. After depositing, the robot travels to waiting
position and sends a signal to the scales to start weighing. After the weight has been measured, molded part pick-up is released. The robot travels to pick-up position and moves the
molded part either to the depositing position or to the reject position depending on the results.

3
1

[1]

Depositing position

[2]

Waiting position

[3]

Pick-up position

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SPECIAL DESCRIPTION

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Symbols
* Part not deposited 132
*Activate robot set-up mode 101
*Axis - positive/negative axis emergency stop 103
*Axis not referenced 103
*Axis reference switch defective 104
*Axis zero impulse statistics omitted 103
*Axis zero impulse statistics too small 104
*Axis zero impulse statistics warning 104
*Clamping unit safety gate 2 not entirely open 28
*Clamping unit safety gate open 24
*Closing safety - Robot within machine area 80
*Core not moved in 173
*Core not moved out 173
*Ejector not advanced at intermediate position 175
*Ejector not in front 174
*Ejector not retracted 81, 174
*Ejector not retracted at intermediate position 175
*EMERGENCY STOP 23
*Flash card is full 71
*Maximum number of parts exceeded 88
*Mold not closed 173
*Mold not closed at intermediate position 174
*Mold not open 81, 173
*Mold not open at intermediate position 174
*Movement to home position enabled 90
*Nozzle safety gate open 10, 24
*Park position sequence still active 91
*Part lost 125
*Quickpos still active 90
*Robot interlock 81
*Robot motor in setup operations requires level 5 101
*Robot motors switched off 101
*Robot safety gate emergency stop unlocking active! emergency stop acknowledgement required! 23
*Robot safety gate acknowledgement key actuated too fast 28
*Robot safety gate acknowledgement key actuated too long 27
*Robot safety gate acknowledgement key not actuated too long
27
*Robot safety gate not connected 28
*Robot safety gate open 27
*Robot safety gate open-close-acknowledge 27
*Robot synchronous axes work area error 111
*Robot test run without machine active 99
*Take-off invalid - robot was not in the take-off area 80
*Value corrected 72

Numerics
3D view 110

A
Accident prevention 16
Actual axis value display 57
Alarm messages 67
Automatic sequence 140
Axis actual values 43

B
barrel 225
Behaviour in case of fire 29

C
Changing user access authorizations 63
Condition editor 187
Consent keys 36, 46
Control panel machine 31
Control system CC200 31
Control system EC 200 33
Copy parts data set 73

Create Teach variant 159


Creating new user access authorization 62
Cross transport 12

D
Data dialogue 70
Delete data set 74
Delete variables 163
Deleting user access authorization 64
Demolding stroke 12
Depositing area 79
Depositing conveyor-belt 88
Depositing variants 126
Division of the instruction manual 7
Dual-side deposit 108

E
Editing mode active 145
Ejector synchronization 226
EMERGENCY STOP 23
EMERGENCY STOP buttons 23
Engel - take-off variants 119
Exchange variants 148

F
Foil keys on the KETOP C100E 47
Function keys of the KETOP C100E 51
Function keys of the KETOP C30E 37
Function of the safety devices 23

G
General 7
General automation information 11
Grid editor 195
Grid types 196
Group configuration 84

H
Hand control device - Display and navigation 41
Hand control device KETOP C100E 45
Hand terminal - Alarm messages 42
Hand terminal - Display 41
Hand terminal - Status page 43
Hand terminal - Waiting messages 42
Hand terminal function keys 35
Hand terminal robot KETOP C30E 34
Handling tips30 34
Help system 66
Home position 140

I
Individual part grid 201
Input keyboard 58
Insert command manually 155
Insert sequence 158
Instruction manual 7
Instruction manual structure 7
Instructions for Use of Ketop C100E 45
Interactive messages 69
intermediate deposit 234
Intermediate layers 133

M
Machine area 79
Manual buttons on KETOP C30E 35
Mask editor - components of masks 218
Mask editor - Paste a comment 222
Mask editor - Paste new strips 220

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244
Mask editor - Paste of existing strips 219
Mask editor - Paste variables from a list 221
Mask editor - Paste variables from existing screen pages 221
Mask editor - stripes 219
Mold synchronization 226
Mount takeover head 105
Moving-in intermediate position 121
Moving-out intermediate position 124

N
Normal position (Bring robot in normal position) 105

P
Park position 91
Part deposit 127
Parts sequence 210
Pictographs 18
Place of work-operating personnel 22
Plant 112
Plant areas 113
Pneumatic axes 13
Position compensation for tiebar-less machines 228
Powering up the robot 101
Print 74
Printing textually and graphically 75
Program keys 57
Program sequence 152
Prohibited area 107

Q
Quality Control part depositing 130
Quick position 43
Quick setting of robot position 92
Quick Setup 79
QuickSet QuickPos 92

R
Read data set 72
Read sequence 141
Reject deposit 129
Removing variants 162
Robot function instructions 170
Robot general settings 89
Robot move instructions 164
Robot overview 12
Robot position checks 165
Robot program switches 97
Robot Safety guarding 26
Robot sequence 140
Robot special instructions 167
Robot status 95
Rotary axes overview 13

S
Safety 15
Safety controls 35, 46
Safety distance for tiebarless machine range 24
Safety equipment 22
Safety gates injection molding machine 24
Safety guarding that can be entered 22
Safety hints 15
Save robot sequence 146
Saving user access authorization 64
Screen keys on the KETOP C100E 50
Screen page editor 217
Screen page editor - Edit screen page 219
Screen structure 56
Sequence 140
Sequence editor 139

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Sequence instructions 164
Sequence instructions - grid 176
Sequence instructions - injection molding machine 172
Sequence instructions - peripheral unit 171
Sequence instructions - robot 164
Sequence instructions - sequence control 176
Sequences 177
Servo axes referencing 102
Servomotor axes 13
Set sequence 145
Set up robot on tool 137
Setup 61
Shot grid 196
Softservo 227
Sprue deposit 132
Sprue separation 231
Standard interface 225
Standards 8
Status display 57
Storage media 71
structure instructions 178
Switching on the system 55
Swivelling limit 81

T
Tach grid 208
Take-off area 79
Take-off Standard 120
Take-off stroke correction 225
Teach preview on manual control unit 42
test mode 146
Text formattings 9

U
USB interface 55
Use as directed 8
User access authorization - login with card 60
User access authorization - password login 60
User accesss authorization 60
User administration 62
User sequence 140
Using the Teach pointer to insert a command 153

V
Vertical stroke 12

W
weigh scale 236
Work area 107
Work area settings 109
Work area setup 107
Work area setup settings 108
Write a parts data set 73

X
X-axis 12

Y
Y-axis 12

Z
Z-axis 12

be the first.

ENGEL AUSTRIA GmbH. A-4311 Schwertberg


tel: +43.50.620.0 fax: +43.50.620.3609
e-mail: service@engel.at www.engel.info