Operating Manual R8 B2

Operating Manual
UNIROB R8 – UNILOG B2
Read before using the robot and

keep it near the robot for reference purposes.
Robot - Type R8 / B2 6-10-20

Controller type UNILOG B2
Robot No.: 26358
Model: 2003
Version R82GBV00 04/03

Injection moulding
Battenfeld GmbH
Scherl 10 • D-58527 Meinerzhagen
Tel. ++49 2354/72-0 • Fax ++49 2354/72-234
Battenfeld Kunststoffmaschinen Ges.m.b.H.

Wr.Neustädter Straße 81• A - 2542 Kottingbrunn
Tel. ++43 2252/404-0 • Fax ++43 2252/404-261
R82GBD1A.PMD
www.battenfeld.com
DIN EN ISO 9001

Index
Chapter 1 General information
Chapter 2 Safety
Chapter 3 Technical Data
Chapter 4 Transport - Installation
Chapter 5 Structure and function

?
Chapter 6 Comissioning 0
Chapter 7 Maintenance
Chapter 8 Spares / Plans
Chapter 9 Customer service
Chapter 10 Extra chapter for special modules
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Index
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Table of contents
1.0 General 3.2 Robot axles

1.1 Introduction 3.2.1 Linear axles
1.2 Use 3.2.2 Auxiliary axes
1.3 Symbols 3.3 Performance data /
Mechanical interfaces /
1.4 Copyright
Technical features
1.5 Confirmation of receipt
3.3.1 Linear axes (main axes)
1.6 Declaration of Conformity Main axis paths – Axis
lengths
3.3.2 Drives / Repeat accuracy
2.0 Safety
3.3.3 Maximum speeds of main
2.1 Safety regulations and linear axes
2.1.1 General 3.3.4 Maximum speeds of rotating
2.1.2 Installation and auxiliary axes
2.1.3 Operation and maintenance 3.4 Pneumatic system
2.1.4 Safety - Personnel 3.4.1 Compressed air connection
2.1.5 Safety regulations – 3.4.2 Creating a vacuum

Pneumatic systems 3.4.3 Pneumatic valves
2.1.6 Safety regulations – 3.4.4 Pressure monitoring
Electrical systems
3.4.5 Central configuration
3.5 Guideways on main axes
3.6 Motors / Gearing
3.0 Specifications
3.6.1 Maintenance-free servo
3.1 Machine description
three-phase a.c. motors for
UNIROB B2 industrial robot
main linear axes
3.1.1 Kinematics
3.6.2 Planetary gearing for the X
3.1.2 Handling loads (Z) and Y and Z axis drive
3.1.3 Mechanical interface
3.1.4 Delivery side selection
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3.7 Drive elements on main axes 4.1.7 Installation layout

3.7.1 X + Z-axis 4.1.8 External stand
3.7.2 Y-axis immersion pipe 4.1.9 Removing protective
coatings
3.8 Mechanical interface
4.2 Connecting to the power
3.8.1 Gripper interfaces
supply
3.8.2 Manual gripper quick change
4.3 Commissioning
3.9 R8/B2 robot options
4.3.1 Connecting to the power
3.10 EUROMAP 12 supply
3.10.1 Robot / Injection moulding 4.3.2 Harting connector
machine interface
4.3.3 Lubrication points
3.10.2 Injection moulding machine
4.3.4 Compressed air supply
signals
4.3.5 Activating the main switch
3.10.3 Handling device signals
4.3.6 EMERGENCY STOP test
4 Transport - Installation 4.3.7 Power ON
4.1 General
4.1.1 Storage ? 5 Assembly and Operation
5.1 Modules
4.1.2 Unloading
5.2 Pneumatic system
4.1.3 Securing devices
5.2.1 Directional control valves
4.1.4 Crane transportation
5.2.2 Vacuum suction nozzle
4.1.5 Transport weight
5.2.3 Cleaner
4.1.6 Injection moulding machine
assembly 5.3 Electrical systems
5.3.1 Electric motors
5.3.2 Control cabinet
5.3.3 Terminal box 1
5.3.4 Terminal box 2
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5.4 Unirob B2 controller 5.5.5.3 Token commands for additio-

nal devices
5.4.1 Manual Control Device
(MCD) 5.5.5.4 Palletising program
5.4.2 PCS General 5.5.6 Examples of programs
5.4.3 CP476 status display 5.5.7 Lock areas
5.4.4 CAN CP476 node number 5.5.8 Error messages
switch
5.4.5 Digital inputs and outputs 6 Operation
0
5.5 B2 Control System 6.1 Start-up
Handbook
6.2 Referencing
5.5.1 Manual Control Device
6.3 Manual operation
(MCD) – Key functions
6.4 Single step mode
5.5.2 Start-up display
6.5 Automatic operation
5.5.3 Status pages
6.6 Stopping the program
5.5.4 Teach, Edit, Save, Load,
Delete, Print programs 6.7 Automatic mode STOP
5.5.5 Creating token programs 6.8 EMERGENCY STOP
5.5.5.1 Token commands: Gripper
(GRP), Robot (ROB),
Injection Moulding Device
(IMD)
5.5.5.2 PCS token commands
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7 Maintenance 7.5.1 X, Y and Z axis greasing

points
7.1 General
7.6 Drive units
7.2 Transport, Storage and
Waste Disposal 7.6.1 Belt
7.2.1 Lubricants 7.6.1.1 Belt tension - X, Y, Z axes
7.2.2 Electrical components 7.6.1.2 X and Z axis belt drive
7.3 Electrical systems 7.6.1.3 Toothed belt replacement
7.3.1 Electromechanical limit 7.6.1.4 Noise
switch
7.6.2 Gears
7.3.2 Proximity switches
7.7 Power guide chains
7.3.3 Indicator lights
7.8 Maintenance catalogue
7.3.5 Battery change
8 Spare parts / Diagrams
7.4 Pneumatic system
7.4.1 Compressed air servicing
unit
9 Customer Services
7.4.2 Pneumatic connections
7.4.3 Pneumatic C-axes
7.4.3.1 Settings C – axis (tilting)
7.4.4 Pneumatic B-axes 10 Additional section for
7.4.4.1 Settings: B - axis (swivel) special models
7.4.5 Pneumatic installation

components
7.4.6 Sound absorbers
7.5 Linear axis guideways
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Attention! Attention! Attention! Attention!
Important notes for initial operation!
A factory password is required for robot operation.

It enables the user to switch to Password level 1.
PASSWORD: 2002
Further details of the various password levels can be found in Section 5.5.2
Start-up display.
R82GBPAA.PMD
General
General Should you encounter any problems in operating

the robot system, please get in touch with our
Service section or one of our agents (Addresses
1.1 Introduction can be found in the ”Servicing” section).
All persons involved in the operation of the This operating manual only applies to operation
Battenfeld robot system must read and pay of the robot system depicted on the title page.
close attention to each section of this manual.
Diagrams and specifications contained in this
The complete manual should always be kept manual are subject to change where these are
near the robot system for use by machine deemed necessary in improving and developing
operators and service engineers. the robot system.
The manual should be read thoroughly, paying 1.2 Use

special attention to the Section on ”Safety”, in
order to avoid any faults occurring and ensure
The Battenfeld robot system is generally used in
smooth operation of the robot system. It is
conjunction with other injection moulding
therefore essential that the manual is available
equipment.
to all persons who are responsible for operation
of the system. The manual must be studied
The robot is not designed for any other purpose.
before start-up. We cannot accept responsibility
We cannot be held responsible for damage
for any damage or stoppages which are due to
resulting from improper use. Any risks incurred
failure to read the manual.
in such use shall be borne by the user.
We offer operator training courses in our
company. In-house courses can also be
arranged Contact our Training Department for
further details.
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General
1.3 Symbols
”Danger of crushing” indicates there is a risk of

being crushed.
The safety symbol can be found in all the work or jammed etc.
safety regulations in this operating manual
where operators and service technicians are
exposed to the risk of physical and fatal injuries.
Follow these instructions and take extreme care
in such situations. Ensure that all other users A ”Do not enter” sign warns that a surface or
are familiar with the work safety instructions. area must not be used / entered.
Apart from the instructions found in this
operating manual, it is also important to be Attention
aware of general safety and accident prevention ”Attention” is used throughout this operating
rules. manual where it is especially important that
guidelines, rules, instructions and proper work
The following safety symbols and prohibiting procedures and processes are adhered to. It is
signs are used on the robot system. They are also intended to ensure that measures are taken
intended to warn operators and service to prevent the robot system from being
engineers of any dangers which may result in damaged or destroyed.
physical and fatal injuries.
The high voltage symbol is used in sections of

Areas labelled ”Hot surface” indicate there is a the operating manual which describe where
risk of burning. Operators and service engineers operators and service engineers may come into
must wear suitable protective clothing (refer to contact with electrical components and
DIN EN 407). operating materials. It is important to ensure that
local electrical safety regulations are adhered to.
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General
1.6 Declaration of Conformity

The Declaration of Conformity can be found at
The symbol indicating environmental hazards the end of this section.
indicates that there is a risk of environmental
pollution when disposing of various materials.
Local laws and regulations must be observed
when carrying out any necessary repairs or
maintenance.
1.4 Copyright
The copyrights to this operating manual are the
property of Battenfeld GmbH. The operating
manual is intended for assembly, operating and
monitoring staff. It contains regulations and
diagrams which may not be copied, distributed
or used for competitive purposes – in part or
whole - without prior authorisation, or revealed to
third parties.
1.5 Confirmation of receipt

The confirmation of receipt supplied with this
operating manual serves to verify that the
manual has been received and is complete.
Please sign the Confirmation of receipt to
confirm that you have received the complete
manual and return it to the ”Documentation”
department.
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General
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Fax transmission
General
To: BKU Documentation Department ++43/2252 404 - 3002
Confirmation of receipt
to confirm that the technical documentation has been received
by the customer
1) Robot - Type _______________________________________ Robot No.: ________________
2) Customer’s address ___________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
3) The robot specified under Item 1 was acquired by our company. Upon receipt of the robot
we were supplied with ___________________________________ (quantity)
operating manual (s) in __________________________ supplied.
_________________________ ___________________________________________
Date Customer’s signature
4) Supplied: _____ ___________________________________________
5) Signature of dealer or importer:
Company stamp / signature
6) The robot was supplied to the cus-

tomer in accordance with the
manufacturer’s guidelines:
_______________________________ Signature if different to 5

Date Signature of service engineer
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General
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Safety
2 Safety Intended use of the system shall include

adherence to the assembly, dismantling, start-
up, operation and maintenance procedures
2.1 Safety rules specified by the manufacturer.
2.1.1 General The responsible persons and the work

procedures involved in assembly, dismantling,
The injection moulding machine and the robot start-up, operation, conversion and maintenance
are fitted with numerous safety devices to of the system must be recorded in the form of
provide safe operation and to prevent accidents general instructions.
occurring. The user is responsible for ensuring
that the safety devices are functioning properly. Any modifications and changes which affect
safe operation of the system as well as all
The robot system has been designed and built maintenance work must be recorded in an
in accordance with currently valid safety inspection book and kept for at least 10 years.
specifications (EN 201) and is an operationally
reliable machine. The system can, however, be It is important to be familiar with the safety
dangerous if it is operated by untrained persons regulations specified in the ”Injection Moulding
in an improper manner or not used for the Machine” operating manual before using the
intended purpose. SGM with a robot system.
Safe operation can only be guaranteed provided Before using the robot system in conjunction
the control program is not modified. Any with an attached peripheral device (e.g.
unauthorised changes made to the program materials transport device) it is important to be
shall invalidate any guarantee claims. familiar with the safety regulations in the relevant
operating manual.
The robot system must always be operated in
accordance with current environmental, safety Peripheral devices may only be installed and
and accident prevention rules and the specified connected by authorised specialists.
operating procedures.
The user is responsible for making sure that the
The user may not make any modifications or system is operated as specified in the operating
changes which may affect the operating safety manual, i.e. in a safe manner in view of the
of the system. potential risks involved.
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Safety
Tool cranes may only be erected by authorised The robot system may only be transported using
persons. Cranes may only be used for the the eyebolts and elements specified in the
purpose of mounting and removing tools. Do not Section entitled ”Transport – Installation”.
stand under suspended loads! The maximum
load is indicated on a sign on the crane. The safety measures specified in DIN EN 292-2,
Item 6.1.2 must be taken into account before the
The robot system must be disconnected from IMM is installed.
all power supply sources whenever it is moved
to another location or moved only slightly. It is necessary to ensure that all the IMM power
Reconnect all the power supply points as sources are deactivated (electrical system) or
specified in the manual before restarting the not in operation (pneumatic system) before
system. mounting the ”self-supporting protective grating”.
If the robot system is transferred to a third party The safety devices must be tested after fitting or
or company it must be supplied with the carrying out repairs on electrical systems.
operating manual. We recommend you request
this be confirmed in writing. Potential risks may be created if untrained
persons are allowed to make adjustments to the
2.1.2 Installation robot system in an improper manner and
without due regard to its intended use.
Individual components, modules and the entire
robot system must be securely attached to the Adjustments may therefore only be made by
lifting gear whenever any assembly, trained set-up engineers.
disassembly, conversion, adjustment or
maintenance is work carried out in order to Set-up engineers are persons who, based upon
guard against any potential hazards. their specialist raining and experience, have a
wide knowledge of the materials, tools and
control systems used in robot systems and who
Only use suitable lifting gear which is in perfect are also familiar with the relevant national work
working order and has sufficient load capacity. protection and accident prevention regulations,
Do not stand or work under suspended loads. as well as guidelines and generally accepted
technical specifications, such as DIN norms.
Loads may only be attached, secured and
transported by experienced authorised
specialists.
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Safety
2.1.3 Operation and maintenance Replacement parts must at least meet with the
technical requirements specified by the
Servicing may only be carried out when the manufacturers.
robot system is not in operation. Here, it is
important to follow the corresponding shut down The user must ensure that electrical
procedures. components, motors etc. do not come into
contact with liquids.
Before carrying out any work on the robot
system make sure that the drives and auxiliary Before carrying out any repairs, clean the
devices are secured against accidental start-up, surrounding area thoroughly, especially the
e.g. by attaching a padlock to the main switch. connections and screw fittings.
The safety devices must always be tested Cleaning agents are toxic, inflammable liquids.
before the robot system is restarted. Follow the manufacturer’s instructions. Do not
use any aggressive cleaning agents. Use non-
Make sure that all the safety devices are liming cleaning cloths.
properly attached before you restart the robot
system after carrying out maintenance work. Observe the relevant product safety regulations
when handling oil, grease and other chemical
Check the gap between the IMM and the ”self- substances.
supporting protective grating”. The gap must be
small enough to prevent anyone from reaching The user must ensure that process materials
inside. If it is too large, the grating must be are disposed of in a safe, environmentally
repositioned by the user. friendly manner.
Safety devices may only be removed when the Always tighten any screw fittings which have
IMM and the robot system have been shut down been slackened off during maintenance and
and secured. repair work. Check for leaking pipes, loose
screw fittings, signs of wear and damage.
When operating the ejector mechanisms or the Remedy any defects immediately.
core pullers with the safety door open, it is
necessary to ensure that there are no crushing
or shearing marks on the tool.
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Safety
2.1.4 Safety - Personnel When carrying out any form of assembly/

disassembly, conversion and maintenance
Every person concerned with the IMM and the activities the IMM and the robot system must be
robot system at the user’s plant must have read deactivated at the main switch and secured
and understood the relevant operating manual, against accidental start-up, e.g. by padlocking
especially the section entitled ”Safety”. This the main switch.
applies to all persons involved in assembly/
disassembly work, commissioning, operation During any work involving assembly/
and repair activities (servicing, maintenance and disassembly, conversion, operation and
repairs). Users are recommended to require maintenance activities, inflammable liquids must
this be confirmed in writing by each of the not be allowed to come into contact with
persons concerned. components which may create a fire hazard or
explode as a result of high temperatures.
The IMM and the robot system may only be
operated, serviced and repaired by authorised, The following systems must be allowed to cool
qualified persons who have received special down to a safe temperature before carrying out
training on how to deal with potential hazards. any work involving assembly/disassembly,
conversion or maintenance activities:
Persons who are to be trained and instructed or
who are participating in general training courses • Heating elements and guards.
may only work on the IMM and the robot system
• Temperature stabilisers, including
provided they are constantly supervised by
fittings, feeder/return pipes and
authorised, qualified persons.
mountings.
Operators must not have long hair, wear loose- • Water/heat transfer oil-filled surface
fitting clothing or wear any form of jewellery or cooling on the worm cylinder (optional)
rings. Here there is the risk of injury, e.g. getting and/or worm feed zone (optional),
caught in moving parts. including all fittings, feeder/return pipes
Responsibility for assembly/disassembly, and mountings.
commissioning. operation and maintenance • Water/heat transfer oil internal cooling on
activities must be clearly defined and adhered to the worm (optional), including all fittings,
in order to avoid any potential feeder/return pipes and mountings.
misunderstandings with regard to safety.
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Safety
Operators must wear suitable protective The operator must immediately report any
clothing to guard against burns caused by changes which will affect the safety of the IMM
contact with heating elements, temperature and the robot system. The robot system must
stabilisers and their protective coverings, always be stopped immediately using the
fittings, feeder/return pipes and mountings as emergency stop button and by deactivating the
well as electric motor housing sections (refer to main switch.
DIN EN 407).
The IMM and the robot system may only be
The IMM and the robot system may only be operated when they are in perfect condition.
operated with the safety covers and doors
closed. Users must issue the appropriate instructions
and carry out the corresponding checks to
No work must be allowed to affect safe ensure that the IMM and the robot system are
operation of the IMM or the robot system. kept clean and tidy.
Operators must ensure that no unauthorised The operator must observe all safety
persons are allowed to work on the IMM or the instructions and warning signs on the IMM and
robot system. the robot system. These must all be kept in a
legible condition.
The operator and any other persons may only
stand in front of the IMM on the operating side Safety ladders and platforms must be used
whilst the machine is in operation. when assembling/disassembling, converting,
operating or servicing overhead sections of the
Do not enter the IMM or the robot system IMM and robot system, in accordance with legal
operating area or reach into the injection rules and regulations. Do not climb onto any
moulding unit during operation. parts of the IMM or robot system. Safety
harnesses must be worn when working at
Operators must always follow the shutting-down heights.
procedures specified in the operating manual
when carrying out any work on the IMM and the
robot system.
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Safety
2.1.5 Safety regulations – Pneumatic The electrical system may only be connected to
system a power supply of a current type, voltage and
frequency which corresponds to the
Compressed air pipes for the pneumatic system specifications on the robot system rating plate.
must be properly routed and fitted. The fittings, Electrical feeder cables must meet with the
length and cross section must meet with the specified requirements.
requirements.
Shut down the robot system at the main switch
Carry out regular checks on all pipes, hoses, before carrying out any assembly/disassembly,
and screw connections to determine any leaks conversion or maintenance work. Make sure
and recognisable exterior damage. Any damage that the electrical system is de-energised,
must be repaired immediately. earthed and short-circuited.
2.1.6 Safety regulations – Electrical system The electrical system must be checked
regularly. Any defects such as loose
The IMM and robot electrical system, which connections or burned cables must be
have been designed and built according to remedied immediately.
currently valid DIN EN 60204-1 and IEC 801-2
norms, are operationally reliable. Hazards may For safety reasons, the operator must log off the
however be created in the IMM robot’s electrical control system after completing the set-up
system if it is improperly operated by untrained operation in order to prevent unauthorised
persons or used for purposes other than its persons from specifying any other values.
intended use. All assembly/disassembly,
conversion and maintenance work may Legal rules and regulations must be observed
therefore only be carried out by electricians when carrying out any assembly/disassembly,
(according to DIN VDE 0105 or DIN EN 60204- conversion or maintenance work.
1).
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Specifications
3 Specifications 3.1.2 Handling loads
The ”Specifications” section contains all the

required technical data which are usually
required for installation, start-up and operation of
The rated and maximum load (operating
the UNIROB B2 industrial robot.
load) is 8 kg (18lb) for the component and
gripper.
3.1 UNIROB B2 Industrial robot
3.1.3 Mechanical interface
The UNIROB B2 industrial robot was developed
for automation of injection moulding machines The robot is supported by a torsion-free base
with medium clamping forces of up to 3500 kN which is mounted on the IMM injector plate. The
(385 sh tn). mechanical interface can be attached to the
Battenfeld injection moulding machine and to
3.1.1 Kinematics machines with Euromap drilling patterns.
The kinematic structure of the UNIROB B2 3.1.4 Delivery side selection

comprises a portal robot whose main axes
consist of two horizontally aligned unsupported Component delivery is at the rear of the IMM.
linear axes (X/Y) and a vertically aligned linear
axis (Y). It has a maximum of two (B/C)
auxiliary axes.
The linear axes (main axes) are driven by

electric motors whilst the B and C auxiliary axes
are pneumatically driven.
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Specifications
3.2 Robot axis definitions 3.2.2 Auxiliary axes
The axes are defined according to a fixed The following rotating and auxiliary axes are
cartesian co-ordinate system made up of the pneumatically driven:
horizontal X and Z axes and the vertical Y axis.
B auxiliary axis parallel to the Y-axis or
Industrial robots are, in a broader sense, other main rotating axis
numerically controlled machines. The axes are C auxiliary axis parallel to the Z-axis
therefore defined as in DIN 66 217.
The most common axes are shown in the ”Axis
Extensive use of DIN 66 025 creates a uniform
definition” diagram below.
addressing system for the purpose of controlling
the axes.
3.2.1 Linear axes
The following linear and main axes are driven by

electric motors:
X main horizontal linear axis parallel to the

first axis of the reference co-ordinate
system (IMM longitudinal direction)
Z main horizontal linear axis parallel to the
second axis of the reference co-ordinate
system (IMM transverse direction)
Y main vertical linear axis parallel to the
third axis of the reference co-ordinate
system
R8B2_001.JPG
The axis letter symbols are positioned at

suitable, clearly visible points to indicate the type
and direction of movement of each axis.
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Specifications
3.3 Performance data / 3.3.3 Maximum speeds of main and linear

axes
Mechanical interfaces /
Technical features Units X-axis Y-axis Z-axis
m/s inch/s 3 118,1 4 157,5 3 126
R8B2_GB003.XLS
3.3.1 Linear axes (main axes) Main axis

paths – Axis lengths Position detection:
R8 / B2
ACOPOS servo-assisted (B&R drive
Units X-axis Y-axis Z-axis
Robot mechanism)
B2 4-8-15 mm inch 400 15,7 800 31,5 1500 59,1
B2 6-10-20 mm inch 600 23,6 1000 39,4 2000 78,7
B2 6-12-25 mm inch 600 23,6 1200 47,2 2500 98,4 refer to 5.3.1"Electric motors“.
R8B2_GB002.XLS
3.3.4 Maximum speeds of rotating and

3.3.2 Drives / Repeat accuracy auxiliary axes
The main axes (X/Y/Z) are driven by a servo Turning max.

Axis Drive
three-phase a.c. motor. angle speed
C 90° 90 °/s pneumatic
Travel: Axis sequencing of the main and linear B (Option) 0° - 90° 90 °/s pneumatic
R8B2_GB004.XLS
axes.
The performance data apply at a minimum
The Y-axis is fitted with an immersion pipe. operating pressure of 6 bar (87 psi).
The repeat accuracy of +/- 0.1 mm (+/- 0.004

inches) is based upon the centre of the gripper
mounting.
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Specifications
3.4 Pneumatic system 3.4.3 Pneumatic valves
The system uses pneumatic 5/2-way valves

3.4.1 Compressed air connection
with multiple mounting plates. The integrated
vacuum nozzle in the valve block means that it
The compressed air servicing unit for non-oil
can only be used with oil-free air.
compressed air is fitted with a pressure
regulator valve and a gauge which keeps the
The vacuum valve air consumption is 27 l/min
operating pressure constant virtually all the time.
(7.13 US gallons).
The minimum operating pressure is 6 bar (87
psi). Pressure losses and fluctuations make it
3.4.4 Pressure monitoring
necessary to set the supply pressure at the
control valve to 6 bar (87 psi). ( refer to Section
The standard pneumatic system is fitted with a
7 Maintenance/Repairs).
pressure switch which acts as a pneumatic-
electronic converter (closer). If the pressure falls
below the 3 bar (44 psi) setting the robot sends
out a fault signal.
The available initial pressure must not be
This is indicated in the display. The pneumatic
allowed to fall below 7 bar (102 psi) and or
axis and gripper functions cannot operate safely
exceed 12 bar (174 psi).
if the supply pressure drops below the specified
setting. The user shall be liable for any
The pressure control valve is not designed to be
consequential damage.
able to deenergise the system pneumatically.
This is done by activating the electrical main
3.4.5 Central configuration
switch via the main valve which then vents the
system.
All the pneumatic elements are located on the
Z(X) slide except for the servicing unit.
3.4.2 Creating a vacuum
The vacuum which is required to operate the

gripper is created using a vacuum injector
(Venturi principle). A blow out function is used to
place the components in the correct position.
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Specifications
3.5 Guideways on main axes The servo drives produce a constant sustained
torque over the entire speed range up to a
All the main linear axes have guiderails and S maximum ambient temperature of 45°C (113°F).
(standard) precision circulating ball steering, This produces a motor temperature of 60°C
with a max. 0.01 mm (0.0004 inch) play and no (140°F) depending upon the thermal motor time
pretensioning. constant.
Each of the guide units running along the ground 3.6.2 Planetary gearing for the X (Z) and Y
guiderails with hardened tracks has 4 rows of and Z axis drive.
balls.
• single stage
The guiderails and guide units can be replaced • Circumferential backlash < 8 angular
separately. The reversing flaps on the guide minutes
units have an integrated sealing lip and a force-
• Max. input speed of 4500 rpm.
feed lubrication nipple or a connector for the
central lubrication circuit. • 94-97% efficiency at a max. operating
temperature of 100°C (212°F)
3.6 Motors / Gearing • Shaft linked to motor by a clamping hub
(sleeve shaft)
3.6.1 Maintenance-free servo three-phase
a.c motors for main linear axes • Smooth drive shaft with clamping hub
link
The servo controlled axle drives are fitted with • Maintenance-free synthetic oil (refer to
integrated motor brakes which are activated at Section 7).
the end position.
Standard high quality bearings permit speeds

ranging from approx. 1 revolution per day up to a
maximum of 4000 rpm (depending upon the
gearing).
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Section 3
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Specifications
3.7 Drive elements on main axes 3.8 Mechanical interface
3.7.1 X and Z axis 3.8.1 Gripper interface
The power transmission and conversion from The gripper flange measures 80 x 80 mm (3.15
rotary to linear movement is produced by means x 3.15 inches) with a centred M6 – 40 x 20 (1.57
of a toothed belt which is clamped to the slide, a x 0.79 inches) drilling pattern and 60 x 25mm
pinion attached to the gearing drive shaft and a (2.36 x 0.98 inches) spacing.
bearing-mounted deflection roller at the end of
the axis. The quick-fitting coupling for the vacuum action
and the gripper compressed air connectors are
3.7.2 Y-axis immersion pipe located on the pneumatic connecting block.
The power transmission and conversion from 3.8.2 Manual gripper quick change
rotary to linear movement is produced by means
of a toothed belt clamped to the immersion pipe A optional manual quick change gripper device
and a pinion attached to the gear shaft. is available for frequent gripper changes.
It is possible to change the gripper in approx. 1

minute by pushing it into the dovetail guideway
and then securing it with clamping elements.
Two mounting plates are supplied with the
gripper.
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Specifications
3.9 R8/B2 robot options 3.10.2 Injection moulding machine signals
Description of options 01/09 EMERGENCY STOP (IMM)

RA B02 B-axis, pneumatic 0° - 90°
The contact must be opened by the
Quick change flange, C-axis
RM C03 EMERGENCY STOP switch on the IMM.
(manual fasr change flange, ds/ss)
RG M01 Gripper quick change100x100 02/16 Start handling procedure

RP D02 Additional clamp circuit (IMM)
RP D02 Additional vacuum circuit
RE L01 Equipped acc. NFPA Start HD approach. The signal from the IMM
R8B2_GB005.XLS
indicates that the contact is closed when the
minimum width for forward movement has been
3.10 EUROMAP 12
reached. It must not be possible to accidentally
adjust the opening to a narrower setting than the
3.10.1 Robot / Injection moulding machine
minimum required tool width.
interface
The signal must be indicated while the tool is
The 32-pin HAN 32A plug connector is used to
open. It must not be interrupted if the machine is
provide a secure link between the injection
switched to a different mode or when the guard
moulding machine (IMM) and the handling
door is opened. Damage may occur if the signal
device (HD). HD contacts and contacts inside
is indicated too early (incorrect or accidental
the IMM are all floating and can be used with
adjustment of the limit switch or position
maximum loads of 64V/200mA.
encoder signal).
The pin assignment of the plug connector
03/11 Guard doors closed
between the injection moulding machine and the
(IMM)
handling device is as in EUROMAP 12.
Forward/Backward movement of the HD is
prevented. The contact is closed when the IMM
guard doors are closed (and the anti-slip device
is not activated).
04/16 Ejector retracted (from IMM)
The IMM signals that the ejector has been

retracted regardless of the position of the
moveable mounting plate.
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Specifications
05/16 Ejector forward (from IMM) 3.10.3 Handling device signals
IMM signals that the ejector is forward. 17/32 Start Tool close sequence (by HD)
06/16 Core pullers released, HD can move Activate Tool close: The contact is closed when
in (IMM) the HD has been extended to the point where
the tool can be closed and when other HD
The IMM signals to the HD that the core pullers control devices activate the Tool close
are in position to allow the removal device to sequence.
enter (regardless of the position of the mounting This contact is only bypassed automatically
plate). when the IMM is operated without the HD.
07/16 Core pullers in removal position It must not be possible to activate the Tool close
(IMM) action when closing the guard door, in manual
operation or by using the ”OR” function button.
The IMM signals to the HD that the core pullers The signal is activated during the closing
are in position to remove the casting. sequence. If the signal is cancelled, the closing
movement must be interrupted.
08/16 Defective casting (from IMM)
18/26 Tool area monitoring free (HD)
The IMM signals to the HD that the removed
casting is defective. The signal must be Open/close tool monitoring: The contact is
triggered by ”Tool open” and can be reset by made by the limit switch on the positioning slide.
”Close tool”. The limit switch is activated when the
positioning slide leaves its starting position in the
10/16 IMM Fully automatic mode (from IMM) IMM area (before it enters the tool area). If the
link is open, the IMM can neither be opened or
The IMM signals to the HD that the operating closed. The contact can also be made without
mode selector is set to ”Fully automatic”. the HD.
12/16 Tool closed (IMM)
The IMM signals to the HD that the closing

sequence has been completed. The ”Start
closing” signal is then cancelled.
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Specifications
19/27 EMERGENCY STOP (HD)
The IMM control system is deactivated when the

contact is opened. The contact must be in
series with the IMM EMERGENCY STOP.
20/32 Handling device operation (HD)
Operating mode switch: Opened contact signals

to IMM: Operation with HD (Position 1).
Closed contact signals to IMM: Operation
without HD (Position 0).
21/32 Ejector retracted (from HD)
The closing contact returns the tool ejector.
22/32 Ejector forward (from HD)
The closing contact moves the tool ejector

forward.
23/32 Core pullers in removal position

(from HD)
Move core pullers into position to remove the

moulded component.
24/32 Core pullers retracted (from HD)
Move core pullers into position to move in the

HD.
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Section 3
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Specifications
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Transport - Installation
4 Transport - Installation 4.1.1 Storage
All robots are adequately packaged in order to

4.1 General prevent any damage occurring in transit. The
robot must be put into operation immediately
Upon delivery, the handling device (hereafter after it has been delivered by the transport
referred to as the ”robot”) it must be checked company.
immediately for any damage and for
completeness. Contact our Customer Services department if
the robot is to be stored for a prolonged period
The scope of delivery also includes: of time.
• Operating Manual 4.1.2 Unloading

• Data carriers with the required
software
• Dummy plugs for bypassing We cannot guarantee the robot will function
EMERGENCY STOP perfectly or accept any guarantee claims
(refer to 4.3 Commissioning) unless it has been unloaded in the proper
All keys, e.g. for the switch cabinet, enclosures manner.
etc. can be found at the main switch.
The robots may only be transported and
We recommend you arrange for the robot to be lifted horizontally on the special transport
assembled by Battenfeld engineers. We cannot and loading elements The lifting gear must
accept liability for any damage resulting from be secured to prevent it from slipping.
improper assembly.
The crane carrying capacity and the lifting
gear must be at least the same weight as the
robot. (refer to Installation layout– Section
3.0 Specifications)
Do not stand inside the danger area around

suspended loads!
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4.1.3 Securing devices 4.1.6 Injection moulding machine assembly
All forms of securing devices (ropes, cable

ties, adhesive tape etc.) must be removed Safety ladders and platforms must be used
before commissioning. They must always be when assembling/disassembling,
reattached before the machine is converting, operating or servicing overhead
transported again. components belonging to the robot in
accordance with legal regulations and
4.1.4 Crane transportation specifications. Do not climb onto any of the
robot components. Safety harnesses must
be worn when working at heights.
If the robot is mounted on the injection moulding

machine, it is important to ensure that the
machine is aligned to within 0.1 mm (0.004
inches). (refer to the IMM Operating Manual –
Section 4: Transport - Installation).
4.1.7 Installation layout
The precise space requirements are specified in

the ”Installation layout” diagram at the end of this
section.
R8B2_164.PDF
4.1.5 Transport weight

Model S Length Width Height
400 kg 2700 mm 1600 mm 1800 mm
R8 4-8-15 B2
882 lbs 106.3 inch 63 inch 70.9 inch
430 kg 3200 mm 1800 mm 2000 mm
R8 6-10-20 B2
984 lbs 126 inch 70.9 inch 78.7 inch
460 kg 3700 mm 1800 mm 2200 mm
R8 6-12-25 B2
1014 lbs 145.7 inch 70.9 inch 86.6 inch
30 kg 700 mm 600 mm 300 mm
Control cabinet B2
66 lbs 27.6 inch 23.6 inch 11.8 inch
R8B2GB_165.XLS
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Section 4 B: R82DE0DA.PMD
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4.1.8 External stand 4.2 Connecting to the power

supply
If external stands are used, make sure that the
robot can be positioned horizontally on the
The robot may only be connected up to power
stands.
supplies which conform with the current type,
Smooth operation cannot be guaranteed unless
voltage and frequency specified on the rating
the robot is mounted in a horizontal position.
plate (control cabinet).
4.1.9 Removing protective coatings
Remove the rust protection agent from all

polished, moving parts and guideways, as well It is important that users comply with
as all non-coated and non-galvanised bolts. Use national regulations relating to earthing and
cleaning cloths soaked in degreasing solvents, protective measures (overcurrent and
benzine, petrol or similar agents. residual-current protection devices) in TN, IT
and TT systems. External and neutral
conductors (IT systems) and must be
protected against short-circuiting as
specified on the rating plate.
These cleaning agents are toxic,
inflammable liquids. Pay attention to the
Conventional protective multiple earthing
manufacturer’s instructions!
(PEN conductors) may not be used. PE
conductors and N conductors (if required)
must always be connected separately.
It is also important to observe local
regulations relating to the disposal of such
liquids and impregnated cleaning cloths!
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Section 4
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Attach the outer conductors to the terminals 4.3. Commissioning

inside the control cabinet.
Attachment type:
Feeder + neutral conductor
Before you start the commissioning
procedure, it is important to read and make
L1a L2a L3a N sure that you have understood all the items
contained in the ”General” and ”Safety”
sections.
X1 This section deals with the key points to be

observed when activating the electrical systems
for the first time. It is important to adhere to each
of these points in order to ensure that the
machine runs properly.
5(L1, L2, L3, N, PE)
4.3.1 Connecting to the power supply
R8B2_006.BMP
Connect up the power supply to terminal row X1
Main incoming supply. Refer to the circuit using a 5 x 6 mm2 cable as described in 4.2..
diagram on Sheet B1. No.: 10
4.3.2 Harting connector
The Harting connector point is located on the

side of the control cabinet.
18X0 HAN6 - Hand control

12X2 HAN10 - 3 x 400 V power supply
Servo booster
21X0 HAN16 - 24V DC power supply
CAN
100X1 HAN24 - Interface
Service door
80X1 HAN32 - IMM interface
Sections of the control cabinet are shown in the

circuit diagram on Sheet 71 and in Section 5
Assembly and Operation, 5.3.2 Switch cabinet.
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4.3.6 EMERGENCY STOP test
To test the EMERGENCY STOP

If no peripheral device is used or if there is (hardware and software) on the
no service door, it is important that the manual control device, press and
supplied dummy plugs for bypassing the release the button. Also check that
EMERGENCY STOP are connected. all the other EMERGENCY STOP
devices (IMM, Periphery) are
The plugs can be clearly identified by the released. This procedure must be repeated
coded sockets and pins. each time the main switch is activated/
deactivated.
4.3.3 Lubrication points
4.3.7 Power ON
Check all lubrication points.
After checking the EMERGENCY
4.3.4 Compressed air supply STOP line and activating the slam
button, press the START button
Connect the compressed air supply to the robot together with the TOTMANN button
service unit and adjust to 6 bar (87 psi). Refer to on the MCD and observe the robot
Section 2.0 Safety, 2.1.5 Safety regulations – (visual check).
Pneumatic systems.
Once all the initial start-up steps have been
4.3.5 Activate main switch carried out, the main contactor (40 K1) activates
the power supply at the ACOPOS servo booster.
Activate the main switch on the control cabinet The motor holding brakes remain activated. The
to start the control system. The motors are three servo axes are not controlled. (Axis
initially interrupted by the main fuse (40 K1). sequencing)
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Assembly and Operation
5 Assembly and
Operation
5.1 Modules
1 Pneumatic system (refer to 5.2)
2 Electric motors (refer to 5.3.1)
3 Terminal box 1 (refer to 5.3.3)
4 Terminal box 2 (refer to 5.3.4)
4
2
3
1
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Section - 5
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5.2. Pneumatic system Solenoid valve
The pneumatics are a key component of the

robot system. They provide a ”source of energy”
for the auxiliary axes and the gripper clamping /
vacuum circuits.
R8B2_010.PDF
5.2.1 Directional control valves
Principle:
These valves shut off, release and divert the Electrically activated 5/2 monostable directional
compressed air channels. control valve Once it has been set, the valve
only remains in position while the adjusting
Electromagnetic valve signal is activated. A mechanical spring resets
the valve when the signal is deactivated.
These valves adjust the auxiliary axes (basic
and end positions) and set/reset the clamping 5.2.2 Vacuum suction nozzle
circuits.
R8B2_009.PDF
Principle:
Electrical, indirectly activated 5/2 bistable,
directional valve. The valve remains in position
after it has been adjusted until it is reset by a
counter signal.
R8B2_011.PDF
A vacuum is created inside the vacuum

generator by the compressed air passing
through it (Venturi principle). The vacuum
generator is switched on/off by an input signal.
The housing has an integrated filter to keep out

any dirt.
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5.2.3 Maintenance unit 5.3. Electrical systems
1 1 - Pressure control valve 5.3.1 Electric motors

adjusting knob
2 2 - Condensate drain
3 - Pressure gauge
3 4 - Condensate tank
5 - Drain plug
4
5
R8B2_013.PDF
R8B2_133.PDF
General:
The cleaner removes any liquids and solid The three linear axes on the 3-axis handling
materials in the compressed air flow and device are driven by three motors which are
regulates the air pressure. controlled by a digital servo booster. (B&R/
Type:8V1090.00-2)
The cleaner may only be used with properly
processed compressed air which does not Axis change-over:
contain any aggressive agents. The motors are activated together with the required
digital inputs/outputs. (e.g. HW limit switch)
A filter and a water separator remove any solid
particles and water from the compressed air. The drive is not controlled when it is not moving.
This protects the downstream pneumatic The holding brake keeps the axis in position when
elements from premature wear. the servo booster is not activated.
Attention! The booster communicates with the CP276

The robot system pneumatics may only be controller via CAN. (refer to Section 5.4.2 PCS)
operated using oil-free air!
Connections are specified in Section 4.2 Transport
and Installation – Electrical connections.
Electrical components may only be serviced

by qualified electricians!
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The control cabinet is located near the robot

system. It must be mounted in an easily
accessible position.
R8B2_014.PDF
1 Socket 8 HAN24 operating door interface

2 Printer interface or floppy disc 9 Injection moulding machine interface
DSUB9 EUROMAP12 HAN32
3 Main switch 10 HAN16_E plug, 24 V DC power supply
for Terminals 1, 2 and CAN
4 Conveyor belt cable gland
11 HAN6 manual control panel with 24-pin
5 Peripheral cable gland
contact unit
6 Power supply (3x400V) cable gland
7 HAN_E plug, power supply connection
Attention!
3x400V ACOPOS servo booster
Refer to the circuit diagram for details of the
individual plugs!
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5.3.3 Terminal box 1 LED Description Colour

1 Ready green
Terminal box 1 is located at the end of the main 2 Run orange
axis support. It contains the servo booster as 3 Error red
well as the motors and sensor analysis change- R8B2_GB016.XLS
over.
After switching off the devices the intermediate

Do not alter change the shielding on the circuit requires a discharge time of at least 5
motor cables! minutes. Use a suitable measuring device to
check that the current intermediate circuit
The fan inside the terminal box must be voltage is below 24 V DC to ensure that the
switched on in order to prevent the ACOPOS system is safe before carrying out any work. If
servo booster from overheating. the LED indicator is extinguished this does not
necessary mean that the device has been
Basic design of the B&R 8V1090.00-2 servo deenergised!
booster:
The LED is illuminated when the ACOPOS Signal LED
servo booster is connected to the 24 V DC
Ready green
power supply. R8B2_GB130.XLS
Description:
Illuminated when the ACOPOS servo booster is
ready for operation and the power stage can be
activated. (Operating system available and
booted up, no permanent or temporary faults
detected).
3
Signal LED
2 Run orange
R8B2_GB131.XLS
1
Description:
Lights up when the ACOPOS servo booster
power stage is activated.
F
.PD
15
_0
B2
R8
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Signal LED LED indicators:

Red LED: Power is switched off. Green LED:
Error red POWER ON and system stationary.
R8B2_GB132.XLS
Description: During adjustment, i.e. when an axis is moving,

Lights up when there is a fault at the ACOPOS the green and orange LEDs are illuminated.
servo booster. The LED is extinguished
automatically once the fault has been remedied. The servo booster has four card sockets. All
t four sockets are used in this application:
Permanent faults include:
1. Socket AC110:
Motor feedback interrupted or not CAN interface
connected
Low level at Enable input 2.3.4 Socket AC112:
3 Resolver cards
Motor temperature sensor not connected
Internal fault 5.3.4 Terminal box 2
Terminal box 2 is located on the main slide and

Temporary faults include:
contains the following Beckhoff components:
24 V DC voltage supply or intermediate LS5100 CAN coupler
circuit voltage is outside of the tolerance
KL1104 input terminals.
range
KL2134 output terminals.
Internal 15 V DC voltage supply is
outside of the tolerance range
The input and output terminals are read in and
Motor overheated
triggered by the CP476 controller via CAN.
Servo booster overheated
Braking resistance overheated, CAN or
powerlink network fault.
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LS5100 transceiver Faults are coded as follows:

24 V DC power supply
Fast flashing Error code start
(See circuit diagram for details of connections)
1st. slow sequence Error code
2nd. slow sequence Error cause
The two K bus LEDs indicate the operating R8B2_GB018.XLS
statuses of the bus terminals and the Error code Error cause
connections to them. 1 pulse 012
R8B2_GB154.XLS
Green LED illuminated: In operation, no faults.

Red LED flashing. Fault signal. Two different Description:
frequencies. 0 EEPROM check sum fault
1 Inline Code Buffer overrun
2 Unknown data type
Address left: Field bus LED

selector right: C bus LED
Error code Error cause
K bus
2 pulse 0 n(n>0)
Configuration left: CAN-H
R8B2_GB155.XLS
interface
right: CAN-L Description:
Programmed configuration
V+ Incorrect table entry / bus coupler Table
Transceiver
supply comparison (Terminal ”n”) incorrect
V-
3 pulse 0
R8B2_GB156.XLS
Shield
Power contacts Description:
Terminal bus command fault
R8B2_017.PDF

4 pulse 0n
R8B2_GB157.XLS
Description:
Terminal bus data error: Breakage behind
Terminal ”n” (0: coupler)
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Error code Error cause KL2134 output terminals

5 pulse n
R8B2_GB158.XLS
Description:
Signal – LED 1 A B Signal – LED 2
Terminal bus fault in signal communication with
Signal – LED 3 C D Signal – LED 4
terminals
Error code Error cause 1 5

A1 A2
7 pulse n
R8B2_GB159.XLS
Description: 2
6
+24 V
Non-supported terminal at ”n”.
7
KL1104 input terminals Power- 3 0V
contacts
4 8
A3 A4
A C
Signal – LED 1
B D Top view
Signal – LED 3
R8B2_020.PDF
1 5
E1 E2
6
2
7
Power- 3
contacts
4 8
E3 E4
Top view
R8B2_019.PDF
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5.4. Unirob B2 controller 5.4.1 Manual Control Device (MCD)
The Unirob B2 is straightforward and easy to The MCD consists of:

operate.
• LCD (approx. 2.76") with 8 x 21
The main axes and auxiliary axes are regulated character lines.
by a sophisticated control system. • Green START button and a red
EMERGENCY STOP slam button.
The sequential programming process (hereafter
referred to as token programming) is structured • Four function keys (F1 to F4) for
in a simple format which is easy to understand. selecting the various functions.
• Two cursor keys on either side of the
This program also facilitates universal usage. display, ON/OFF (right) and START/
STOP (left).
The current token program can be saved to a
• A ”Num.” key for switching the numeric
floppy disc via an RS232 interface or printed out.
pad (0-9) on/off.
• Four positioning keys for controlling the
movement and speed of the axes.
• Seven object selection keys (e.g.
gripper, IMM etc.) for use in Manual
mode and token programming.
The MCD key configuration and functions are
explained in Section 5.5 Handbook.
R8B2_021.JPG
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5.4.2 PCS General 5.4.3 CP476 status display
The CP476 B&R SYSTEMS 2003 comprises a

sophisticated central component of the robot
system.
Features:
750 kByte User SRAM
1.5 mByte User FlashPROM
CP interface with four module slots
Two node number switches
The CP476 central unit has a system bus for R8B2_021.JPG
additional expansion units. Two CAN node

number switches eliminate the need for offset
LED Colour Decription
adjustments. The actual node number always
CAN orange Data flow from/to CAN controller
corresponds to the switch position. Indicates whether data are
RS232 orange
received/sent
Lights up in Service mode and if a
ERR red
fault occurs
Lights up in RUN and in Service
RUN green
mode
RDY green Lights up in Service mode
Lights up during FlashPROM
MODE green
programming
LEDs indicate operating status of
1, 2, 3, 4 orange
each adapter module.
R8B2_GB023.XLS
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RS 232 interface Positions 00, FD, FE and FF are reserved for

special software programming functions. (not
Interface Connection configuration
RS232 required for standard operation)
User interface RS232 1 NC Reserved
2 RXD Receive Signal
3 TXD Transmit Signal
5.4.5 Digital Input/Output module
4 + 5 VCD/max. 500 ma Panelboard power
5 GND Ground
6 NC Reserved
DI439.7 Digital input module – 16 inputs, 24 V
9-pin 7 RTS Request To Send DC
DSUB plug 8 CTS Clear To Send
9 NC Reserved
R8B2_GB028.XLS
The non-isolated RS232 interface is used for

programming the central unit or the signal is
transferred to the disc drive and the printer
interface at the control cabinet.
5.4.4 CAN CP476 node number switch

R8B2_030.JPG
Features:
16 digital inputs
24 V DC input voltage
1 ms input delay
PCS control-to-load isolation
R8B2_029.JPG
The CAN node number is adjusted using the two All inputs can be sink or source-connected.
HEX switches.
The switch positions can be determined at any The UNIRON-B2 system uses a sink RC circuit
time with the aid of the user program. The (refer to circuit diagram on page 14).
switch position is only registered by the
operating system at start-up.
UNIROB-B2 switch position for Node number 1

• RIGHT ”0”
• LEFT ”1”
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DM435 Digital hybrid module – 8 x 24 V DC DO722 Digital output module – 8 240 VAC /
outputs, 8 x 24 V DC inputs 24 V DC isolated relay outputs
R8B2_031.JPG R8B2_032.JPG
Features: Features:
8 digital inputs 8 isolated relay outputs, make contact elements
24 V DC input voltage Switching voltage
1 ms input delay 240 VAC/24 V DC
8 digital outputs 2.5 A continuous current
24 V DC switching voltage
Max. continuous current: 0.5 A per output

Short circuit and overload proof
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Handbook
UNIROB R8 – UNILOG B2
Read before using the controller and

keep it near the controller for reference purposes.
Version R82GBV00 04/03

Injection moulding
Battenfeld GmbH
Scherl 10 • D-58527 Meinerzhagen
Tel. ++49 2354/72-0 • Fax ++49 2354/72-234
Battenfeld Kunststoffmaschinen Ges.m.b.H.

Wr.Neustädter Straße 81• A - 2542 Kottingbrunn
Tel. ++43 2252/404-0 • Fax ++43 2252/404-261
R82GBD2A.PMD
www.battenfeld.com
DIN EN ISO 9001

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Operation and Control System
5.5 B2 Handbook
5.5.1 Manual Control Device (MCD) – Key
functions
R8B2_033.JPG
1
17
16
2
15
3
14
4
5 13
6
12
7 8 9 10 11
1 – ON/OFF and START/STOP buttons 2 - PROG button
Press one of the two buttons to start/stop Press the PROG to switch to the
the automatic program. The START Programming menu and then
button is also used to move the servo Programming mode in User level 1. The
axes in Manual mode after entering a orange LED indicates that Programming mode
numerical value. Press STOP to interrupt is activated. This button is not activated in
the movement. The red LED in the Automatic mode.
STOP button lights up when the power is
deactivated or when the robot has been stopped 3 - ERROR button
in Automatic mode.
Press this button to switch to the Error
list. The red LED lights up if an error is
detected.
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4 - AUTO/SINGLE button 8 - PERIPHERY button
Press this button to switch from Manual Press this button in Manual mode to
(MAN) to Automatic (AUTO) or Single switch to the Periphery and Conveyor
(SINGLE) mode. The left orange LED pages. Press PERIPHERY in
indicates Single mode and the right LED Programming mode to select Periphery and
indicates Fully Automatic mode. Conveyor commands. The orange LED
belonging to this button lights up when one of
5 - PCS button these pages is selected.
Press this button to switch to the User 9 - Move buttons

variables status page. If this button is
pressed in Programming mode, the These four buttons are
system switches to the PCS commands menu. used for moving the
The orange LED belonging to this button lights servo and auxiliary
up on this side. axes. The two outer buttons (snail, hare) adjust
the servo axis overrides. The orange snail LED
6 - REF/MAN button lights up at 5% override and the orange hare
LED at 100%.
Press this button to switch between The arrow buttons are used for moving the main
Manual mode (MAN) and Reference and the auxiliary axes. These buttons have
(REF). It automatically switches to MAN different functions on some of the other pages.
mode when the system is switched ON/OFF. The LEDs light up wherever the arrow buttons
The right orange LED lights up in MAN mode are in use.
and the left orange LED in REF.
10 - PAL button
7 - ROB button
Press the PAL button to switch to the
This button is used to carry out various Palletising program status page in
display change functions in any User Manual and Automatic mode. In
level or mode. In Manual and Automatic Programming mode the system switches to the
mode it switches to the Axis status page. Press Palletising command pages. The orange LED
the ROB button twice in User level 2 to switch to belonging to this button lights up when one of
the Service page. In Program mode it switches these two pages is selected.
to the Axis selection page The orange LED
belonging to this button lights up when one of
these pages is selected.
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11 - Gripper button 15 - C button
Press this button to switch to the Gripper The C (CLEAR) button is activated when
status page in Manual and Automatic the numerical keypad is on. Press to
mode. In Programming mode it switches delete the last entered number on the
to the Gripper command selection page. The numerical keypad. If this button is pressed in
orange LED belonging to the Gripper button the Programming page this deletes the selected
lights up when one of these two pages is program line after an option box has been
selected. confirmed.
12 - ENTER button 16 - IMM button
Select ENTER to confirm a numerical Press the IMM button to display the IMM
entry. interface status page in Manual mode. or
the IMM commands in Programming
13 - NUM button mode. The orange LED for this button lights up
when one of these two pages is selected.
Press the NUM button to activate the
numerical pad and ”,” and ”+/-” on the 17 - Cursor buttons
MCD. The orange LED belonging to this
button lights up when the numerical pad is The Cursor buttons are used to move the
activated. screen cursor up and down.
14 - ESC
Press the ESC button to switch to the

Start-up display, or, in Programming
mode, to move back one level to the
program.
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Green START BUTTON on MCD 5.5.2 Start-up display
Press the START BUTTON to

activate the power supply (main 1
2
contactor).
EMERGENCY STOP BUTTON on MCD
The red Emergency Stop button is

intend to protect both the machine
and the machine operators.
R8B2_GB052.JPG
These details appear in the MCD display when

the controller is activated.
TOTMANN BUTTON
Top line:
1 ”err” flashes if an error has been
The TOTMANN button must
detected.
be pressed for every
movement. 2 The current operating mode is shown
here, i.e. MAN (Manual mode), REF
(Reference), AUTO (Automatic), SINGLE
(Single Step mode) or HOME after
referencing.
Enter the password in the box. Set to the

required language.
Password level:
0 The axes can be moved manually and
the Automatic program stopped/started.
1 As in Level 0, users can write, load and
delete token programmes.
2 Service level (only to be used by
Battenfeld service engineers).
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5.5.3 Status pages In Automatic mode it is possible to stop the

current program by pressing F1. Select F4 to
Axis status page (ROB button) switch to the Program status page to monitor
the current program.
Press ROB button.
R8B2_GB054.JPG
R8B2_GB053.JPG
Press F4 button.
Use the arrow buttons to move the
selected axes.
The ”Snail” and ”Hare” buttons are

used to adjust the override.
The current axis positions (Actual values) are

shown on the Axis status page in both Manual
and Automatic mode.
In Manual mode the axis moves next to the
cursor.
At Password level 1 or 2, select F1 to display

”Sdata” (Service data) and F3 for ”L.Area” (Lock
area). For further details, refer to Section 5.5.7
Lock areas. R8B2_GB055.JPG
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Gripper status page (Gripper button) IMM status page (IMM button)
Press Gripper button. Press IMM button.
R8B2_GB056.JPG R8B2_GB057.JPG
This display shows the current clamping and

vacuum circuit statuses in Manual and
Automatic mode. The clamping circuits can be
set and reset in Manual mode.
R8B2_GB058.JPG
This display shows all signals sent from the

robot system to the IMM (digital outputs) and all
signals sent from the IMM to the robot system
(digital inputs) in Manual and Automatic mode.
The digital outputs can be set and reset in
Manual mode.
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Periphery status page (PERIPHERY button) Conveyor status page (PERIPHERY button)
Press the Periphery button.

R8B2_GB145.JPG
R8B2_GB061.JPG
Press F4 ”Start” to start the conveyor in Manual

mode.
R8B2_GB060.JPG
Here all the Periphery signals (digital inputs and

outputs) are displayed in Manual and Automatic
mode. The digital outputs can be set and reset
in Manual mode.
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Palletising status page (PAL button) User variables status page (PCS button)
Press the PAL button. Press the PCS button.
The status of the current Palletising

programmes are shown here in Manual and The status of the User variables (max. 10) is
Automatic mode. Counter in X, Y & Z direction. shown here in Manual and Automatic mode. In
Select F4 to reset the counter of any selected Programming mode this button can be used to
palletising program. select the corresponding PCS commands (refer
to 5.5.5.2 PCS token commands).
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5.5.4 Teach, Edit, Save, Load, Delete, Print Teach, Edit,

programs
Press the PROG button.
General
Display is possible in Manual mode (MAN) and

from Password level 1 upwards.
Continue by pressing F4 according to the cursor

position.
”EDIT-TEACH” program:
The program display has the same format in the
subprogram and in the parallel program.
Select <-- (F1) to return to the previous display.

R8B2_GB064.JPG
R8B2_GB065.JPG
R8B2_GB066.JPG
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Save Load
Press the PROG button. Press the PROG button.
Press the buttons to move the cursor to Use the buttons to move the cursor to
Save program. Press F4 to continue. Load program. Press F4 to continue.
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Delete In the start display use the buttons to

move the cursor to the ”Delete project”
Press the PROG button. program Press F4 to continue.
Use the buttons to move the cursor to

Delete program. Press F4 to continue.
R8B2_GB072.JPG
R8B2_GB071.JPG
R8B2_GB070.JPG
”Delete project”:
Select ”Yes” to delete (irretrievably) the selected
R8B2_GB070.JPG program from the specified hard drive (A or C).
”New project”:
Select ”Yes” to delete the lines in the current
program. The lines in the saved program are not
deleted. Select ”No” to cancel. The display
switches back to ”Delete” in both cases.
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Print 5.5.5 Creating token programs
Press the PROG button. Switch to the ”Program” display to create an

Automatic program (see 5.5.4).
Use the buttons to move the cursor to Example: NC axes command

Print program.
Use the F4 button (Teach/Edit) to enter the
corresponding command in the previously
selected line of the token program.
Attention!
Any existing command in the selected line
will be overwritten.
Use the F3 function key (INS) to enter the

command. The line at which the cursor was
positioned is then moved down one space and
the new line is inserted at the current cursor
position.
R8B2_GB073.JPG
R8B2_GB064.JPG
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Press the ROB button. Attention!

In TEACH programming mode the system
will automatically move to the selected value
when START is pressed.
Adjust X-axis -> Move relative -> 100
R8B2_GB074.JPG
Select the axis to be edited (e.g. X-axis -> Move

Absolute -> 300)
R8B2_GB077.JPG
X-axis adjustment -> Move parallel -> 1st

position 100 -> 2nd position 150
R8B2_GB075.JPG
R8B2_GB078.JPG
R8B2_GB076.JPG
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Adjust X-axis -> Stack stop -> 300) 5.5.5.1 Token commands: Gripper (GRP),
Robot (ROB), Injection Moulding
Machine (IMM)
Gripper (GRP)
V1 BLOUT 01.00
G2 OPEN
Blow out vacuum gripper 01.00 s
Open gripper
R8B2_GB079.JPG
V1P BLOUT 01.00
G2P OPEN
Adjust X-axis -> Speed -> 100% -> Acceleration Blow out vacuum gripper parallel 01.00 s
-> 100% Open parallel gripper
V1 VACUUM
G2 CLOSE
Attach by suction
Close gripper
V1P VACUUM
G2P CLOSE
Attach parallel by suction
Close gripper parallel
V1 monit. ON STOP
R8B2_GB080.JPG G2 monit. ON STOP
The program is stopped immediately if the
component monitor indicates a fault.
All other commands are entered with the aid of
the corresponding buttons following the above V1 monit. ON PStop
example. G2 monit. ON PStop
If the part monitor indicates a fault, the program
is stopped at the end of the cycle or at the next
PStop line in the program.
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V1 monit. OFF Robot (ROB)

G2 monit. OFF
Part monitor OFF.
x 0050.00
V1 If BLOUT L1 Move to absolute axis position
G2 If OPEN L1
System jumps to Label 1 at the blowing out x Rel 0100.00
point. Move to relative axis position
System jumps to Label 1 when the gripper is
open. y P 350.00 100.00
Absolute axis position with parallel value
V1 If VACUUM L1 Position 1: End point
G2 If CLOSE L1 Position 2: Command in next command line
The system jumps to Label 1 at the vacuum
suction point. xStp 0100.00
System jumps to Label 1 when the gripper is X-axis stack stop at 100.00
closed.
The selected axis moves to the target position. If
V1 If Monit. =1L1 the stack stop signal "logic 1" is activated during
G2 If Monit. =0 L1 this movement, the axis remains in this position
If the part or vacuum monitor is set to the logic (should the axis move beyond this position
value “”0”” or ””1””, the system jumps to Label 1. whilst running at high speeds, the system then
returns to the stack stop position).
The digital input for the stack stop is wired at

Terminal 8 on Terminal box 2 (refer to 5.3.4 and
the circuit diagrams on pages 21 and 51). The
signal is sent from here to Trigger input 1 (21X8)
PIN 1 on the ACOPOS.
z v=100% a=100%
Specify axis speed and acceleration
C ---
Pneumatic axis in basic position
C P ---
Pneumatic axis in parallel basic position
C P +++
Pneumatic axis in parallel end position
C +++
Pneumatic axis in end position
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Signals from injection moulding Ej.forw. if1 (wait1) L1

machine to robot system Wait for the ”Ejectors forward” signal from the
IMM. If the signal is ”0” or ”1” the system then
Start H if 1 (wait 1) L1 jumps to a label. The IMM signals to the robot
Wait for the signal from the IMM ”Mould open”, system that the ejectors are fully extended by
”Activate Start Handling” if the signal is ”0” or ”1”. setting the signal to logic ”1”. This signal is
The system then jumps to a label. The IMM frequently used so that the casting is not gripped
signals to the robot system that the mould is until the ejectors have moved it to the furthest
fully open by setting the signal to logic ”1”. In forward position. is The sprue grippers, for
many removal procedures the robot cannot example, cannot grip the sprue until the casting
enter the IMM until this signal has been given. has been correctly positioned by the ejectors.
Close mould if 1 (wait 1) L1 Ej.bk. if1 (wait 1) L1

Wait for the ”Mould closed” signal from the IMM. Wait for the ”Ejectors retracted” signal from the
If the signal is ”0” or ”1” the system then jumps IMM. If the signal is ”0” or ”1” the system then
to a label. jumps to a label. The IMM signals to the robot
The IMM signals to the robot system that the system that the ejectors are fully retracted by
mould is fully closed by setting the signal to logic setting the signal to logic ”1”. This signal is
”1”. In many removal procedures the frequently used to prevent the robot from being
combination of the ”Tool open – Start handling raised out of the tool area before the ejectors
procedure” and ”Tool closed” signals provides have been withdrawn from the casting.
an additional safety feature to prevent the robot
from colliding with the mould. Autom. if1 (wait 1) L1
Wait for the ”Machine in Automatic mode” signal
from the IMM. If the signal is ”0” or ”1”, the
system then jumps to a label.
The IMM signals to the robot system that it is in
”Fully Automatic” mode by setting the signal to
logic ”1”. In the token program this signal is
used, for example, to prevent the robot from
moving between the two mould halves before
the machine is operating in ”Fully Automatic”
mode.
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Cp.in if 1 (wait1) L1 Stop if1 (wait1) L1

Wait for the ”Core puller retracted” signal from Wait for the ”Tool at stop point” signal from the
the IMM. If the signal is ”0” or ”1”, the system IMM. If the signal is ”0” or ”1” the system then
then jumps to a label. jumps to a label.
The IMM sets the signal to logic ”1” to indicate to The IMM sets the signal to ”1” to indicate to the
the robot system that the core pullers are ready robot system that the movement into the
to be retracted. This signal can be given before machine can begin. This signal can be given
the mould halves are fully opened. This makes it before the mould halves are fully opened. This
possible to achieve faster removal times. makes it possible to achieve faster removal
times.
Cp.rem. if 1 (wait1)L1
Wait for the ”Core puller in removal position”
signal from the IMM. If the signal is ”0” or ”1”, the
system then jumps to a label.
The IMM sets the signal to logic ”1” to indicate to
the robot system that the core pullers are ready
to remove the casting. This signal is used to
prevent the casting from being removed before
it has been fully released by the core pullers.
Reject if1 (wait1) L1

Wait for the ”Reject” signal from the IMM. If the
signal is ”0” or ”1” the system then jumps to a
label.
The IMM signals to the robot system that the
casting is defective by setting the signal to logic
”1”. The token program can therefore be used to
distinguish between ”good” and ”bad” castings.
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Signals from robot system to the Ej. back SET

injection moulding device. Resets the IMM signal – Enable ejector back.
The robot system sets the signal to logic ”1” to
Cl. mould SET indicate to the IMM that the ejectors can be
Sets the signal to the IMM – Enable tool (TL) retracted. This signal is reset by ”Ejector is
close. The robot system sets the signal to logic retracted” in the RPS.
”1” to indicate to the IMM that the mould can be
closed. It is important that the robot is outside of Ej. forw. SET
the mould halves so as to avoid collisions Resets the IMM signal – Enable ejector forward.
occurring. This signal is reset by ”Mould closed” The robot system sets the signal to logic ”1” to
in the PCS. indicate to the IMM that the ejectors can be
moved forward. This signal is reset by ”Ejector
Op. mould SET is forward” in the RPS.
Sets the signal to the IMM – Enable tool (TL)
close. The mould is opened automatically after Cp. rem. SET
completion of the cooling cycle. This prevents Resets the IMM signal – Enable core pullers
the casting from cooling down completely and removal. The robot system sets the signal to
becoming stuck inside mould. The closing plate logic ”1” to indicate to the IMM that the core
opens until it reaches the ”TL at intermediate pullers can be moved to the removal position.
stop” position. The robot enters the machine This signal is reset by ”Core pullers in removal
and grips the casting. In the case of extremely position” in the RPS.
deep moulds, e.g. for barrel-shaped vessels, the
machine should be allowed to open the mould Cp. in SET
further after gripping it. To do this, the robot Resets the IMM signal – Enable enter core
signals to the injection moulding machine that pullers. The robot system sets the signal to logic
the mould can be opened further by setting the ”1” to indicate to the IMM that the core pullers
”Enable TL open” signal to logic ”1”. The can be moved to the feed position. This signal
machine then pulls the long core out of the is reset by ”Feed in ejectors” in the RPS.
barrel-shaped vessel and activates the ”Tool
open” signal when it reaches the end position.
The ”Enable TL open” signal is reset by the ”TL
open” signal in the PCS.
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Entering IMM commands from IMM to IMM
Press the PROG button. Type

Signals from injection moulding
Signals to the injection
moulding machine to the robot
machine to robot system
system
Mould open,
Start.H Enable Start Cl. mould Enable Cl. mould
Handling
Enable Open
Cl. mould Mould closed Op. mould
mould
Enable Ejector
Ej.forw. Ejector forward Ej.back
back
Enable Ejector
Ej.back Ejector is back Ej.forw.
forward
Signal
Enable Core puller
Autom. IMM in Automatic Cp.rem.
to Removal Pos.
Core puller in Enable Core puller

Cp.rem. Cp.forw.
Removal Pos. forwarde
R8B2_GB064.JPG
Cp.forw. Core puller forward
Press the IMM button. Reject Reject component
Tool at
Int.Stp.
intermediate stop
If0
Set (to logic 1)
Wait0
Action
If1
RST (to logic 0)
Wait1
Label 1-10
Goto
(only at "If")
R8B2_GB134.XLS
R8B2_GB081.JPG
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5.5.5.2 PCS token commands DEC 8.Uv

Defines an increment. The user variable value is
PCS token commands make it possible to insert increased by 1.
simple jumps, delays and ”If” commands into
the token program. StrParpr
Start parallel program. In a parallel program it is
Delay 1.2s only possible to use IMM, PCS and Peripheral
Waiting period of X.X s. commands.
The Automatic program is continued after a
certain period of time. StpParPr
Stop parallel program.
Goto 01
The system jumps to a label which must be set. PStop
A fault signal is indicates there is no label To activate the Pstop function, press the F4
available and vice versa. If a fault occurs, the button in the Axis status page. The program
Automatic program cannot be started. runs until the Pstop command point where it is
then stopped. Select START to continue the
Label 01 program.
Label is set.
Prog.Halt
Palx5=3 L 5 If the Prog.Halt command is inserted into the
See ”Entering If instructions” for details of If- sequential program the program is stopped at
instructions. this point. Select START to continue the
program.
CallSub 8
Call subprogram (max10). Prog.End .
Select to end the program. The Automatic
Return program is stopped and the system then
Return to main program. Activated automatically switches to Manual mode.
at end of subprogram.
Set 5.Uv=10
Sets user variable.
CLEAR 6.Uv
Deletes user variable.
INC 8.Uv
Defines an increment. The user variable value is
increased by 1.
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Entering IF commands Press the F4 function button.
In token programs it is possible to make label

jumps under certain conditions.
R8B2_GB083.JPG
Use the "+" and "-" arrow keys to

adjust the individual objects.
R8B2_GB64.JPG
"If" commands:
Press the PCS button.
Type 1 Description Value1 Description
User variable
number. Enter
Uservar User variable 1-10
actual value
under "Uservar".
Pos Position X,Y,Z Servo axes label
Palletising
Palletising
Pal counter Total 1-5
Program No.
amount
Palletising X- Palletising
R8B2_GB161.JPG Palx 1-5
direction Program No.
Palletising
Palletising
Use the cursor buttons to select ”If”. Paly counter Y- 1-5
Program No.
direction
Palletising
Palletising
Palz counter Z- 1-5
Programm No.
direction
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5.5.5.3 Token commands for additional

Sign Goto
devices
= equal
Your robot system has a standard peripheral
<> unequal
interface and a conveyor interface.
< smaller than
> larger than

Label 1-10 The peripheral interface enables you to control
System jumps to
selected label when one of your application peripheries with 4 digital
<= smaller than/equal to
condition is fulfilled inputs/outputs from the token program.
>= larger than/equal to (specially defined digital inputs/outputs are
EVEN even
shown in the circuit diagram)
ODD odd
R8B2_GB136.XLS
Periphery
Type 2 Description Value2 Description
Constant fixed
Constant 0-9999 Value
value
User variable
number. Enter
Uservar User variable 1-10
actual value
under "Uservar".
End of
PallFull Palletising x,y,z Servo axes label
program
R8B2_GB137.XLS
Program line: 01 Palx=5 L10

02 2Uv ODD L6
R8B2_GB064.JPG
Definition:
01 If Value 1 of the X-axis palletising counter Press the Periphery button.
is equal to Value 2 = 5 of the constants,
go to Label 10.
02 If User variable 2 is an odd number, go to
Label 6.
If-commands make it easier to solve complex

tasks. For details of Peripheral If-commands,
refer to 5.5.5.3 Token commands for additional
devices.
R8B2_GB084.JPG
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Press the F4 function button. DO1 SET

The digital output is set (to logic ”1”).
DO1 RST
The digital output is reset (to logic ”0”).
DI DO
Type
Digital input Digital output
No. PeriIP1-4 PeriOP1-4
SET (to
Wait0 Wait1
logic "1")
Action
RST (to
If0 If1
logic "0")
R8B2_GB085.JPG
Goto Label 1-10
Use the "+" and "-" arrow keys to Time X.X s
adjust the individual objects. R8B2_GB138.XLS
Periphery command
D12 wait1 1.2sL5

D12 wait0 1.2sL5
The system waits X.X seconds until the digital
input is logic ””0”” or ””1”” and then jumps to the
label. No time need be specified. When the
conditions have been fulfilled, the system jumps
to the label.
D12 if0 L6
D12 if1 L6
When the digital input is logic ”0” or ”1”, the
system jumps to the label.
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Conveyor Press the F4 function button.
The conveyor interface enables you to integrate

a conveyor into the system.
R8B2_GB086.JPG
Use the "+" and "-" arrow keys to

adjust the individual objects.
R8B2_GB064.JPG
R8B2_128.JPG
From the Wait objects point, ”Switch” becomes

”Goto”.
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Conveyor commands
Action Switch Goto Time
Conveyor ON/OFF
Conveyor ON
Conveyor OFF
Band ein X.X s
Conveyor ON/OFF
WaCONV ON
Conveyor ON 1.2s
Conveyor is switched on and deactivated after WaCONV OFF
X.X seconds.
WaPOS ON
WaCON Signal ON
WaCON Signal OFF WaPOS OFF
At WaCON signal ON, the system waits until the
input signal indicates ””Conveyor full””, logic “”0”” If CONV on Label 1-10
and the output signal indicates ””Conveyor ON””,
logic ""0””. At WaCON signal OFF, both signals If CONV off Label 1-10
must be logic ””1””.
If POS free Label 1-10
WaPos1 Signal ON
WaPOS1 Signal OFF If POS n free Label 1-10
The system waits for the ””Position space free”” R8B2_GB139.XLS
input signal. OFF indicates that the position is
free. ON indicates that it is occupied.
IfCON ON L5
IfCON OFF L5
At CON ON (Conveyor is not full and
deactivated), the system jumps to Label 5. At
CON OFF the conveyor is full and activated.
If POSfree
If POSNfree
At ””Position free”” and ””Position not free”” the
system jumps to Label 5.
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5.5.5.4 Palletising program Entering a palletising program:
The Palletising function enables you to integrate Press the PROG button.
basic positioning and removal tasks into the
token program.
Example of the palletising input:
R8B2_GB064.JPG
Difference
along Y axis Press the PAL button.
Difference
along X axis
1 Difference
along Z axis
R8B2_121.JPG
1 Palletising tasks – First position.

Removal tasks – Final position.
2 Palletising tasks – Final position.
Palletising tasks – First position.
R8B2_GB089.JPG
The diagram above shows an example of the

process. Every different corner position can be Select ”Pal Prog” and press F4 function
used as a starting or final position. button.
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Select ”New” to create a new palletising Specify the position of the first part in this
program. Any already existing palletising display. The position can be specified using the
programs are displayed. Use TEACH or EDIT to TEACH or EDIT function. If the program already
insert it into the token program. exists, the old values are displayed on the right.
Press the F4 function button.
R8B2_GB093.JPG
Enter the First position followed by the Quantity

(Quant.) in each direction and the Difference
(Diff.) between the parts. In the case of removal
tasks, enter the difference (spacing) with "-".
R8B2_GB091.JPG
(After you have selected the Entry type, First
position, Final position and Quantity, the Final
Use the arrow buttons to select position is scanned and the spacing is then
the Palletising program No. The calculated according to the quantity.
type of entry can be selected
here. First position, Spacing and Number, or
First position, Final position and Number. (e.g.
Position cursor at 1st pos, Spacing, Number)
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Palletising program commands
PalProg 1 START
This command starts the selected palletising
program.
Definition: The system moves to the next
position following the specified movement
sequence.
PalProg 1 RESET
R8B2_GB095.JPG
All counters are zeroed.
Palletising pattern This is the pattern in which This can also be done from the Palletising
the parts are to be positioned and removed, e.g. status page. (Used in conjunction with IF
first the X-row, followed by the Z-row and then commands)
the Y-row.
Delete PalProg
Deletes the palletising program.
R8B2_GB094.JPG
Movement sequence: This is the sequence in

which the servo axes move to the next
positioning and removal point.
Always press the F1 function button to return to

the previous display.
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5.5.6 Examples of programs

Line
001 Start H wait1
A) Standard Removal – Positioning: 002 Ej.bk. wait1
003 Autom. wait1
A handling device removes an article from a 004 y 10.0
machine and places it on the conveyor. The 005 x 10.0 Start routine
handling device is mounted on the machine with 006 z 75.0
the positioning side at the rear of the machine. 007 C---
008 Cl. mould SET
The following program is divided into: 009 Con ON 2.0s
010 Label 1
011 Start H wait1
- Start routine 012 Ej.bk wait1
- Removal cycle 013 Autom. wait1
014 y 900.0
- Positioning cycle for good parts 015 Ej. forw. SET
- Positioning cycle for defective parts 016 Ej.forw. wait1 Removal cycle
017 x 100.0
018 V1 vacuum
019 x 10.0
020 Ej. back SET
021 Ej.bk wait1
022 y 10.0
023 Cl. mould SET
024 Reject if1 L2
025 z P 1400.0 75.0
026 C +++
027 wa POS signal OFF
028 x 400.0
029 y 800.0
030 V1 BLOUT 0.6 Positioning cycle
031 y 10.0 for good casting
032 Con ON 2.0s on conveyor
033 x 10.0
034 z P 75.0 1400.0
035 C---
036 PStop
037 Goto 1
038 Label 2
039 z P 1000.0 75.0
040 C +++
041 x 400.0
042 y 800.0 Positioning cycle
043 V1 BLOUT 0.6 Reject
044 y 10.0 e.g. into a crate
045 x 10.0
046 z P 75.0 1000.0
047 C---
048 PStop
049 Goto 1
050 End of program
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B) Palletising program: Program
A handling device loads parts into a crate with Line

specified dimensions. 001 Start H wait1
002 Ej.bk. wait1
003 Autom. wait1
The model program comprises:
004 y 10.0
- Program
005 x 10.0 Start routine
Start routine 006 z 75.0
007 C---
Removal cycle 008 Cl. mould SET
Positioning cycle with palletising 009 Conv ON 2.0s
program 010 Label 1
011 Start H wait1
Positioning cycle for defective parts 012 Ej.bk. wait1
013 Autom. wait1
- Subprogram
014 y 900.0
015 Ej. forw. SET
Subprogram (Call Sub1) 016 Ej. forw wait1 Removal cycle
017 x 100.0
Line 018 V1 vacuum
001 Sub 1 019 x 10.0
002 Conveyor ON 2.0s 020 Ej. back SET
003 PAL reset 021 Ej.bk wait1
004 Return 022 y 10.0
023 Cl. mould SET
024 Reject if1 L3
025 C +++
026 wa POS signal OFF
027 Pal Prog 1 Start
028 V1 BLOUT 0.6
029 y 10.0
030 x 10.0 Positioning cycle
031 z P 75.0 1400.0 for good casting
032 C--- on conveyor
033 PStop
034 Pal 1 = Pal full L2
035 Goto 1
036 Label 2
037 Callsub 1
038 Goto 1
039 Label 3
040 z P 1000.0 75.0
041 C +++
042 x 400.0
043 y 800.0 Positioning cycle
044 V1 BLOUT 0.6 Reject
045 y 10.0 e.g. into a crate
046 x 10.0
047 z P 75.0 1000.0
048 C---
049 PStop
050 Goto 1
051 End of program
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Palletising program entries The individual parameters are entered according

to this model (refer to 5.5.5.4 Palletising
Example of workpiece dimensions: program) (Palletising program entries are
explained in 5.5.5.4)
Parameter Value
50mm X 200.00
First position Y 800.00
50mm
50mm Z 1200.00
Qux 3
Quantity Quy 2
Example of positioning pattern inside a crate: Quz 2
Dfx 80.00
Y
Difference Dfy 51.00
Dfz 70.00
Z Palletising pattern XZY
X Movement sequence ZXY

R8B2_GB140.XLS
Data displayed on the PalStat page after

positioning:
Quantityx y z
1 1 0 0
2 2 0 0
3 0 0 1
4 1 0 1
5 2 0 1
6 0 1 0
Example of the crate position:
7 1 1 0
8 2 1 0
9 0 1 1
10 1 1 1
11 2 1 1
0 0 0 0
Notes:
- All the PalStat page data for this
First position:
x 200.00
palletising program are displayed
y 800.00 together. The PalStat page only shows
z 1200.00 the each current line.
- In palletising pattern XYZ, Z indicates the
number of already filled rows. Y shows
the number of full levels.
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5.5.7 Lock areas Lock area 1 (mould area) is only treated as a

lock area provided the mould is not fully open.
General This lock area is deactivated by the ”Start
handling device procedure” or ”Tool at
Lock areas are basically used to provide intermediate stop” (IMM interface) signal in order
sofeware-side backup for the mechanical to allow the vertical axis to be inserted between
functions in the robot system and the injection the two mould halves.
moulding device. The robot cannot enter these
areas. It is important to define the mould area. This is
because the ”Enable close mould” signal is not
Users are given a total of 5 lock areas, whereby sent to the IMM in Set-up or Automatic mode and
Lock area 1 is a fixed mould area. Lock area 2 the robot cannot be started automatically
is for the tool closing side and Lock area 3 for (”Operating area violation” fault).
the tool nozzle side. An ”Operating area violation” fault occurs when
all the axes ”violate” a lock area.
Lock areas 4 and 5 can be used as required. A
lock area is fully defined by specifying the start Example:
and end positions. Diagram showing the lock area coordinates
The start coordinates "-" of the lock area define
the minimum coordinate for each axis. ALL MIN coordinates
Axis 1: 500,00 Lock area start - Axis 2:
50.00 Lock area start
The end coordinates "+" of the lock area define Axis 3: 200.00 Lock area start
the maximum coordinate for each axis.
Current position Protection AREA
If all the "-" and "+"positions for a single lock Axis 1: 475,00 Along X-axis 50,00
area of the three main axes are entered, this Axis 2: 25,00 Along Y-axis 50,00
Axis 3: 175,00 Along Z-axis 50,00
produces a cube containing the lock area as
shown in the diagram.
MIN
MIN
200.00 mm
Axis 3 50.00 mm
350.00 mm
MAX
Axis 2
locked
area
400.00 mm
MAX
MAX Axis 1 MIN
100.00 mm 500.00 mm
ALL MAX coordinates

Axis 1: 100.00 Lock area end+
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Specifying lock areas
Lock areas can only be specified at Password

levels 1 or 2. Lock areas 1- 5 are available to
users. Lock areas 6-10 are reserved for
Battenfeld service engineers.
Attention!
If TEACH enter mode is selected, the system
will automatically move to the selected value
when START is pressed.
R8B2_GB099.JPG
Use the arrow buttons, with the This page is used to select either TEACH or
cursor positioned accordingly, to EDIT to specify the lock areas.
activate/deactivate the Enable
function. This applies to all pages where Enable
can be selected.
Always use the F1 function button to

return to the previous display.
Always use the F4 function button to

switch displays. R8B2_GB100.JPG
Enable: All lock areas ON or OFF.
Press the ROB button.
R8B2_GB101.JPG
Enable: ProtArea (area to be protected) ON or

OFF.
R8B2_GB098.JPG
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Specify the area to be protected, the gripper and

Enter the end coordinates for the selected lock
the auxiliary axes. The old values are shown on
area in this display.
the right.
R8B2_GB102.JPG
Enable: Selected operating area ON or OFF.
R8B2_GB104.JPG
Enter the start coordinates for the selected lock

area in this display.
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5.5.8 Error messages ACOPOS ERROR
All existing errors shown on the two PCS and Error No. 4008, 4009
ncAxis (ACOPOS servo booster) error pages One of the main axes has reached the positive
can be confirmed here. or negative hardware limit switch.
Effect:
- Current axis controller is stopped
Select the Error button.
- ACOPOS servo booster indicates an
error.
To remedy:
1. Reconnect the power supply
2. Activate movement in the opposite
direction
This error may indicate that the software limit

positions have been incorrectly configured.
Error No. 5003, 5004

Reached positive or negative SW limit position.
R8B2_GB106.JPG
To remedy:
Activate movement in opposite direction.
The number of PCS errors is indicated at the
top right of the display.
Select ”Quit all” (F1 function button) to confirm

all errors including ACOPOS errors.
R8B2_GB107.JPG
The ACOPOS error number is shown at the top

left of the display (here 4008).
Select ”Quit” (F1 function button) to confirm the

current ACOPOS error.
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PCS ERROR 15 Pos. in TL

This error message occurs when an automatic
1 Emergency Stop 1 activated program is activated with the robot in the mould
Emergency stop button on MCD activated. area.
To remedy: To remedy:
Deactivate Emergency Stop. - Switch to Manual control and move the
The error need not be confirmed. It disappears axes out of the mould area.
automatically after it has been remedied.
- Confirm error.
5 Activate Emergency Stop 1x
To test the Emergency Stop button on the 52, 53 Casting Mon. 1
manual control device (MCD) press once and One of the casting monitoring devices was
release. activated and the required status of the casting
monitor inputs (switching status) logic ”0” and
6 Rob 0 logic ”1” is not available when the casting is
The injection moulding device is set to ”Rob 0” clamped. The number at the end is the number
when it is running without the robot. of the clamping and vacuum circuit.
Effect (52):
- Movement stops at end of cycle (Pstop)
Effect (53):
- Current servo axis stops moving (Stop)
- Enable signals to IMM disappear.
To remedy 52, 53:
- Adjust the sensitivity of the limit switches
on the gripper finger.
- Adjust the sensitivity of the vacuum
monitor on the Venturi nozzle of the
suction gripper.
R8B2_GB108.JPG - Press the START button on MCD
Use F1 to select ”Rob 1” to operate the IMM with (System continues in Automatic mode).
the robot.
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58 Axis in Bpos. 61 Warn.Con. full 1

Effect: Cause:
This error message is sent out if the auxiliary Signal indicates that the ”Warning Conveyor full”
axes are not in the specified position when the limit switch has been reached.
reference movement is started. Effect:
To remedy: - Error message is only an instruction. It
Switch to Manual mode and move the axes to need not be confirmed.
their basic position.
To remedy:
- Clear conveyor.
59 Compressed air monit.
Possible cause: - Check limit switches.
Compressed air dropped below 3 bar (44 psi).
Effect: 62 Conv. full 1
- Current servo axis stops moving. Cause:
- Enable signals to IMM disappear. Conveyor was stopped by the limit switch
(conveyor stop).
- Movement of all pneumatic axes and
Effect:
gripper functions is blocked.
- Conveyor is stopped.
To remedy:
- Error need not be confirmed.
- Check compressed air.
To remedy:
- Press the START button on the MCD
- Clear conveyor.
(System continues in Automatic mode).
- Check limit switches.
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120 Lock area 2 126 Controller error!

The robot has been moved into a specified lock
area by the X,Y or Z axis. Effect:
Effect: Controller indicates an error. Select F4 to view
- Current servo axis stops moving. more details on the PCS ERROR page (refer to
ACOPPS errors on page 22 in Section 5)
- IMM enable signals are cancelled if Lock
area 1 (moulding area) is affected.
To remedy:
To remedy: - A different procedure must be used,
- If an axis has been moved into a lock depending upon the ACOPOS error.
area, exit the violated lock area in the
opposite direction.
134 Battery change
- Confirm error. The CP476 B&R 2003 controller battery must
be changed.
123 Control parameter To remedy:
Effect: Discharge the static on the top-hat rail
Control parameter was not loaded. and the earth connection (Do not reach
To remedy: into the power pack!).
- Load service data (PWL 1). Remove the cover on the lithium battery
- Confirm error. with a screwdriver.
Pull the removal tape to take the battery
124 Controller! out of the holder. Avoid short circuits by
Effect: not gripping the battery with pliers or
One axis movement command was tarted. uninsulated pliers! Only touch the top
Servo booster not activated or power supply not surfaces of the battery. It can also be
connected. removed using insulated pliers.
To remedy:
- Power ON. Correct: Incorrect:
- Confirm error.
R8B2_160.BMP
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Insert the new battery with the poles Abbreviations:

correctly positioned. To do this, lift the
removal tape and insert the battery into MCD Manual Control Device
the compartment with the ”+” side facing SD Service door
downwards. It is important to ensure that na not available
the removal tape is on top of the battery nposs not possible
so that it can be removed again. PWL Password level
TL Tool
Put the overlapping end of the removal
M Main program
tape under the battery to prevent it
P Parallel program
protruding from the battery
S Subprogram
compartment.
Mount the cover. Make sure that the Battenfeld Customer Services
screwdriver recess is facing upwards
(1). First insert the top end of the cover If you require any further information please
into the recess of the battery contact Battenfeld Customer Services.
compartment (2). Press down the cover
to lock the bottom end in place (3).
R8B2_166.JPG
Note
Lithium batteries are classed as hazardous
waste! Used batteries must be disposed of
in the proper manner.
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Operation
6 Operation Activating the main switch
All the control system components are checked

Taking into account the various influencing
for faults during the start-up sequence. When
factors we recommend that the commissioning
the control system (CP 476 central processing
procedure be carried out by Battenfeld staff.
unit) is ready for operation, the green RUN LED
This is not only done for warranty reasons but
on the controller lights up and the start-up
also for the purpose of:
display appears.
• Checking the robot system for any
If an error is detected during the start-up
possible transport damage and also for
sequence, the red ”ERROR” LED lights up at
defects during installation and when
the controller. The controller is not ready for
connecting it up to the power supply.
operation and therefore the display remains
• Training operating personnel. blank. (refer to 5.5.2 Start-up display)
• Providing additional advice on operating,
maintaining and repairing the system. Enter your password
Your must enter your password in order to be

6.1 Commissioning able to use any of the functions.
Installation and Preparation Attention!

Password level - refer to 5.5.2 Start-up
• It is important that you read the operating display
manual and pay attention to the safety
instructions. Refer to the Section on Test the EMERGENCY STOP slam button
Safety. on the MCD
• Unload the robot system, transport it to
To test the Emergency Stop slam
the installation site and mount it on the
button on the manual control
IMM. Refer to the Section on Transport
device (MCD) press once and
and Installation.
release. This also generates an
• Set up the pneumatic system. Refer to error message. Also check that all
the Section on Transport and Installation. the other EMERGENCY STOP
• Set up the electrical system. Refer to the devices (IMM, peripherals) are
Section on Transport and Installation. released.
• Connect up the power supply

(secondary distribution).
• Check the lubrication points. Refer to the
Section on Transport and Installation
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Operation
Press START + Totmann button on the MCD Confirm error
After checking the EMERGENCY Any occurring errors, as well as potential errors,
STOP line and activating the must be remedied and confirmed before any
EMERGENCY STOP slam button further movements can be carried out.
press the green ”START” button and
the ”TOTMANN” button on the MCD If an error occurs, this is indicated to the
simultaneously. operator by the red LED in the "ERROR" button.
The main contactor then connects the power Press the "ERROR" button to switch to the
supply to the ACOPOS servo booster. The "ERROR" page in the display.
power is now ON! If the power supply is not
connected this generates an error message. After remedying the error, press the F1 function
button to confirm the error message or allow it
The ACOPOS servo booster is now ready for to disappear automatically. (refer to 5.5.8 Error
operation. The motor holding brakes remain messages)
activated. The three servo axes are not
controlled. (Axis change-over)
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Operation
6.2 Referencing Provided none of the linear axes are in a critical

position (visual check), switch to Manual mode
(MAN appears in the display) in order to move
When the controller is ready for operation after the axis (axes) out of the danger zone (tool,
the starting sequence, ”REF” (Referencing) periphery).
appears in the top right of the display.
The green LED in the START button Press the MAN button.
begins flashing. This indicates that the
servo axes must be referenced in order
obtain an accurate zero position.
Use the arrow buttons to move
the linear axes out of the danger
zone and to move the auxiliary
axes into the required end position.
After start-up the current position of the
servo axes is assumed to be the zero point.
(Direct referencing is not recommended). It is usually only necessary to move the Y-axis to
its basic position.
The B and C (if available) auxiliary axes must

also be located in a specified end position in
order to facilitate unobstructed referencing. If this
is not the case, an error message is generated
and the referencing movement cannot be
completed (refer to 5.5.8 Error messages). This
should therefore be checked before starting the
referencing movement.
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Operation
Once all the referencing conditions have been It is now possible to start the token programs
fulfilled, the referencing movement can begin. and Teach functions.
Press the REF button.
When moving servo axes which have not

The green LED in the START button been referenced it is important to note that
lights up. the paths of the main axes are not defined.
This means that the robot can move up to
the hardware limit switches, where it is
automatically stopped by the movement of
Press the START the ACOPOS servo control, which generates
button and the an error message at the pos./neg. HW limit
TOTMANN button switch.
simultaneously.
This activates the referencing movement. First

the Y-axis moves to its reference point in a ” - -
direction”. Once the Y-axis has been calibrated
(stationary), the horizontal axes (X, Z) move
towards their reference points.
When all three linear axes have reached their

reference positions, ”HOME” appears at the top
right of the display and the controller
automatically switches to Manual mode (LED in
button lights up).
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Operation
6.3 Manual operation The override function

is adjusted in 5%
Press MAN switch the robot to increments (Minimum
Manual mode. value = 5%, Maximum value = 100%) using the
two buttons (snail, hare) to the left and right of
the arrow buttons.
Use the arrow buttons (+,-) to Override values can also be entered using the
move the linear and the auxiliary numerical pad on the Axis status page.
axes according to the cursor
position on the Axis status page. (Page Manual mode speeds
selection is explained in Section 5.5.3 Status
pages). In unreferenced mode the linear axes move at
5% of the Override setting depending upon the
Axis status display: maximum speed.
In referenced mode the linear axes move at 10%

of the Override setting depending upon the
maximum speed.
R8B2_GB053.JPG
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Operation
6.4 Single step mode Press the TOTMANN button

and the START button.
In Single step mode each of the program lines is
implemented after pressing the START and the
TOTMANN buttons simultaneously (Automatic
mode - Individual steps).
to start the program sequence.
If the Automatic program is new or been
modified it is advisable to test it in Single step
mode before allowing the sequence to start fully The token program sequence is carried out line
automatically. This makes it possible to detect by line, i.e. it is interrupted at the end of each
and remedy any programming errors or program line. Press the START button again to
incorrectly entered data in advance. continue. The control system switches to STOP
at the end of each line and waits for the next
Start command.
Press the AUTO/SINGLE button twice

to activate Single step mode. Press the START button again to move
to the next line in the token program. This
”AUTO” appears at the top right of the display enables you to control the program
after the button has been pressed once. sequence before switching over to Fully
This is replaced by ”SINGLE” after the button Automatic mode. This function is especially
has been pressed again. important for executing movement commands.
The green LED in the START button then Any program errors detected during the step
begins flashing. movement sequence can be corrected using
the program Editor. (refer to 5.5.5 Creating token
programs)
The override function

is adjusted in 5%
increments (Minimum
value = 5%, Maximum value = 100%) using the
the arrow buttons.
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Operation
Status displays: Press the F4 function button (=continue) to read

off the current program status. Press the START
button to execute the command in the marked
program line.
R8B2_GB114.JPG
The current axis positions can be read off the

Axis status page during Single step mode. (refer
R8B2_GB115.JPG
to Section 5.5.3 Status pages)
Exiting Single step mode:
Press the MAN button to switch to Manual mode.
Press the ”AUTO/SINGLE” button to switch to

Automatic mode. (refer to 5.5.5 Creating token
programs)
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Operation
6.5 Automatic mode Status displays:
Once the Automatic program has been The status displays are used in the same way
adequately tested in Single step mode, you can as in Single step mode. (refer to 6.4)
start the token program for Fully Automatic
operation. Automatic mode speeds
Automatic mode must be started outside of the In Automatic mode the linear axes are operated
danger zones. (e.g. in the mould area) according to the Override function setting (5% -
100%).
Press the AUTO/SINGLE button. The override function

is adjusted in 5%
increments (Minimum
Activate the START button. value = 5%, Maximum value = 100%) using the
the arrow buttons.
Override values can also be entered using the

Press the TOTMANN button numerical pad on the Axis status page.
and the (Minimum value = 5%, Maximum value = 100%).
Exiting Automatic mode:
START button to start the program Press the MAN button to switch to
sequence. Manual mode.
The program sequence automatically runs to

the end of the program or until it is interrupted by
the user. Press the AUTO/SINGLE button to
switch to Single step mode. (refer to
5.5.5 Creating token programs).
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Operation
6.6 Stopping the program The Automatic program runs until the last
program line and then stops.
In Fully Automatic mode the Automatic program (End of cycle).
is stopped by using the ”Pstop” function (Stop
program).
The control system is still in Automatic

mode.
Press the TOTMANN button

and
R8B2_GB117.JPG
activate the START button to restart the
program sequence at the next program
line.
The ”PStop” function is no longer activated!
Exiting Automatic mode:
Press the MAN button to switch to

R8B2_GB118.JPG Manual mode.
Press the F4 function button on the Axis status

page or the F1 function button on the Program
status page to activate the ”Stop program” Press the AUTO/SINGLE button to
function. If the Automatic program uses jumps switch to Single step mode. ( (refer to
to different labels, it is necessary to insert the 5.5.5 Creating token programs).
Pstop command line.
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Operation
6.7 Automatic mode STOP Exiting Automatic mode:
Press the STOP button to stop the Press the MAN button to switch to
Automatic program during Fully Manual mode.
Automatic mode.
If a servo axis (X,Y,Z) is moving in a linear

direction at this moment it is stopped Press the AUTO/SINGLE button to
immediately. switch to Single step mode. (refer to
5.5.5 Creating token programs)
Movement of the B/C auxiliary axes or any other
possible peripheral pneumatic movements 6.8 EMERGENCY STOP
cannot be stopped for technical reasons. These
movements are continued until the final position If the EMERGENCY STOP slam
is reached. button is activated whilst the
machine is in operation or if the
EMERGENCY STOP circuit is
interrupted by the IMM/periphery, all
movements are stopped
The control system is still in Automatic immediately and the robot is
mode. deenergised.
To restart the system it is necessary to take into

Press the TOTMANN account and adhere to all the Start-up conditions
button and the specified in 6.1 Start-up.
START button to restart the program

sequence.
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Maintenance
7 Maintenance The various operating conditions make it

impossible specify how often it is necessary to
check for wear and carry out servicing,
7.1 General maintenance and repair work. Draw up a
servicing schedule to suit your own operating
Careful installation and maintenance are conditions.
essential for reliable operation of the robot
system. If you have any queries regarding robot
maintenance or repairs, please contact our
Daily visual checks help avoid downtime. service engineers or one of our subsidiaries.
Checks and servicing should be carried out and
worn components replaced at regular intervals. If you decide to take advantage of a service
Only use components of the same quality contract, we will be able to ensure that your
(strength, material) and design. robot is properly serviced and maintained.
Please contact out Customer Services
Stoppages due to inadequate or improper Department. The address of your contact
maintenance can result in excessive repair person can be found in Section 9 Customer
costs and the robot system being out of Services.
operation for long periods. Regular maintenance
is therefore essential. It is important to adhere to the safety regulations
specified in the ”Safety” section.
Thorough maintenance requires the use of
machine cards for recording all servicing and
maintenance work as well as any detected
defects and repairs which are carried out.
Shut down the robot system at the main
switch and secure it against accidental start-
up before carrying out any maintenance or
repair work!
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Maintenance
7.2 Transport, Storage and 7.3 Electrical systems

Waste Disposal
7.2.1 Lubricants
Lubricants are environmentally hazardous It is essential that legal directives and

products. It is therefore important to observe stipulations as well as the safety regulations
local safety laws and regulations, such as those in the ”Safety” section are adhered to when
concerning water, buildings, waste disposal, carrying out any activities involving
transport and industrial facilities as well as those assembly/disassembly, conversion or repair
relating to health and safety in the workplace. work.
These legal areas also apply to Transport,

Storage and Waste disposal.
7.2.2 Electrical components Electrical components may only be serviced

by qualified electricians!
7.3.1 Electro-mechanical limit switches
Pay attention to local laws and regulations

when disposing of electrical and electronic
components.
R8B2_121.JPG
• Make sure that the limit switches are

clean, operating smoothly and securely
attached.
• Check that the limit switches can be
depressed far enough.
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Maintenance
7.3.2 Proximity switches 7.3.4 Control cabinet
• The doors on the control cabinet must

always remain closed whilst the
machine is in operation.
• Make sure that the control cabinet is kept
clean.
• Carry out visual checks on electrical
components for any damage or burnt
areas.
• Tighten all the terminals in the control
cabinet and check the wires for any
damage or burnt areas every 2500
R8B2_122.JPG
hours.
• Check that the limit switches are clean

and correctly adjusted and make sure 7.3.5 Battery change
that the proximity switches (non-contact
limit switches) are securely attached. The control system must be fitted with a back-
up battery in order to avoid losing data. It has a
• The distance to the surface which service life of approximately 3 years. If the ”134
triggers the proximity switch must be 1 Change battery” error message appears, the
to 2 mm (0.04 to 0.07 inches). back-up battery must be replaced. (refer to 5.5.7
Error messages)
7.3.3 Indicator lights
• Any defective indicator lights must be

replaced immediately.
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Maintenance
7.4 Pneumatic system 7.4.2 Pneumatic connections
7.4.1 Compressed air servicing unit Check all pneumatic connections are securely
tightened (e.g. downstream valve block).
The transparent filter shell has a bayonet socket
which makes it easy to remove for cleaning.
1 1 - Pressure control valve

adjusting knob
2 2 - Condensate drain
3 - Pressure gauge
3 4 - Condensate tank
5 - Drain plug
4
5
R8B2_123.JPG
R8B2_133.JPG
7.4.3 Pneumatic C-axis

The condensate level must be checked every
week and emptied when the container is 3/4 full. The swivel axis is a compact twin blade part-
This is done by opening the drain plug. Adjust turn actuator. The continuous shaft is fitted with
the supply pressure to 6 bar (87 psi). maintenance-free ball bearings on both sides
inside the housing. The part-turn actuator
• Connector G 1/4" rotates at a maximum angle of 100°. The
smooth shafts are connected to the swivel fork
• Rating at 8 bar supply pressure 550 l/ by a clamping hub. The required angle of
min (116 psi, 145.2 US gall/min). rotation is achieved by means of externally
• Supply pressure max. 10 bar (145 psi) mounted, adjustable, locked stops.
• Medium temperature -10° C to +60° C
• Medium-filtered compressed air
(+14 °F to +140° F)
• Operating pressure: 4 to 8 bar (58 to 116
• Filter 0.03 mm (0.0012 inches)
psi)
• Vertically mounted
• Ambient temperature: +5° C to +60° C
• Metal protective cage and automatic (41 °F to 140° F)
condensate drain can be retrofitted.
• Medium temperature: +5° C to +60° C
(optional)
(41 °F to 140° F)
• Swivel time: 0.1 to 1.4 s/90°
• Torque at 6 bar –16 Nm (87psi – 11.8 lbf
ft.)
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Maintenance
If the power from the rotary shaft decreases, 7.4.4 Pneumatic B-axis
this may be due to leaking blade or housing
gaskets or sluggish bearings. The swivel axis is a compact twin blade part-
turn actuator. The continuous shaft is fitted with
maintenance-free ball bearings on both sides
7.4.3.1 Settings C - axis (tilting) inside the housing. The part-turn actuator
rotates at a maximum angle of 100°. The
smooth shafts are connected to the swivel fork
by a clamping hub. The required angle of
rotation is achieved by means of externally
Exhaust air Exhaust air
valve valve
mounted, adjustable, locked stops.
At 0° at 90°
(Basic position) (End position) • Medium-filtered compressed air
• Operating pressure: 4 to 8 bar (58 to 116
psi)
• Ambient temperature: +5° C to +60° C
(41 °F to 140° F)
• Medium temperature: +5° C to +60° C
(41 °F to 140° F)
Adjusting bolts for 90° swivel
angle + 3.5° • Swivel time: 0.1 to 1.4 s/90°
• Torque at 6 bar – 16 Nm (87 psi – 11.8
R8B2_162.PDF
lbf. ft.)
The swivel angle can be adjusted at the end
positions with the aid of the setting screws and
the stop. If the power from the rotary drive decreases this
may be due to a leaking blade or housing gasket
Speed adjustment: or a sluggish bearing unit.
The swivel speed can be adjusted using the
outlet valves on the swivel cylinder.
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Maintenance
7.4.4.1 Settings: B - axis (swivel) 7.4.5 Pneumatic installation components
The swivel angle can be adjusted at the end Various hoses are used connect the
positions with the aid of the stop and the compressed air servicing unit to the load and
adjusting screws. also for the vacuum supply to the gripper. The
hose labels can be found in the spare parts list.
The quantity and lengths may be different to the
90° 180° listed specifications.
2 2
3 The hose/coupling links must be checked for

tightness and leaks every month. The hoses
must not be kinked. Use replacement hoses
3 of the same quality. The hose ends must be
cut off using a special cutter. Check the
integrated compressed air connectors –
screw unions, quick-release screw fittings
and instant plug-in connectors – for leaks
every month and replace if damaged. The
maximum permitted temperature is 60°C
(140°F).
7.4.6 Sound absorbers
1 1 The integrated sound absorbers are designed to

reduce noise levels and to act as air filters in
vacuum systems. Contaminated air can clog
the sound absorbers and diminish the
performance of the entire system. Sound
absorbers should be checked and cleaned
every 3 months and replaced if necessary. See
Parts list for Item Nos.
1 1
1 - Adjusting bolts for swivel angle

2 - Exhaust air valve at 90° (end position)
3 - Exhaust air valves at 0° (basic position)
R8B2_163.PDF
Speed adjustment
The swivel speed can be adjusted using the
outlet valves on the swivel cylinder.
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Maintenance
7.5 Linear axis guideways It is necessary to break away the covers in order
to access the mounting bolts on the guiderails.
The main linear axes (X, Y and Z) each have two Any broken or damaged covers must be
guideways with recirculating ball systems. replaced with new parts.
The guide units must be replaced one after

another in sequence. Carefully slide the guide
unit onto the rail and bolt it to the slide. The
The guiderails must be cleaned regularly guide unit must be touching the edge of the slide
and any accumulated dirt removed. Check contact surface. Mount the rails individually. The
the wipers for damage and the mounting axis slide and the (correctly) mounted guide
bolts for tightness. Lubricate until the units can be used as an alignment guide. The
lubricant is forced out of any openings. pre-assembled rail is aligned by moving the
slide unit along the entire stroke path by hand
and then bolting it in position.
On Size 15 rails the mounting bolts must be

If the guide units or guiderails become secured with LOCTITE 242 B Item No. 8200048.
damaged stop the robot, deenergise the Mounting bolts on Size 25 and 35 rails are
electrical system, disconnect the secured with retaining washers to prevent them
compressed air supply and secure the axis. from becoming loose.
The rails and the guide units can be replaced
individually. Split rails are a single module
and must be replaced together. Pay attention
to the markings on the joints.
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Maintenance
First lubrication:
First lubrication involves using a total of

Guiderails normally have a service life of 3 separate amounts of grease as specified in
12,000 operating hours when handling the table.
weights of up to 8 kg. (18 lb.), provided the
robot is operated in accordance with its 1 Apply the first amount of grease to the
intended use and the following conditions guide unit as specified in the table.
are adhered to.
2 Move the guide unit back and forth with
three double strokes covering at least 3x
Use the correct regreasing compounds
the length of the unit.
depending upon how the rails are used and any
ambient factors. 3 Repeat 1 and 2.
4 Make sure that there is visible layer of
We recommend you use DIN 51825 K2K grease on the guiderail.
lubricating grease.
In the case of heavier loads, use Consistency Regreasing:

grade NLGI 2 acc. DIN 51818 / KPZK.
Regreasing intervals for Sizes 15 and 25 under
Capacity normal operating conditions are: 1000 km (620
miles) stroke distance
1st. lubrication 2nd. lubrication
Size
[cm³] [cu in]
Size 35: 500 km (310 miles) stroke distance
15 0,5 0,03
Shorter regreasing intervals are recommended
25 2 0,12
35 3,3 0,20 in cases where it is necessary to take into
R8B2_GB124.XLS account ambient factors such as dirt, vibration
and impacts.
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Maintenance
7.5.1 X,Y and Z axis greasing points
Y-axis - 4 lubrication points X-axis – 3 lubrication points
R8B2_126.JPG
Z-axis - 4 lubrication points
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Maintenance
7.6 Drive units Z-axis
7.6.1 Belts
All axes are driven by toothed belts and are

therefore maintenance-free.
The toothed belts must be checked for tears
and damage each week in order to avoid any
breakages.
7.6.1.1 Belt tension - X, Y, Z axes
X-axis R8B2_147.JPG
2 1
The toothed belt runs between the fixed plate

above the deflection pulley, drive roller and
clamping plate.
To change the belt tension it is necessary to

slacken off the 4 clamping bolts (Pos.1) and
adjust the tensioning nut (Pos.2). This does not
alter the toothed belt clamp.
R8B2_146.JPG
Retighten the clamping bolts after adjusting the
2 1 belt tension.
Y-axis
The drive wheel must be allowed to move in

order to tension the lower end of the belt. It
is therefore necessary to release the motor
brake.
2
R8B2_148.JPG
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Maintenance
Toothed belt tension values 7.6.1.3 Toothed belt replacement

Tension length Frequency
Axis If a damaged toothed belt has to be replaced, it
mm inch 1/sec
X 300 11,8 143 is important that the new belt is retightened
Y 500 19,7 90 during the first 5-6 operating hours.
Z 500 19,7 85
R8B2_GB150.XLS
7.6.1.4 Noise
The frequency is measured using a belt tension After a while the toothed belts are likely to make
measuring device. a noise when the brakes are applied with force
at high speeds.
7.6.1.2 X and Z axis belt drive
The toothed belts are made of polyurethane
After mounting the robot on the injection which tends to make a noise when the belts are
moulding machine it is necessary to check and running over the aluminium drive wheels.
adjust the belt in order to eliminate any tension This, however, does not affect the operation or
caused by the axis support. The belt must not repeating accuracy of the robot.
be allowed to touch the flanged wheels on the
deflection roller at any point during the stroke Solution: Spray the drive wheel teeth with
movement. commercial soap solution (1 part solution/1 part
water) 1 to 2 times a week.
This is done by slackening off the 4 clamping
bolts (Pos.1) and adjusting the deflection wheel
axis using the setscrews (Pos.2) in the cover
plate on the axis support. Then retighten the
clamping bolts.
R8B2_149.JPG
1 2
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Maintenance
7.6.2 Gears 7.7 Power guide chains

All the axis gears are life-time lubricated. It is Power supply chains (partly unsupported or in
therefore only necessary to change the oil if a channels) are used to provide moveable loads
leak occurs or when repairs are carried out. with safe, maintenance-free supplies of
electricity and compressed air.
The PVC chains are non-conductive. The chain

links and separating elements can be replaced
Check for oil leaks and noise each month individually. It is not possible to retrofit cables or
and make sure that connecting elements are hoses.
firmly attached. If any damage occurs, the
entire gear unit must be replaced. The bending radius must not be reduced. Do not
subject the chains to any additional stress by
When remounting the motor and the gears it is climbing or placing loads on them.
important that they are correctly aligned and not
forced together. The precise specifications can Carry out visual checks each month on the
be found on the housing. connecting elements as well as the integrated
power supplies and cable grips. Defective
components must be replaced immediately.
Specifications can be found on the side of the
chain links.
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Maintenance
7.8 Maintenance catalogue If any major deviations occur, appropriate

changes must be made. Non-operation-based
The maintenance items listed below are testing and maintenance procedures must be
recommended. It is important to observe and specified as follows:
adhere to the specific maintenance rules
relating to individual components and modules. d = daily
w = weekly
Maintenance intervals, which are based upon m = monthly
machine operation, are specified in operating a = annually
hours. The number of operating hours can be
read off the UHD and the counter zeroed.
If testing and maintenance procedures are
The operating hours can be estimated using the necessary at longer intervals than stated, this is
comparison table. The maintenance intervals indicated by a prefixed number, e.g., 6 m =
assume that each of the axes was running for every 6 months.
40% of the total operating hours (ED 40%).
Operating hours comparison table

Operating Operating hours/Maintenance cycles [h]
Operating mode
hours/year [h] 200 300 500 1000 1500 12000 24000
Constant operation approx. 500 to 1000
Single shift operation approx. 2000 1m, 1w 1m, 3w 3m 6m 9m 6a 12a
Single shift operation aprrox. 4000 2w 4w 1m, 2w 3m 3a 3a 6a
Single shift operation approx. 6000 2w 2w 1m 2m 3m 2a 4a
Constant operation approx. 8500 1w 2w 3w 1m, 2w 2m 1a, 4m 2a, 8m
R8B2_GB125.XLS
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Maintenance
Maintenance list
Frequency
refer to
Object Work required Performance- Time-dependent
Sect.
dependent
Repairs &
Lubricants 7.2.1 Dispose
Servicing
Repairs &
Electronic components 7.2.2 Dispose
Servicing
Check for cleanness m
Electro-mechanical limit
7.3.1
switches Check for tightness m
Check setting m
Check for cleanness m
Proximity switches 7.3.2 Check for tightness m
Check setting if indicated
immediately if
Indicator lamps 7.3.3 Replace
defective
Door closed during
Always
operation
Control cabinet 7.3.4
Clean m
Visual check w
Tighten terminals 2500h
Battery 7.3.5 Replace *when indicated
Condensate status -
w
check/empty
Druckluftwartungseinheit 7.4.1 Eingangsdruck prüfen w
Clean condensate filter 3m

Test 3m
Pneumatic valve 7.4.2
Check for tightness 3m
Pneumatic C-Axis Test w
7.4.3
(valves)
Check for tightness w
Check for leaks and
Pneumatic system m
7.4.4 tightness
(installed components)
Check hoses * - 3m
Sound absorber 7.4.5 Check for dirt / Clean 3m
* = Process materials required
R8B2_GB127.XLS
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Maintenance
Maintenance list
Frequency
refer to Time-
Object Work required Performance-
Sect. dependent
dependent
Check for cleanness w
Linear guideway 7.5 Check for damage w
Check for tightness w
Repairs and
Cover plate 7.5 Replace
Servicing
Check for tightness m
7.6.1.1 to Check for damage m
Belt tension
7.6.1.4 Tension 1000h
Replace = Repairs
Drive 7.6.2 Check for leaks = Repairs
Check for tightness and
Power chains 7.7 m
damage
Visual check
Cable connector w
Mains lead cleat
Fan filter Replace = 3m
* = Process materials required
R8B2_GB129.XLS
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Maintenance
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Spare parts / Diagrams
8.0 Spare parts / Diagrams

The Spare parts / Drawings section includes
parts lists, diagrams and drawings of the
various modules which make up the robot
system. There is an assembly drawing for each
module. Each spare part can be found under a
separate Item number.
In order to avoid confusion it is necessary to

specify the Machine No. on each spare parts
order. Please also include the relevant ID No.,
description and required quantity.
To place an order please contact your

BATTENFELD agency or contact us directly
(Addresses and telephone numbers can be
found in the Customer Services section).
A: R82GB0IA.PMD
B: R82DE0IA.PMD
E: 080403 / T. Wenger
Section 8
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Spare parts / Diagrams
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Page 2 G: 020403 / TCS
Customer Service
9.0 Customer Service

9.1 General
The "Customer service" chapter contains all contact
addresses of all customer service partners and
agencies of Battenfeld Injection moulding technology.
A: TB2GB0OC.P65
B: TB2DE0OC.P65
E: 180202 / Ruder
Chapter - 9
Customer Service
Egypt Brasilia (VBR) Agency for: Guangdong (VHK)
MEISCA Battenfeld do Brasil Ltda. Battenfeld Hong Kong Ltd.

Middle East Industrial Services & Commercial Rod. Castelo Branco, km 30 2/Fl., No. 18 Dai Fat Street
Agencies Av. Gupê, 10.767 Tai Po Industrial Estate
27 Ahmed Fakhry Str., 06422-120 Barueri-SP / Brazil Tai Po, N.T.
Apt. 2-Zone 6 Nasr City HONG KONG
Cairo / Egypt Tel.: 0055-11-4789-1877
Fax: 0055-11-4789-9045 Tel.: 00852-2666-9140
Tel.: 0020-2-2717032 e-Mail: battenfeld.brasil@vbr.battenfeld.com Fax: 00852-2665-2526
Fax: 0020-2-2717032 e-Mail: bathk@hk.super.net
Bulgaria
Algeria Columbia
WTC GmbH & Co. KG
Wassel Plast Sarl Dag-Hammarskjöld-Weg 3 Represantationes maquineq
Cité des Annassers BT. 807 Nr. 8 D-65760 Eschborn Uwe Koch
(B.P. 136) Deutschland Calle 68, No. 12-21, Oficina 304
Kouba Alger / ALGERIEN Bogota / Columbia
Postal address:
Tel. / Fax: 00213-229-2780 Postfach 6142 Tel.: 0057-1-2494581
Tel. / Fax: 00213-229-2215 D-65735 Eschborn Fax: 0057-1-2494581
Tel.: 0049-6196-5010-0
Argentina (VAR) Fax: 0049-6196-5010-20 Danmark (VDK)
GMO Gabelsberger & Cia.S.A. Battenfeld Danmark AS

Av. Belgrano 423/427 Piso 5° Canada (VCA) Stengaardsvej 7
1092 Buenos Aires / Argentina 4340 Toelloese / Danmark
Battenfeld Canada Co. Ltd.
Tel.: 0054-11-4342-7812 940 Westport Crescent Tel.: 0045-59185949(TB, KD, Ersatzteile)
Fax: 0054-11-4331-7689 Mississauga Fax: 0045-59186922(TB, KD, Ersatzteile)
e-Mail: info@gabyc.com.ar Ontario L5T 1G1 / Canada e-Mail: hagemann.k@battenfeld.dk
Tel.: 001-905-6709384
Australia (VAU) Fax: 001-905-7958226 Germany
e-Mail: batt@netrover.com
Battenfeld Australia Pty. Ltd. Battenfeld GmbH
3, Phoenix Court Scherl 10
Braeside, 3195 Chile D-58540 Meinerzhagen / Deutschland
Melbourne / Australia
BBL PACK S.A. Postal address:
Postal address: Av. Pedro de Valdivin No. 3317 Postfach 1164
P.O.Box 614 Nuñoa - Santiage - Chile D-58527 Meinerzhagen / Deutschland
Mordialloc, 3195
Melbourne / Australia Tel.: 0056-2-209-2880 Siehe Anhang
Fax: 0056-2-209-2869
Tel.: 0061-3-9587-5211 e-Mail: bbl@entelchile.net
Fax: 0061-3-9587-5224 England (VUK)
e-Mail: bardsley@battenfeld.mel.net
China Battenfeld U.K. Ltd.
6, The Valley Centre
Belgium (VBE) Agency for: Heilongsiang,Jilin, Liaoning, Nei Gordon Road
Mongol, Hebei, Sichuan, Shanxi, Shaanxi, High Wycombe
Battenfeld Belgium N.V. Shandong, Gansu, Henang, Beijing, Tianjin Bucks HP13 6EQ / Great Britain
Nieuwlandlaan 1A
Industriepark H&Z Tel.: 0044-1494-450911
B-3200 Aarschot Belgium Import + Export Fax: 0044-1494-445470
Office Beijing Room A 402 e-Mail: 100733.3061@compuserve.com
Tel.: 0032-16-551180 Long bo Building
Fax: 0032-16-562659 Nr. 3, Nanlishi Road
e-Mail: loos.I@vbe.battenfeld.com Xicheng District Ecuador
P.C. 100037 Beijing
P.R. China Battenfeld do Brasil Ltda. (VBR)
Bolivia (siehe unter Brasilien)
Tel.: 0086-10-68025224
Battenfeld do Brasil Ltda. (VBR) Fax: 0086-10-68025227
(see Brasilia) Finland (VFI)
Agency for: Chekiang, Jiangsu, Shanghai, OY Suomen Plastmaschinen AB

Bosnia and Herzegovina Hupeh, Anhui, Kiangsi, Hunan, Fukien Kaakelitehtaankatu 2
SF-24260 Salo / Finnland
Fokuma Planungs- u. Vertriebsges.m.b.H. Royaland International
Further Straße 27 Trading (Shanghai) Ltd. Tel.: 00358-2-7312-555
A-2564 Weißenbach No. 631, Ling Ling Road Fax: 00358-2-7312-660
AI-LE Building 10H e-Mail: horst.schallschmidt@plma.inet.fi
Tel.: 0043-2674-87427 Shanghai
0043-2674-87413
Fax: 0043-2674-874135 Tel.: 0086-21-64866856
e-mail: fr0198@aol.com 0086-21-64866857
0086-21-64863796
Fax: 0086-21-64866858
e-Mail: royaland@value-net.com.cn
A: TB2GB0OC.P65
Chapter - 9 B: TB2DE0OC.P65
E: 180202 / Ruder
Customer Service
France (VFR) Israel Lebanon
Battenfeld France S.A. PLAST-TECH & Co. Industrial Engineering Technology S.a.r.l.
Central Parc Industrial & Prod. Engineering Sed El Bauchrieh
255, Blvd. Robert Ballanger Vingait 30 A Electricity Street
F-93421 Villepinte P.O. Box 492 P.O.Box 90120 (Jdeidet El Metn)
Zihron Ya’acov 30900 / ISRAEL Beirut/Libanon
Postal address:
8, Allée du Daim Tel.: 00972-6-6292333 Tel.: 00961-880597
Boite Postale 42 Fax: 00972-6-6292444 Fax: 00961-880599
F-93421 Villepinte Cedex
Tel.: 0033-1-49634070 Italia (VIT) Malaysia (VSI)

Fax: 0033-1-49634081
e-Mail: 100701.177@compuserve.com Battenfeld Italia S.r.l. Battenfeld Injection Moulding Technology (S)
Via Donizetti Pte. Ltd.
I-20020 Solaro(MI) Italien Blk. 196, Pandan Loop #01-16
Greece Pantech Industrial Complex
Tel.: 0039-2-96 981045 SGP 128384 / SINGAPORE
General Plastics Ltd. 0039-2-96 981040
Representatives - Importers Fax: 0039-2-96 981049 Tel.: 0065-773-0821
Laskaridou 143 e-Mail: service@vit.battenfeld.com Fax: 0065-773-2427
Kallithea e-Mail: batasean@singnet.com.sg
17675 Athens / Greece
Jamaica
Tel.: 0030-1-9567885
Fax: 0030-1-9560137 Battenfeld Mexico S.A. de C.V. (VMX) Mazedonia
(siehe unter Mexico)
Fokuma Planungs- u. Vertriebsges.m.b.H.
Hong Kong (VHK) Further Straße 27
Jordan A-2564 Weißenbach
Battenfeld Hong Kong Ltd.
Units 910-911 UCM Tel.: 0043-2674-87427
No. 1 Hung To Road United Chemicals Marketing Est. 0043-2674-87413
Kwun Tong P.O. Box 1505 Fax: 0043-2674-874135
Kowlon Amman / Jordan e-mail: fr0198@aol.com
Tel.: 00852-2666-9140 Tel.: 00962-6-611906

Fax: 00852-2665-2526 Fax: 00962-6-611907 Mexico (VMX)
e-Mail: bathk@hk.super.net
Battenfeld Mexico S.A. de C.V.
Antonio Noemi No. 83
India Yugoslavia Col. Lomas de Memetla
05330 Mexico, D.F. / Mexico
Kromes Marketing India Fokuma Planungs- u. Vertriebsges.m.b.H.
13-C Ground Floor, Further Straße 27 Tel.: 0052-5-812-6666
Parmanand Co-op.Hsg. Society, A-2564 Weißenbach Fax: 0052-5-812-6670
5th Road, Khar West, e-Mail: battenfeld.mexico@vmx.battenfeld.com
Mumbai-400052 Tel.: 0043-2674-87427
India 0043-2674-87413
Fax: 0043-2674-874135 New Zealand
Tel.: 0091-22-6008463 e-mail: fr0198@aol.com
Fax: 0091-75-6008462 via Melbourne / Australia
e-Mail: kromes@rediffmail.com
Korea
Netherlands
Iran Trico International Ltd.
Room 1007, Dae Ha Bldg. Wilmod B.V.
Sunnywell Co. Ltd. 14-11, Yoido-Dong Industrieweg 10
3rd Floor, Ark Building Yungdungpo-Gu NL-2712 LB Zoetermeer / HOLLAND
Nr. 316 Ostad Motahari Ave. CPO Box 892
P.O.Box 15875/5753 Seoul / Korea Postal address:
Tehran / I.R. IRAN Postfach 40
Tel.: 0082-2-7847202 NL-2700 AA Zoetermeer
Tel.: 0098-21-8821095 Fax: 0082-2-7849074 HOLLAND
0098-21-8821096 e-Mail: A852510@magiclink.dacom.co.kr
0098-21-8833127 Tel.: 0031-79-346-1919
0098-21-8833128 Fax: 0031-79-346-1911
Fax: 0098-21-8821096 Croatia e-Mail: info@wilmdo.nl
Fokuma Planungs- u. Vertriebsges.m.b.H.

Irland Further Straße 27 Norway
A-2564 Weißenbach
Battenfeld U.K. Battenfeld Sverige AB
(see England) Tel.: 0043-2674-87427 c/o Ökonomi Partner Oslo AS
0043-2674-87413 Postboks 8704 Yonngstarget
Fax: 0043-2674-874135 N-0028 Oslo
e-Mail: fr0198@aol.com NORWEGEN
A: TB2GB0OC.P65
B: TB2DE0OC.P65
E: 180202 / Ruder
Chapter - 9
Customer Service
Austria (BKU) Romania Slovenia
Battenfeld Kunststoffmaschinen Ges.m.b.H. Jueng Engineering Fokuma spol. S.r.o.

Wiener-Neustädter-Straße 81 Niklas-Steuber-Gasse 24 Gololova 18
2542 Kottingbrunn / Austria A-2361 Laxenburg 85202 Bratislava
Slowakai
Tel.: 0043-2252-404-0 (Zentrale) Tel.: 0043-2236-72283
Fax: 0043-2252-404-1062 (Zentrale) Fax: 0043-2236-72509 Tel.: 00421-7 63811858
e-Mail: office@jungmayer.at Fax: 00421-905821858
Quality management - Customer service e-Mail: fr0198@aol.com
Tel.: 0043-2252-404-7500 Just Plast Technologies srl
Fax: 0043-2252-404-7502
e-Mail: schnabel.r@bku.battenfeld.com Str. Braziliei 14 Slovakia
RO-71221 Bucuresti
Customer service - Hotline Machinery Tel.: +40 1 2314611 Fokuma spol. s.r.o.
Tel.: 0043-2252-404-7511 Fax: +40 1 2304892 Gogolova 18
Fax: 0043-2252-404-7505 Servicehotline: + 40 93 313611 SK-85202 Bratislava / Slowakei
e-Mail: misera.w@bku.battenfeld.com e-Mail: battenfeld@pcnet.ro
Tel/Fax: 00421-7-638-11-858
Customer service - Hotline Automatisation Russia
Tel.: 0043-2252-404-7590
Fax: 0043-2252-404-3902 Vadim Zviagintsev Spain (VES)
e-Mail: kamel.m@bku.battenfeld.com 1 Novokuznetzkij Per. 5/7-KW 37
113184 Moskau Battenfeld Iberica S.A.
Spare Part Sale Russische Föderation Poligono Industrial
Tel.: 0043-2252-404-7550 La Ferreria
Fax: 0043-2252-404-7552 Tel.: 007-095-9538077 Avda. La Ferreria 29
e-Mail: navrkal.g@bku.battenfeld.com Tel.: 007-095-3051466 ES-08110 Montcada i Reixach / Espagna
Fax: 007-095-2306261
Training Tel.: 0034-93-5646053
Tel.: 0043-2252-404-7410 Fax: 0034-93-5646600
Fax: 0043-2252-404-7505 Sweden (VSV)
e-Mail: wagner.p@bku.battenfeld.com
Battenfeld Sverige AB South Africa
Ryttarevägen 18A
Peru 30260 Halmstad D.K. Machinery Pty. Ltd.
Schweden D.K. Machinery House
Battenfeld do Brasil Ltda. (VBR) No. 8, Engineering Close
(see Brasilia) Postal address: KYA SAND EXT. 15 / South-Africa
Box 9046
30009 Halmstad / Schweden Postal address:
Poland P.O.Box 2193
Tel.: 0046-351-55950 2162 Northriding / SOUTH AFRICA
Battenfeld Polska Fax: 0046-351-55959
Injection Moulding Technology Sp. z.o.o. e-Mail: battenfeld.@battenfeld.se Tel.: 0027-11-708-2090
Adamowizna 151 Fax: 0027-11-708-2085
05-825 Grodisk Maz / Polen
Switzerland (VSZ)
Tel: 0048 22 724 38 07 Taiwan
Fax: 0048 90 213 014 Battenfeld Schweiz AG
e-Mail: battenfeld@hot.pl Brunnenstraße 7 Royaland Co. Ltd.
8604 Volketswil 10-8 Floor, No. 104,
Schweiz Ming-Chuan West Road
Portugal (VES) Taipei, Taiwan 103 / ROC
Tel.: 0041-1-9086565
Battenfeld Iberica S.A. Fax: 0041-1-9086550 Tel.: 00886-2-2550-6788
Poligono Industrial e-Mail: sekretariat@battenfeld.ch Fax: 00886-2-2550-6766
La Ferreria e-Mail: royaland@ms4.hinet.net
Avda. La Ferreria 29
E-08110 Montcada i Reixach Singapore (VSI)
Espagna Thailand
Battenfeld Injection Moulding Technology (S)
Tel.: 0034-93-5646053 Pte. Ltd. C. Melchers & Co. (Thailand) Ltd.
Fax: 0034-93-5646600 Blk. 196, Pandan Loop #01-16 15th Floor Sorachai Building
Pantech Industrial Complex 23/39-39 Sukhumvit 63 Klongton-Nua
SGP 128384 Watthana Bangkok 10110
SINGAPORE Thailand
Tel.: 0065-773-0821 Tel.: 00662-714 30705

Fax: 0065-773-2427 Fax: 00662-714 3076
e-Mail: batasean@singnet.com.sg e-Mail: melchers@samart.co.th
A: TB2GB0OC.P65
E: 180202 / Ruder
Customer Service
Czech Republic
Belorussia
Smid Spol. sro.
Ke Kastanku 236 Vadim Zviagintsev
CZ-252 18 Uhonice / Tschechische Republik 1 Novokuznetzkij Per. 5/7-KW 37
113184
Tel.: 00420-311-670253 Russische Föderation
Fax: 00420-311-670795
e-Mail: zastoupeni.battenfeld@pvnet.cz Tel.: 007-095-9538077
Tel.: 007-095-3051466
Fax: 007-095-2306261
Turkey
MELTEM Cyprus
Makina Sanayi Ve Ticaret Ltd. Sti.
Dogu Sanayi Sitesi Block: 6 Nr. 11 M. Sideris & Son. Ltd.
Yenibosna 34520 Istanbul 18, Pindarus Street
Türkei P.O. Box 2353
Nicosia
Tel.: 0090-212-5522361 Zypern
Fax: 0090-212-5529670
e-Mail: meltemltd@turk.net Tel.: 00357-2-755141
00357-2-755142
00357-2-758300
Tunesia Fax: 00357-2-754198
e-Mail: consider@spidernet.com.cy
Battenfeld France S.A.
(siehe unter Frankreich)
Hungary
THEGE-PLASTIC GmbH
Dugonics u. 11
H-1043 Budapest
Ungarn
Tel.: 0036-1-3700010
Fax: 0036-1-3700020
e-Mail: thege@netvision.hu
Uruguay
GMO Gabelsberger & Cia.S.A.

(siehe unter Argentinien)
U.S.A. (VUS)
Battenfeld of America, Inc.

James P. Murphy Ind. Highway
West Warwick Industrial Park
West Warwick, RI 02893
U.S.A.
Tel.: 001-401-823-0700
Fax: 001-401-823-5641
e-Mail: batserve@aol.com
Venezuela
Kast, asesoria tecnica, c.a.

Av. Rio Paragua,
Res. Prado Humboldt
Edf. Cuji, S1, Ofic. CHR-S4
1081 Caracas
Venezuela
Tel.: 0058-2-9765397
Fax: 0058-2-9774379
A: TB2GB0OC.P65
B: TB2DE0OC.P65
E: 180202 / Ruder
Chapter - 9
Customer Service
Customer Service Germany
Postfach 1164 Head Customer Service: ++49 (0) 2354/72-120

58527 Meinerzhagen Sekretary: ++49 (0) 2354/72-121
Scherl 10 Telefax: ++49 (0) 2354/72-129
58540 Meinerzhagen e-Mail: Barutta.j@bmf.battenfeld.com
Training
Tel.: ++49 (0) 2354/72-334
Fax: ++49 (0) 2354/72-503
Spare Parts
e-Mail: Gust.m@bmf.battenfeld.com Tel.: ++49 (0) 2354/72-161
Fax: ++49 (0) 2354/72-139
e-Mail: Hinz.m@bmf.battenfeld.com
Technical Customer Service

Tel.: ++49 (0) 2354/72-140
Fax: ++49 (0) 2354/72-159
e-Mail: Berger.a@bmf.battenfeld.com
Spare Parts
Tel.: ++49 (0) 2354/72-131 Hamburg
Fax: ++49 (0) 2354/72-139
e-Mail: Sander.i@bmf.battenfeld.com
Bremen
Tel.: ++49 (0) 2354/72-130
Fax: ++49 (0) 2354/72-169
e-Mail: Vormberg.w@bmf.battenfeld.com
Berlin
Kassel Dresden
Meinerzhagen
Frankfurt
Spare Parts and

Tel.: ++49 (0) 561/518081
Fax: ++49 (0) 561/5102487
Nürnberg e-Mail: Service@plastconsult.de
Spare Parts
Tel.: ++49 (0) 2354/72-161
Fax: ++49 (0) 2354/72-139
e-Mail: Hinz.m@bmf.battenfeld.com Stuttgart

Tel.: ++49 (0) 2354/72-160
Fax: ++49 (0) 2354/72-169
e-Mail: Salmen.j@bmf.battenfeld.com München
Spare Parts
Tel.: ++49 (0) 2354/72-151
Fax: ++49 (0) 2354/72-159
e-Mail: Catrin.o@bmf.battenfeld.com

Tel.: ++49 (0) 2354/72-150
Fax: ++49 (0) 2354/72-159
e-Mail: Kuech.o@bmf.battenfeld.com
A: TB2GB0OC.P65
E: 180202 / Ruder

Operating Manual R8 B2

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Operating Manual

Read before using the robot and

Robot - Type R8 / B2 6-10-20

Version R82GBV00 04/03

Battenfeld Kunststoffmaschinen Ges.m.b.H.

DIN EN ISO 9001

Chapter 1 General information

Chapter 3 Technical Data

Chapter 4 Transport - Installation

Chapter 5 Structure and function

Chapter 8 Spares / Plans

Chapter 9 Customer service

Chapter 10 Extra chapter for special modules

1.0 General 3.2 Robot axles

2.1.3 Operation and maintenance 3.4 Pneumatic system

2.1.4 Safety - Personnel 3.4.1 Compressed air connection

2.1.5 Safety regulations – 3.4.2 Creating a vacuum

3.7 Drive elements on main axes 4.1.7 Installation layout

5.4 Unirob B2 controller 5.5.5.3 Token commands for additio-

7 Maintenance 7.5.1 X, Y and Z axis greasing

7.4.5 Pneumatic installation

A factory password is required for robot operation.

General Should you encounter any problems in operating

The manual should be read thoroughly, paying 1.2 Use

”Danger of crushing” indicates there is a risk of

The high voltage symbol is used in sections of

1.6 Declaration of Conformity

1.5 Confirmation of receipt

To: BKU Documentation Department ++43/2252 404 - 3002

1) Robot - Type _______________________________________ Robot No.: ________________

2) Customer’s address ___________________________________________________________

we were supplied with ___________________________________ (quantity)

operating manual (s) in __________________________ supplied.

4) Supplied: _____ ___________________________________________

5) Signature of dealer or importer:

Company stamp / signature

6) The robot was supplied to the cus-

_______________________________ Signature if different to 5

2 Safety Intended use of the system shall include

2.1.1 General The responsible persons and the work

2.1.4 Safety - Personnel When carrying out any form of assembly/

3 Specifications 3.1.2 Handling loads

The ”Specifications” section contains all the

The kinematic structure of the UNIROB B2 3.1.4 Delivery side selection

The linear axes (main axes) are driven by

3.2 Robot axis definitions 3.2.2 Auxiliary axes

3.2.1 Linear axes

The following linear and main axes are driven by

X main horizontal linear axis parallel to the

The axis letter symbols are positioned at

3.3 Performance data / 3.3.3 Maximum speeds of main and linear

3.3.1 Linear axes (main axes) Main axis

3.3.4 Maximum speeds of rotating and

The main axes (X/Y/Z) are driven by a servo Turning max.

The repeat accuracy of +/- 0.1 mm (+/- 0.004

3.4 Pneumatic system 3.4.3 Pneumatic valves

The system uses pneumatic 5/2-way valves

The vacuum which is required to operate the

1) Robot - Type _______________________ Robot No.:

4) Supplied: _ _______________________________________