R8.

3 USER MANUAL Page 1

R8.3
USER MANUAL
Original User Manual

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 2

This manual provides the information necessary to properly install, operate and service
Wittmann Robot Systems, and ensure correct and safe operation of our equipment.

Our robots must be installed and operated in accordance with these instructions by
authorized and qualified personnel only.

Improper installation startup and operation may result in injury to personnel and/or
damaged equipment.

Before installation, read this manual completely, paying special attention to the Safety

Warnings marked with .

To ensure optimal use of our equipment, we recommend that you attend the training
courses regularly offered at our Service Centers.

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

according to the instructions given in this manual.

The descriptions in this manual refer to the robot and equipment according to the
specification sheet. These specifications are subject to change without notice.

This manual is for the sole use of the user of the robot and may not be distributed to
unauthorized persons. No part of this manual may be copied or reproduced without our
written consent.

Use original Wittmann USB-sticks only. The function with USB-sticks of third party
suppliers is explicitly not guaranteed.

Do not use hard or pointed objects to operate the touch screen of the Teachbox. This
could damage the touch screen.

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 3

Before starting up the robot for the first time, review this manual thoroughly and
familiarize yourself with the operation of the robot. Improper use may injure personnel
and/or damage the robot, mold or molding machine.

Table of Contents
1 SAFETY PRECAUTIONS ..................................................................... 11
1.1 SAFETY REGULATIONS ......................................................................... 11
1.2 SAFETY FEATURES ................................................................................ 12
1.2.1 Safeguarding ...................................................................................... 12
1.2.2 Emergency STOP Buttons ................................................................. 12
1.2.3 Permit Keys on Teachbox .................................................................. 12
1.3 CAPABILITY OF THE SAFETY CONTROL .............................................. 13
1.4 LIMITATIONS ........................................................................................... 14
1.5 CONTROL OF HAZARDOUS ENERGY – (LOCKOUT / TAGOUT) .......... 15
1.5.1 Glossary ............................................................................................. 15
1.5.2 Lockout/Tagout Kit ............................................................................. 16
1.5.3 Lockout/Tagout Procedure ................................................................. 16
1.5.4 Removal of LOTO .............................................................................. 17
2 MOUNTING THE ROBOT..................................................................... 18
2.1 MECHANICAL INSTALLATION ................................................................ 18
2.1.1 Dimensional Drawing – Adapter Unit .................................................. 18
2.1.2 Transportation of the Robot ................................................................ 19
2.1.3 Demounting the Robot........................................................................ 20
2.2 ELECTRICAL CONNECTIONS................................................................. 23
2.2.1 Main Power Supply ............................................................................ 23
2.2.2 Residual Current Device..................................................................... 23
2.3 ELECTRICAL INTERFACE....................................................................... 24
2.3.1 Interface with the Injection Molding Machine ...................................... 24
2.3.2 Euromap 67 interface ......................................................................... 25
2.3.2.1 Injection Molding Machine (IMM) Signals ..................................... 26
2.3.2.2 Robot Signals .............................................................................. 28
2.3.3 Euromap 12 Interface ......................................................................... 30
2.3.3.1 Injection Molding Machine (IMM) Signals ..................................... 31
2.3.3.2 Robot Signals .............................................................................. 32
2.3.4 Mold Monitoring S5/S6 ....................................................................... 33
2.3.4.1 Settings for Virtual Roller Switches (Mold Safety Switches) ......... 34
2.3.4.2 Initialize Roller Switch Monitoring ................................................. 35
2.3.4.3 Test Procedure for Mold Safety S5 / S6 ....................................... 36
2.4 SAFETY PACKAGE/SAFEGUARDING .................................................... 37
2.4.1 Safety Package .................................................................................. 37
2.4.2 EXTERNAL Safety Package for Safety Door or Access Hatch ........... 38
2.4.2.1 Indication lamp for operating modes at PRO-series robots .......... 40
2.4.3 Safeguarding ...................................................................................... 41
2.5 PNEUMATICS .......................................................................................... 42

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 4

2.5.1 Compressed Air Connection ............................................................... 42

3 OPERATING INSTRUCTIONS FOR R8.3 CONTROL ......................... 43
3.1 BASIC OPERATION ................................................................................. 43
3.1.1 Introduction ........................................................................................ 43
3.1.2 Robot Axes......................................................................................... 44
3.1.3 Emergency Stop Block ....................................................................... 45
3.1.4 Numerical Input .................................................................................. 46
3.1.5 Text Input ........................................................................................... 47
3.1.6 Operating Modes ................................................................................ 48
3.1.7 Operating Mode Reference ................................................................ 49
3.1.7.1 Reference travel in the operating mode Reference Missing ......... 49
3.1.7.2 Reference travel in the operating mode Manual ........................... 50
3.1.8 Override ............................................................................................. 51
3.1.9 ECO-Mode ......................................................................................... 53
3.1.10 Safety System .................................................................................. 54
3.1.10.1 Startup with Safety System ........................................................ 54
3.1.10.1.1 Manual Setup Mode............................................................................................................ 54
3.1.10.1.2 Automatic Mode, Step Mode, Reference Travel................................................................ 54
3.1.10.2 Selection of Operating Modes .................................................... 54
3.1.10.2.1 Manual Setup Mode............................................................................................................ 54
3.1.10.2.2 Automatic Mode, Step Mode, Reference ........................................................................... 55
3.1.10.3 Monitoring of the Safety Gate..................................................... 55
3.1.10.4 Error Effect Analysis .................................................................. 55
3.1.11 User Administration and Passwords ................................................. 56
3.1.11.1 Administrator.............................................................................. 56
3.1.11.2 Users ......................................................................................... 57
3.1.11.2.1 User (create, change) ......................................................................................................... 58
3.1.11.3 Profiles....................................................................................... 59
3.1.11.4 Login .......................................................................................... 60
3.1.11.5 Logout........................................................................................ 61
3.1.11.6 Forgot Password ........................................................................ 61
3.1.12 Manual Functions ............................................................................. 62
3.1.12.1 Numerical Axes .......................................................................... 62
3.1.12.2 Axis Release in Manual Mode (optional) .................................... 64
3.1.12.3 Pneumatic Axes ......................................................................... 65
3.1.12.4 Digital (B-) Axes ......................................................................... 66
3.1.12.5 Counters .................................................................................... 68
3.1.12.6 Placing Counters........................................................................ 69
3.1.12.7 Conveyors.................................................................................. 70
3.1.12.8 Peripheral Outputs ..................................................................... 71
3.1.12.9 Vacuums.................................................................................... 72
3.1.12.10 Grippers ................................................................................... 73
3.1.12.11 Cylinders.................................................................................. 74
3.2 USING THE QUICK NEW WIZARD AND THE QUICK EDIT .................... 75
3.3 FILE MENU OF THE MAIN SCREEN ....................................................... 81
3.3.1 Properties........................................................................................... 81
3.3.2 System Backup/Restore ..................................................................... 83
3.3.2.1 Backup stored Teachprograms .................................................... 84
3.3.3 INIT Menu .......................................................................................... 85
3.3.3.1 Stroke Limits ................................................................................ 85
3.3.3.2 Roller Switches ............................................................................ 86
3.3.3.3 Absolute Encoders (Admin only) .................................................. 86
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 5

3.3.3.4 Setting the zero points at a PRO-series Robot ............................. 86

3.3.3.5 Deactivate Monitoring .................................................................. 87
3.3.3.6 Maintenance - Lubrication Interval ............................................... 88
3.3.3.7 Setup: Robot Settings .................................................................. 89
3.3.3.8 Setup: Date / Time ....................................................................... 91
3.3.3.9 Setup: Language ......................................................................... 92
3.3.3.10 Setup: Custom FTP-Server (only Admin) ................................... 93
3.3.3.11 Setup: Network Settings (Admin only) ........................................ 95
3.3.3.12 Setup: Remote Users Settings (Admin only) .............................. 97
3.3.3.12.1 Create / Edit Remote Users (Admin only) .......................................................................... 98
3.3.3.13 Licenses (Admin only) ................................................................ 98
3.3.3.14 Setup: Email Settings ................................................................. 99
3.3.3.14.1 Tab Basic ............................................................................................................................ 99
3.3.3.14.2 Tab Content ........................................................................................................................ 99
3.3.3.14.3 Tab Timeouts .................................................................................................................... 100
3.3.3.14.4 Tab Recipients .................................................................................................................. 100
3.3.3.14.5 Tab Events ........................................................................................................................ 101
3.3.3.15 Setup: Screensaver Properties ................................................ 102
3.3.3.16 Setup: Calibrate Touch ............................................................ 103
3.3.4 View Menu ....................................................................................... 103
3.3.4.1 Operating Systems .................................................................... 103
3.3.4.2 Operating Data .......................................................................... 104
3.3.4.3 Axes positions............................................................................ 105
3.3.4.4 I / O............................................................................................ 106
3.3.4.5 Safety Areas .............................................................................. 107
3.3.4.6 Counters .................................................................................... 108
3.3.4.7 Placing Counters ....................................................................... 109
3.3.4.8 Conveyors ................................................................................. 110
3.3.4.9 Cylinders.................................................................................... 111
3.3.4.10 POs - Peripheral Outputs ......................................................... 112
3.3.4.11 PIs - Peripheral Inputs ............................................................. 113
3.3.4.12 IMM I / O .................................................................................. 114
3.3.4.13 AutoSwitches ........................................................................... 115
3.3.4.14 Stopwatches ............................................................................ 116
3.3.4.15 Vacuums.................................................................................. 117
3.3.4.16 Default Vacuum Level .............................................................. 118
3.3.4.17 Grippers ................................................................................... 119
3.3.4.18 Alarms ..................................................................................... 120
3.3.4.19 Error Buffer .............................................................................. 121
3.3.4.19.1 Export the Error Buffer ...................................................................................................... 122
3.3.4.20 Command Buffer...................................................................... 124
3.3.4.20.1 Export the Command Buffer ............................................................................................. 125
3.3.4.21 Virtual Subpendant (Emergency Stop Block) ........................... 127
3.3.4.21.1 Tab Standard .................................................................................................................... 127
3.3.4.21.2 Tab Easy ........................................................................................................................... 129
3.3.4.22 Memory State .......................................................................... 130
3.3.5 System Report ................................................................................. 131
3.3.6 Email Functions ................................................................................ 132
3.3.6.1 Manual Email Function .............................................................. 132
3.3.6.2 Automatic Email Function .......................................................... 133
3.3.7 RFID / Digital EOAT (optional).......................................................... 134
3.3.7.1 Link a Teach Program with an EOAT ......................................... 134
3.3.7.2 EOAT Change ........................................................................... 135
3.4 TEACH-MODE USING THE TEXT EDITOR ........................................... 136
3.4.1 Operation of the Text Editor ............................................................. 136
3.4.1.1 Entering the Text Editor ............................................................. 136
3.4.1.2 Exit the Texteditor and transfer the program to the CPU ............ 136
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 6

3.4.1.3 Editing Functions ....................................................................... 137

3.4.1.4 Online Editor .............................................................................. 138
3.4.1.5 Offline Editor .............................................................................. 138
3.4.1.6 Online Conversion ..................................................................... 138
3.4.2 Step Operation ................................................................................. 139
3.4.2.1 Procedure Step .......................................................................... 139
3.4.3 Part Programs, PROGRAM Menu .................................................... 140
3.4.3.1 Part Programs............................................................................ 140
3.4.3.1.1 Robot Program (ROBOT-PRG) .......................................................................................... 140
3.4.3.1.2 Peripheral Program (PERI-PRG) ....................................................................................... 141
3.4.3.1.3 Robot Reference Program (ROBOT-REF) ........................................................................ 141
3.4.3.1.4 Peripheral Reference Program (PERI-REF) ...................................................................... 141
3.4.3.1.5 115 additional Part Programs ............................................................................................. 142
3.4.3.1.6 All Mode Program (ALLMODE PRG) ................................................................................. 142
3.4.3.1.7 Sub-Allmode Part Program................................................................................................. 143
3.4.3.1.8 EOAT Change Program ..................................................................................................... 143
3.4.3.2 Manage Part Programs .............................................................. 144
3.4.3.2.1 Edit a Part Program ............................................................................................................ 145
3.4.4 FILE Menu of the text editor ............................................................. 146
3.4.4.1 New ........................................................................................... 146
3.4.4.2 Open .......................................................................................... 147
3.4.4.3 Import Macro.............................................................................. 149
3.4.4.4 Load Program from CPU............................................................ 151
3.4.4.5 Save (NAME.ZIP) ...................................................................... 151
3.4.4.6 Save As ..................................................................................... 152
3.4.4.7 Export Selection......................................................................... 154
3.4.4.8 Transfer program to CPU ........................................................... 155
3.4.4.9 Properties .................................................................................. 156
3.4.4.10 Print ......................................................................................... 158
3.4.4.11 Exit to Main .............................................................................. 160
3.4.4.12 Properties Window of the File Dialogue ................................... 161
3.4.4.13 Picture Viewer.......................................................................... 163
3.4.4.13.1 Associate a picture with a Teach program....................................................................... 163
3.4.5 EDIT Menu ....................................................................................... 166
3.4.5.1 Selection Mode .......................................................................... 166
3.4.5.2 Copy, Cut, Paste ........................................................................ 167
3.4.5.3 Search-Toolbar .......................................................................... 169
3.4.5.4 Show Prefixes ............................................................................ 170
3.4.5.5 Show Default Names ................................................................. 171
3.4.5.6 Show Internal IDs ...................................................................... 171
3.4.5.7 Show Line Numbers................................................................... 171
3.4.5.8 Show Execution Times .............................................................. 172
3.4.6 Teach program Settings in the SETUP Menu ................................... 173
3.4.6.1 Online / Offline Editor ................................................................. 173
3.4.6.2 Axes Definition ........................................................................... 173
3.4.6.3 Safety Areas .............................................................................. 174
3.4.6.3.1 Create / Edit Safety Areas .................................................................................................. 176
3.4.6.3.2 Properties of the Working Area .......................................................................................... 177
3.4.6.3.3 Graphical Display of the Safety Areas ............................................................................... 178
3.4.6.4 Cylinder Definition ...................................................................... 180
3.4.6.4.1 Create / Edit Cylinders ........................................................................................................ 181
3.4.6.5 Auto Switch Definition ................................................................ 182
3.4.6.6 Counter Definition ...................................................................... 185
3.4.6.7 Counter Names.......................................................................... 186
3.4.6.8 Conveyor Names ....................................................................... 187
3.4.6.9 Peripheral Output Names........................................................... 188
3.4.6.10 Peripheral Input Names ........................................................... 189
3.4.6.11 Stacking Sensor Names........................................................... 190
3.4.6.12 Stopwatch Names .................................................................... 191
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 7

3.4.6.13 Vacuum Names ....................................................................... 192

3.4.6.14 Gripper Names ........................................................................ 193
3.4.6.15 Vacuum Reference States ....................................................... 194
3.4.6.16 Gripper Reference States ........................................................ 195
3.4.6.17 Setup Standard Vacuum Pressure ........................................... 197
3.4.7 Part program Settings in the PART PRG SETUP menu ................... 200
3.4.7.1 Positions .................................................................................... 200
3.4.7.1.1 Create / Edit Positions ........................................................................................................ 201
3.4.7.2 Labels and Subroutines ............................................................. 202
3.4.7.3 Placing Program ........................................................................ 202
3.5 TEACH COMMANDS OF THE TEXTEDITOR ........................................ 203
3.5.1 Axes ................................................................................................. 203
3.5.1.1 Axes Selection ........................................................................... 203
3.5.1.2 Terminology ............................................................................... 203
3.5.1.2.1 Pneumatical Axes ............................................................................................................... 203
3.5.1.2.2 Numerical Axes ................................................................................................................... 203
3.5.1.2.3 Path Axes ............................................................................................................................ 203
3.5.1.3 Move .......................................................................................... 204
3.5.1.3.1 Absolute Movement ............................................................................................................ 205
3.5.1.3.2 Relative Motion ................................................................................................................... 205
3.5.1.3.3 Parallel Movements ............................................................................................................ 206
3.5.1.3.4 Curve ................................................................................................................................... 208
3.5.1.3.5 Stop ..................................................................................................................................... 209
3.5.1.3.6 Soft Torque Push ................................................................................................................ 210
3.5.1.3.7 Release (optional) ............................................................................................................... 212
3.5.1.3.8 Stacking Sensor (optional) ................................................................................................. 213
3.5.1.3.9 Find ´n´ Pick ........................................................................................................................ 214
3.5.1.3.10 Insert ................................................................................................................................. 216
3.5.1.4 Enhanced Conveyor control ....................................................... 218
3.5.1.4.1 Follow Conveyor (optional) ................................................................................................. 218
3.5.1.4.2 Conveyorbelt tact extension ............................................................................................... 221
3.5.1.4.3 Mold Opening Synchronization (optional) .......................................................................... 228
3.5.1.5 3D Motions ................................................................................ 230
3.5.1.5.1 3D Absolute Movement ...................................................................................................... 233
3.5.1.5.2 3D Relative Movement ....................................................................................................... 233
3.5.1.5.3 3D Curve ............................................................................................................................. 233
3.5.1.6 Velocity ...................................................................................... 234
3.5.1.6.1 VMAX .................................................................................................................................. 234
3.5.1.6.2 VABS ................................................................................................................................... 234
3.5.1.6.3 AABS ................................................................................................................................... 235
3.5.1.6.4 R3D ..................................................................................................................................... 236
3.5.1.6.5 V3D...................................................................................................................................... 236
3.5.1.7 Wait Sync .................................................................................. 237
3.5.1.7.1 Wait Path Sync ................................................................................................................... 237
3.5.1.8 Movements and Parameters for Scara Robots ........................... 238
3.5.1.8.1 Pathmode ............................................................................................................................ 238
3.5.1.8.2 Angular Motions - „in degrees“ ........................................................................................... 239
3.5.2 Placing Programs ............................................................................. 240
3.5.2.1 Create/Edit Placing Programs .................................................... 241
3.5.2.1.1 Dialogue for Axes Selection ............................................................................................... 242
3.5.2.1.2 Tab 1. - 1st Position, Name ................................................................................................ 244
3.5.2.1.3 Tab 2. - Stacking Pattern .................................................................................................... 245
3.5.2.1.4 Tab Options......................................................................................................................... 246
3.5.2.1.5 Tab STS - Stacking Sensor ................................................................................................ 247
3.5.2.1.6 Tab Displacement ............................................................................................................... 248
3.5.2.2 Add Placing Program Commands to the Teach Program ........... 249
3.5.3 Injection Molding Machine IMM ........................................................ 251
3.5.3.1 Injection Molding Machine IMM - Standard Functions ................ 251
3.5.3.1.1 MOLD CLOSE and FULLY MOLD OPEN ......................................................................... 252
3.5.3.1.2 EJECTORS FORWARD/BACK and COREPULLERS PULL/SET ................................... 253
3.5.3.2 Injection Molding Machine IMM - Automatic Functions ............... 254
3.5.3.2.1 MOLD CLOSE! WAIT ......................................................................................................... 255
3.5.3.2.2 EJECTORS FORWARD/BACK (WAIT) and CORE PULLERS PULL/SET (WAIT) ......... 255
3.5.3.3 Injection Molding Machine IMM - Logical Functions – Mold Was Closed
.................................................................................................. 256
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 8

3.5.4 Smart Removal................................................................................. 257

3.5.4.1 Smart Removal: In ..................................................................... 257
3.5.4.2 Smart Removal: Out .................................................................. 261
3.5.5 Peripherals ....................................................................................... 265
3.5.5.1 Conveyor ................................................................................... 265
3.5.5.2 Peripheral Outputs PO ............................................................... 266
3.5.5.3 Cylinder function ........................................................................ 267
3.5.5.3.1 Applying cylinders in a teach program ............................................................................... 268
3.5.5.4 Vacuums.................................................................................... 269
3.5.5.4.1 Switching valve vacuum / gripper ....................................................................................... 270
3.5.5.5 Vacuum Level ............................................................................ 271
3.5.5.6 Grippers ..................................................................................... 272
3.5.5.7 Monitoring of Vacuum Circuits, Grippers and Peripheral Outputs273
3.5.6 Counters .......................................................................................... 276
3.5.6.1 64 freely usable Counters .......................................................... 276
3.5.6.2 Reset / Manipulate Placing Counters ......................................... 278
3.5.7 Program branching ........................................................................... 280
3.5.7.1 Jump .......................................................................................... 280
3.5.7.2 Label.......................................................................................... 281
3.5.7.3 If - Elseif - Else - Endif ............................................................... 281
3.5.7.3.1 Variant 1: ............................................................................................................................. 282
3.5.7.3.2 Variant 2: ............................................................................................................................. 282
3.5.7.3.3 Variant 3: ............................................................................................................................. 283
3.5.7.4 Call - Subr – Ret ........................................................................ 284
3.5.7.5 And ............................................................................................ 286
3.5.7.6 Or .............................................................................................. 286
3.5.7.7 End ............................................................................................ 287
3.5.7.8 Jump Conditions ........................................................................ 287
3.5.7.8.1 Jump condition: Counter ..................................................................................................... 288
3.5.7.8.2 Jump Condition: Placing Program ...................................................................................... 289
3.5.7.8.3 Jump Condition: PI-Peripheral Input .................................................................................. 289
3.5.7.8.4 Jump Condition: IMM - Injection Molding Machine ............................................................ 290
3.5.7.8.5 Jump Condition: Vacuum ................................................................................................... 291
3.5.7.8.6 Jump Condition: AutoSwitch .............................................................................................. 291
3.5.7.8.7 Jump Condition: Part program ........................................................................................... 291
3.5.7.8.8 Jump Condition: Area ......................................................................................................... 292
3.5.7.8.9 Jump condition: Position ..................................................................................................... 292
3.5.7.8.10 Jump Condition: Mode ...................................................................................................... 293
3.5.7.8.11 Jump Condition: Stacking sensor..................................................................................... 294
3.5.7.8.12 Jump Condition: Start ....................................................................................................... 294
3.5.7.8.13 Jump Condition: Production End Active .......................................................................... 294
3.5.7.8.14 Jump Condition: Input ....................................................................................................... 294
3.5.7.8.15 Jump Condition: Output .................................................................................................... 295
3.5.7.9 Start/Stop Part Program ............................................................. 296
3.5.8 Wait functions ................................................................................... 297
3.5.8.1 Wait ........................................................................................... 297
3.5.8.2 Wait Timer ................................................................................. 297
3.5.8.3 Time .......................................................................................... 298
3.5.9 More Commands .............................................................................. 298
3.5.9.1 More .......................................................................................... 298
3.5.9.2 Remark (REM) ........................................................................... 299
3.5.9.3 Production End .......................................................................... 299
3.5.9.4 Blockstop lock/unlock................................................................. 300
3.5.9.5 Stopwatch .................................................................................. 301
3.5.9.6 Operating Mode ......................................................................... 303
3.5.9.7 Eco Mode .................................................................................. 304
3.5.9.8 Area Switch................................................................................ 305
3.5.10 AutoSwitches ................................................................................. 306
3.5.10.1 The Teach command AutoSwitch ............................................ 307
3.5.11 User Defined Error Messages ........................................................ 309
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 9

3.5.11.1 Introduction .............................................................................. 309

3.5.11.2 Creating and Storing the File UserErr.txt .................................. 309
3.5.11.3 The Teach Command ALARM ................................................. 311
3.6 QUICK EDITOR ...................................................................................... 312
3.6.1 Introduction ...................................................................................... 312
3.6.2 Operation of the Quick Edit .............................................................. 312
3.6.2.1 Entering the Quick Edit .............................................................. 312
3.6.2.2 Display and Editing Functions .................................................... 312
3.6.2.3 Exit the Quick Edit...................................................................... 315
3.6.3 FILE Menu of the Quick Edit ............................................................. 315
3.6.3.1 Open .......................................................................................... 315
3.6.3.2 Open Template .......................................................................... 317
3.6.3.3 Save (NAME.ZIP) ...................................................................... 317
3.6.3.4 Save As ..................................................................................... 318
3.6.3.5 Properties .................................................................................. 320
3.6.3.6 Print ........................................................................................... 322
3.6.3.7 Exit to Main ................................................................................ 323
3.6.4 Parameters for the Quick Edit........................................................... 324
3.6.4.1 Create Parameters..................................................................... 324
3.6.4.1.1 Create a Parameter-Counter Shortcut for the Quick Edit.................................................. 326
3.6.4.2 Apply Parameters ...................................................................... 328
4 HOW TO TEACH A PROGRAM ......................................................... 329
4.1 PROGRAMMING THE ROBOT IN THE TEXT EDITOR.......................... 329
4.1.1 Creating a New Program in the Text Editor ...................................... 329
4.1.2 Verifying Your Program Using STEP Mode ...................................... 331
4.1.3 Storing Your Program on a storage medium ..................................... 331
4.2 PROGRAM EXAMPLE ........................................................................... 332
4.2.1 Function of Program ......................................................................... 332
4.2.2 Sequence ......................................................................................... 332
4.2.3 Sketch of Sequence ......................................................................... 333
4.2.4 Sketch of Depositing Program .......................................................... 333
4.2.5 Reference Travel of Robot ............................................................... 333
4.2.6 Robot Teach Program (Robot Prg.) .................................................. 334
4.2.6.1 Placing Program Placingp-001 ................................................... 335
4.2.7 Reference Program for the Robot (Robot Ref.) ................................ 335
5 TROUBLESHOOTING ........................................................................ 336
5.1 OPERATING ERRORS .......................................................................... 336
5.1.1 Operating Errors in Plain Text Messages ......................................... 337
5.1.1.1 Axis Error messages .................................................................. 337
5.1.1.2 Vacuum Error messages............................................................ 341
5.1.1.3 Gripper Error messages ............................................................. 342
5.1.1.4 Peripheral Equipment Output Error Messages ........................... 342
5.1.1.5 Cylinder Error Messages............................................................ 342
5.1.1.6 Conveyor Belt Error Messages .................................................. 343
5.1.1.7 Load Cell Error Messages.......................................................... 343
5.1.1.8 Camera Error Messages ............................................................ 343
5.1.1.9 General Hardware Error Messages ............................................ 344
5.1.1.10 General System Error Messages ............................................. 347
5.1.1.11 CAN Device Error Messages ................................................... 347
5.1.1.12 Teach program Compiler Error Messages................................ 349
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 10

5.1.1.13 Teach program Interpreter Error Messages ............................. 351

5.1.1.14 Configuration Error Messages.................................................. 352
6 MAINTENANCE .................................................................................. 353
6.1 GENERAL .............................................................................................. 353
6.2 LUBRICATION INSTRUCTIONS FOR LINEAR GUIDES AND GEAR RACKS
..................................................................................................................... 354
6.2.1 Lubrication Intervals for Linear Guides at Standard Robots .............. 354
6.2.2 Lubrication Intervals for Gear Racks and pinions at Standard Robots355
6.2.3 Lubrication Procedures..................................................................... 356
6.2.4 Grease Recommendation ................................................................. 356
6.2.4.1 Lubricant suitable for food-stuff .................................................. 356
6.3 DRIVE BELTS ........................................................................................ 357
6.4 MOTOR BRAKES ................................................................................... 357
6.5 BATTERY REPLACEMENT.................................................................... 358
6.5.1 IPC ................................................................................................... 358
6.5.2 Sanyo R Inverters at Axes with Absolute Encoders .......................... 359
6.6 MOLD SAFETY RELAYS........................................................................ 361
6.7 MAINTENANCE SCHEDULE ................................................................. 362
6.8 AUTOMATIC LUBRICATION .................................................................. 363
6.8.1 Description for the type VOGEL ....................................................... 363
6.8.1.1 Suitable greases ........................................................................ 364
6.8.2 Description for the type HERION ...................................................... 365
6.8.2.1 Suitable greases ........................................................................ 365
6.8.2.2 Cartridge change ....................................................................... 366
6.8.3 System Maintenance ........................................................................ 367
6.8.3.1 Lubrication System Maintenance Procedure: ............................. 367
7 KEY TERMS ....................................................................................... 368
8 SERVICE CENTERS .......................................................................... 369

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 11

1 Safety precautions
When using a Wittmann robot, the following safety precautions have to be observed
under all circumstances.

Improper installation startup and operation may result in injury to personnel and/or
damaged equipment. Before installation, read this manual completely, paying special

attention to the Safety Warnings marked with .

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

according to the instructions given in this manual.

Wittmann Robots can be operated at high speeds so as to allow short removal and cycle
times. In order to minimize the risk of injury to personnel, the robot and automation
equipment must always be operated with the proper safeguardings, in accordance with
legal regulations.

1.1 Safety Regulations

In many countries the obligation of robot vendors to supply systems meeting applicable
safety regulations and the responsibility of the operator of these devices are governed
by law or by safety standards of professional associations. Always comply with the
regulations applicable for you.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 12

1.2 Safety Features

1.2.1 Safeguarding

The safeguarding required for operation of the robot is not included in our standard scope
of supply, since adaptation to specific site conditions is required. If such safeguarding is
provided by you, note that it must be installed prior to startup of the equipment in order
to be included in the safety circuit of the system upon startup. See Chapter 2.4 Safety
Package/Safeguarding.

The user bears the legal responsibility for following safety regulations.

1.2.2 Emergency STOP Buttons

One emergency stop button is located on the Teachbox.

When an emergency stop button is pressed, the power is turned off. The gripper and
vacuum valves and the vacuum pump are not disconnected, to avoid dropping parts from
the gripper. In addition, the controls and the Teachbox will remain under power to allow
indication of error messages.

The emergency stop button can be released by pulling it.

The emergency stop circuits of the robot and of the injection molding machine are
connected by the robot-machine interface. Therefore, when the emergency stop button
on the molding machine is pressed, the robot will also go into emergency stop and vice
versa.

1.2.3 Permit Keys on Teachbox

One key must be pressed for setting up for manual operation in order to be able to carry
out travel motions with the robot. For more precise operation, see Chapter 3.1.10. Should
this permit key be released during setup, the safety functions will interrupt all travel
motion of the robot.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 13

1.3 Capability of the Safety Control

The capability of the safety control of the robot conforms with PLr = d of
EN ISO 13849-1.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 14

1.4 Limitations

Limitations of use
Specified use This appliance is to be used to handle (plastic-) parts within
the production process of an injection molding machine. The
robot may only be used after safeguarding according to EN
ISO 10218 has been established, and the safety concept
described in this user manual has been realized.
Reasonably Installation and operation without consideration of EN ISO
foreseeable misuse 10218

Field of application
Commerce Yes
Industry Yes

Categories of users Task Qualifications / Impairments

Qualified personnel Installation / commissioning / Professional training
decommissioning / repairs /
Maintenance / removal
Apprentices Guided operation semiskilled
Operators Operation skilled / semiskilled

Spatial limitations
Description of the system The robot consists of the z-axis part, which contains the
electrical system and the CPU of the control system;
furthermore it guides the x-axis. The x-axis part also holds
the y-axis that executes the vertical movements of the
robot. The y-axis additionally holds a rotary device.

Time limitations
Specified time of use 10 to 20 years
Recommended maintenance intervals See chapter 6 Maintenance

Other limitations
Ambient temperature +5 to +40°C
Relative humidity 0% to 85 % Avoid dew point violation!
Required degree of cleanliness No special requirements
Height above sea level 0 to 1000m
Electrical supply Depending on version, see type plate
Required pressure for compressed air 4 – 7 bars, ISO 8573-1: [2:4:3]
Hazardous areas (EX) Do not use in hazardous areas (EX)

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 15

1.5 Control of Hazardous Energy – (Lockout / Tagout)

Lockout / Tagout (LOTO) refer to specific practices and procedures to safeguard
employees from the unexpected energy, startup of machinery/equipment, or the release
of hazardous energy during service or maintenance activities.

This requires that a designated individual turn off and disconnect the
machinery/equipment from its energy source(s) before performing service or
maintenance and that the authorized employee(s) lock and tag the energy-isolating
device(s) to prevent the release of hazardous energy and take steps to verify that the
energy has been isolated effectively.

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

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

1.5.1 Glossary

Affected Employee An employee whose job requires them to operate a machine or piece of
equipment on which service or maintenance is being performed.
Authorized Employee A person who locks or implements a tagout system procedure on
machines or equipment to perform service or maintenance on that
machine or equipment. An authorized employee and an affected
employee may be the same person when the affected employee's duties
also include performing service or maintenance.
Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal, or other energy.
Lockout The placement of a lockout device (such as a lock) on an energy-isolating
device, in accordance with an established procedure that ensures the
device and the equipment cannot be operated until the lockout device is
removed.
Servicing and / Workplace activities such as constructing, installing, setting up, adjusting,
or Maintenance inspecting, modifying, maintaining or servicing machines or equipment.
These activities include lubrication, cleaning or un-jamming of machines
or equipment, and making adjustments or tool changes where the
employee may be exposed to the unexpected energy, start-up of
equipment or release of hazardous energy.
Tagout The placement of a tagout device (such as a tag) on an energy-isolating
device, in accordance with an established procedure that ensures the
device and the equipment may not be operated until the tagout device is
removed.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 16

1.5.2 Lockout/Tagout Kit

Use of an approved LOTO kit is required. It is the customer’s responsibility to provide
this kit.

Fig.: Examples of LOTO devices

Customers are also responsible for ensuring that all employees are properly trained and
utilize the LOTO procedures.

1.5.3 Lockout/Tagout Procedure

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 17

1.5.4 Removal of LOTO

Once the specific maintenance or service work has been completed, the person who
attached the lock or tag is responsible for promptly removing that device.

Removal of LOTO devices will be accomplished by following the steps listed below:
1. Inspect the work area.
Ensure that the equipment/machine is fully assembled and operational, all tools and
nonessential items are removed, and all safety guards are reinstalled.
2. Ensure that all employees are clear of the equipment/machine.
3. Remove the LOTO device.
Each device must be removed by the person who put it on.
4. Reenergize the equipment/machine.
5. Notify Affected Employees that servicing has been completed and the
machine is ready for use.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 18

2 Mounting the robot

2.1 Mechanical Installation

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

to avoid injury to personnel or damage to equipment.

Our trained service engineers are available to assist you.

2.1.1 Dimensional Drawing – Adapter Unit

See the enclosed drawing for the dimensions of the robot with the dimensions for
attachment of the gripper.

The robot is normally mounted on the fixed platen of the injection molding machine by
means of an adapter unit in accordance with VDMA 24466 or FHK-85-12-22.

If the adapter is supplied by us, a drawing for installation on the machine is enclosed.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 19

2.1.2 Transportation of the Robot

The weight of the robot is shown on the robot identification plate on the Z beam.

Depending on the version the robots are equipped with one or more of the following
devices for lifting:
 lifting eyes on the main beam (Z axis).
 milled slots for lifting with a fork lift (e.g., in low bays) or with belts.
 Additional holes for the use of lifting rods.

Before lifting the robot from the transport pallet, make sure, that the main carriage
(Z axis) and kick stroke (X axis) are in their balanced position.

The axes are in a balanced position, when the respective arrow

marks are aligned.

The picture on the left shows the red arrow marks of the
correctly aligned z-axis of a W811 as an example.

The main carriage and kick stroke can only be moved by applying voltage from an
external power supply in the X and Y axes. Because of the high accelerations of servo
drives, this operation is hazardous and therefore should be performed only by our trained
service engineers.

Before lifting the robot, the vertical axis must be secured against tipping.
When lifting with a fork lift, secure the robot against slipping.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 20

2.1.3 Demounting the Robot

The weight of the robot is shown on the robot identification plate on the Z beam.

Depending on the version the robots are equipped with one or more of the following
devices for lifting:
 lifting eyes on the main beam (Z axis).
 milled slots for lifting with a fork lift (e.g., in low bays) or with belts.
 Additional holes for the use of lifting rods.

Before dismantling and lifting away from the console, you have to make sure, that
the main carriage (Z axis) and kick stroke (X axis) are in their balanced position.

The axes are in a balanced position, when the respective arrow

marks are aligned.

The picture on the left shows the red arrow marks of the
correctly aligned z-axis of a W811 as an example.

The easiest way to move the robot axes into balance is to do it with the manual functions
provided by the Teachbox, before the robot is decommissioned.

Before lifting the robot, the vertical axis must be secured against tipping.
When lifting with a fork lift, secure the robot against slipping.

Before dismounting, all electrical and pneumatical connections have to be disconnected.

Before lifting the robot away, all cables and hoses hanging down from the robot have to
be secured properly, in order to avoid damages, locking the transport, and to avoid the
danger of personal injury.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 21

Before lifting the robot with a crane, refer to the following figures.

R83_V8_32_00_WIT_EN / 01.10.2020
R8.3 USER MANUAL Page 22

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 23

2.2 Electrical Connections

2.2.1 Main Power Supply

The required electrical voltage and power supply are indicated on the identification plate
of the robot. Power connection normally is made with cables and CEE plugs.

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

federal, state and local regulations.

For safety, proper installation of the earth ground must be verified.

After connection to the power supply, the direction of rotation must be checked (e.g., on
the vacuum pump). The phasing must be clockwise.

2.2.2 Residual Current Device

Residual current devices (old: FI, new: RCD) may be used only under certain
conditions in combination with frequency inverters:

 At frequency inverters with 3-phase input voltage, in the event of a ground leak,
a part of the rsidual current may prevent release of an FI / RCD safety switch.
 Parasitic capacities in the converter can in principle cause leakage currents,
which may result in false tripping.

Alternative safety measures are for example grounding or protective isolation.

If a residual current device is used in robots with 3-phase inverters, it must be a new
RCD TYPE B or RCMA.

If a residual current device is used in robots with single-phase inverters, it must be a

new RCD TYPE B or RCD TYPE A.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 24

2.3 Electrical Interface

This section is not applicable to robots with an integrated system, since here the signals
are transmitted to the injection molding machine via a CAN-BUS interface.

Robots equipped with a R8.3 control unit are available with 2 different interface versions
to communicate with the injection molding machine:

 Euromap 67
 Euromap 12

Both versions are described in the following chapters.

2.3.1 Interface with the Injection Molding Machine

The robot is equipped with an electrical interface (plug type HAN 32A) according to
Euromap E67 / E12. In robots supplied as integrated systems, molding machines are
equipped with CAN-BUS controls and safety signals are executed by an emergency stop.
See wiring diagram at the end of this chapter and pin description (Section 2.3.2).

Connection of the interface plug to the machine and testing of all signals must be done
by a specialist in injection molding machines and robots. Preferably, this should be done
by one of our service engineers together with a qualified service engineer for the injection
molding machine.

The interface signal functions must be carefully tested, as improper operation may cause
malfunction or damage to the robot and molding machine.

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

 Emergency stop signals from and to the IMM

 Function of mold safety interlock switches S5/S6
 External safety circuits for access door of the safeguarding

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 25

2.3.2 Euromap 67 interface

The Euromap 67 interface defines the connection plug between the injection molding
machine and the robot:

socket

pin
Robot Plug Plug on Injection Molding machine

The robot-injection molding machine interface is designed according to the directives of

Euromap 67, which states:

Unless otherwise noted, the signals level signals, which are maintained during the
described function.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 26

2.3.2.1 Injection Molding Machine (IMM) Signals

Pin contact Function

no.
ZA1 Emergency Stop Channel 1
ZC1 The emergency stop switch of the injection molding machine is used to interrupt
the emergency stop circuit of the robot.
ZA2 Emergency Stop Channel 2
ZC2 The emergency stop switch of the injection molding machine is used to interrupt
the emergency stop circuit of the robot.
ZA3 Safety system active Channel 1
ZC3 For protecting against hazardous motions of the robot. The switch is closed
when the safety system of the injection molding machine is active.
ZA4 Safety system active Channel 2
ZC4 For protecting against hazardous motions of the robot. The switch is closed
when the safety system of the injection molding machine is active.
ZA5 Reject
The signal is HIGH when the molded piece is a reject. The switch must be
closed when the tool is open and must remain HIGH at least until “close tool
enabled“ (see pin contact No. A6).
ZA6 Mold closed
HIGH signal when tool closing has been completed; the signal “close tool
enabled“ is no longer necessary (see pin contact No. A6).
ZA7 Mold open
HIGH Signal if the mold opening position is equal or more than the required
position. Inadvertent alteration to mold opening stroke smaller than that required
for the robot to approach must be impossible.
ZA8 Mold at intermediate position
Optional HIGH signal when the mold opening has reached the specified intermediate
position and remains HIGH until the mold is completely open. The signal may be
used in two ways:
1.) The mold stops in the intermediate position, whereupon a signal is sent to the
robot. Complete opening of the IMM takes place through the signal “complete
mold opening enabled“ (see pin A7).
2.) The IMM transmits the signal, but does not remain in the intermediate
position.
Signal is LOW when the intermediate position is not used.
ZA9 Signal Voltage Robot 24V DC
ZB2 Fully automatic mode injection molding machine
HIGH signal, when operating the injection molding machine together with the
robot is possible.
ZB3 Ejector back position
HIGH signal when the ejector is back, regardless of the position of the movable
tool plate. The signal acknowledges “ejector back enabled“ (see pin contact
No.B3).
ZB4 Ejector forward position
HIGH signal when the ejector is forward. The signal acknowledges “ejector
forward enabled“ (see pin contact No. B4).
ZB5 Core pullers 1 free for robot to approach
HIGH signal when the core pullers, regardless of the position of the movable tool
plate, are in position for the robot to approach.
ZB6 Core pullers 1 in position to remove molding
HIGH signal when the core pullers are in position for removal of the injection
molding.
ZB7 Core pullers 2 free for robot to approach
Optional HIGH signal when the core pullers, regardless of the position of the movable tool
plate, are in position for the robot to approach.
ZB8 Core pullers 2 in position to remove molding
Optional HIGH signal when the core pullers are in position for removal of the injection
molding.
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 27

Pin contact Function

no.
ZC5 reserved for future EUROMAP signal
ZC6 reserved for future EUROMAP signal
ZC7 reserved for future EUROMAP signal
ZC8 free
ZC9 Signal Ground Robot 0V

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 28

2.3.2.2 Robot Signals

Pin contact Function

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 29

Pin contact Function

no.
C7 reserved for future EUROMAP signal
C8 free
C9 Signal Ground IMM 0V DC

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 30

2.3.3 Euromap 12 Interface

The interface consists of the plug connection between the injection molding machine and
the robot:

1 25
9 2 17 26
Pin
10 3 18 27
11 19 28
4
12 20 29
5
Socket 13 21 30
6
14 22 31
7
15 23 32
8
16 24

The robot-injection molding machine interface is designed according to the directives of

VDMA 24465, and/or according to Euromap 12, which state:

Unless otherwise noted, the signals are maintained during the described function and
should not be shorter than 0.5 sec.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 31

2.3.3.1 Injection Molding Machine (IMM) Signals

Pin contact Function

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 32

2.3.3.2 Robot Signals

Pin contact Function

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 33

2.3.4 Mold Monitoring S5/S6

Proper adjustment of the switching points of the roller switches S5 and S6 is extremely
important, since they secure the closing and opening motions of the IMM. These roller
switch signals are independent from the permission signals of the robot program and
are directly wired through the electrical interface to the IMM (redundant safety).

The switches for S5 and S6 can be physical switches (proximity sensors or roller
switches) or virtual switches (software switching points).

Function and Adjustment of Roller Switch S5:

The roller switch S5 is mounted on the vertical axis and is operated by the cam on the
vertical axis. Only when S5 is actuated, the closing/opening motion is released.

Adjust the cam (the switching point) in a way that S5 is only actuated, when gripper and
part are at a position with sufficient safety distance above the mold.

Function and Adjustment of Roller Switch S6:

The S6 switch is mounted to the main traversing carriage and is operated by the cam on
the Z beam. S6 overrides the function of S5, so that the robot arm can move down
outside the machine without interrupting closing or opening of the IMM.

Adjust the cam (the switching point) in a way that S6 is actuated only while providing a
sufficient safety distance outside the protective guarding of the machine (with the largest
part on the gripper!).

After changing switching points for Mold Monitoring, the roller switch monitoring has to
be re-initialized.

After proper adjustment of the cams, double-check the function of the safety switches
S5 and S6. If neither switch is actuated (robot arm inside mold) ensure that even with a
closing signal present from the robot the closing and opening motion of the IMM is not
possible!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 34

2.3.4.1 Settings for Virtual Roller Switches (Mold Safety Switches)

Robots with absolute encoders use virtual mold safety switches instead of real
switches and cams.

Open the Init menu Roller Switches to set the switching points and behavior of those
virtual switches.

Fig.: Roller Switches Position

On the tab Position select the desired axes and press to input the position of the
switching point for the related virtual roller switch with the dialogue for numerical input.

Use the tab Init to define whether the 0-positions of the axes are situated inside or
outside the mold area.

Fig.: Roller Switches Init

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 35

2.3.4.2 Initialize Roller Switch Monitoring

The software constantly monitors the switching points of the roller switches for mold
safety, in order to detect any malfunctions in time. This serves as an additional safety for
avoiding collisions with the mold of the IMM.

Open the Init menu Roller Switches.

The tab Position shows the positions of the switching points as determined by the
software for all mold safety switches present at the robot.

Fig.: Window for roller switches

Switching points that have not been detected since the last time the roller switch
monitoring was reset, will display ??????.? as their position.

If during a product change or during initial setup switching points have been changed by

altering the cams, the roller switch monitoring has to be reset by pressing . All
Positions will display ??????.? and will automatically be re-determined during
movements of the respective axes in operation modes manual and automatic.

Press to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 36

2.3.4.3 Test Procedure for Mold Safety S5 / S6

 Switch off Operation with Robot. The LED at the button is not lit.
 Slightly close the mold. The Signal Mold Open must be off.
 Now try to move the Y-axis into the mold area.
 The Y-axis must stop latest when leaving the S5. The error message "Mold
Monitoring" or "Mold Monitoring Braking Distance" must appear on the Teachbox.
 Confirm the message.
 Check if the robot has left the S5. Use the menu View – I/O to do so; the input 482
Roller Switch S5 must be off. If this is not the case, deactivate mold monitoring in
the menu Init – Deactivate monitoring and carefully move the Y-axis off the switch.
 Now try to close and open the mold. Both movements must be impossible, and an
error message must appear at the IMM.
 Move the Y-axis up and out of the mold area.
 Activate mold monitoring in the menu Init – Deactivate monitoring, if you have
deactivated it previously.

In case of a negative test result, contact our service center.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 37

2.4 Safety Package/Safeguarding

As outlined in Chapter 1, the work envelope of the robot must be properly safeguarded
in accordance with legal regulations.

2.4.1 Safety Package

Our robots with R8.3 controls are equipped as a standard with a safety package.

The safety package includes:

 Emergency Stop Disconnect Unit with two channels
 2 Safety contactors for hardware shutoff of the axis drive when the safety door
(hatch) is opened. In addition, the software monitors these contactors for proper
operation (redundant safety).
 Remote control with 2 permit keys
 Software safety package (monitoring of inputs and outputs)
 Cable with plug for ease of connection of all necessary switching and display
elements for mounting on an access door or hatch

The robot can be operated only if all safety requirements have been met, which means,
all protective devices have been properly installed prior to startup of the robot.

For a detailed description of the function of the safety package see Section 3.1.10.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 38

2.4.2 EXTERNAL Safety Package for Safety Door or Access Hatch

H302 Lamp red *

H301 Lamp green *

Control with
S304 Emergency Stop hard- and software for
the safety package
H302 Lamp red

S303 Button Automatic Control panel

H301 Lamp green with permit keys

S303, H303
Button Acknowledgement /
Block Stop

U3 Solenoid Interlock

S313
a) Step/Automatic/Reference
b) Manual/Setup

* … optional

 Solenoid interlock with contact for software monitoring of function.

The door can be opened only when the robot motions have come to a complete stop
(U3)
 Emergency Stop (S304)
 Lamp H302 red (robot enabled)
 Button Automatic S303 / Lamp H301 green (robot disabled)
 Button Acknowledgement / Block Stop (S303, H303)
 Key operated selector switch for manual/automatic operation (S313)
 Mounting panel with junction box, plug and 2 optional indicator lamps:
(H301): robot disabled (H302): robot enabled

These parts are required in order to confirm the function of the safety door in the safety
circuit of the robot program and are obtainable, as an option, with or without safety door.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 39

Before starting up the robot, check the safety circuits as follows:

1) Install the complete safety package.

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

Function of Safety Package:

A) Block Stop during automatic mode

The key switch is in the AUTO position.
1) Pressing the „Block Stop“ key on the Teachbox or the button at the safety door
allows the robot to complete the last motion, then the safety door will be unlocked
and can be opened.
In any other case, the safety package immediately interrupts the motion in both
the hardware and software upon forcible opening of the safety door.
2) To resume automatic mode after Block Stop:
- Close the safety door
- Press outside acknowledgment button
- Press automatic start key. Cycle will resume with the next command in the
teach program.

B) Manual operation of the robot inside the safety area

1) Set the key switch to MANUAL and remove the key.
2) The door will be unlocked, can be opened and the safety area entered. The key
has to be taken with the person entering the safety area. This ensures, that no
other person is able to start automatic mode while an operator is still inside the
safety area.
3) All motions can be performed by remote control by simultaneously pressing the
acknowledgment button and the function keys. After 30 seconds or the error
message timeout, the permit key has to be released one time and then pressed
again.
A maximum drive speed of 250 mm/sec is possible In Manual/Setup Operation.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 40

4) To resume operation in automatic mode:

- Leave the safety area
- Close the safety-doors
- Insert the key and set the switch to automatic mode
- Press the outside acknowledgment button
- Press the automatic start key; this ensures that the system cannot inadvertently
be started by another person, although an operator is still in the protected area.

Note:

According to applicable safety regulations, slow motions of the robot axes (max. of
250 mm/sec or 10 in/sec) are not sufficient to allow access to the work envelope of
the robot and to avoid accidents. Access is allowed only if the automatic mode is
completely interrupted and this condition is secured by hardware contactors that
prevent any motion.

2.4.2.1 Indication lamp for operating modes at PRO-series robots

The ambiLED Indication lamp shows four different operating modes.

1. Automatic Mode: The ambiLED lights up permanently

in green.

2. Manual Mode: The ambiLED lights up permanently in darkblue. Intervention of

the operator is necessary.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 41

3. Block Stop: The ambiLED lights up alternatingly darkblue and lightblue as long
as the robot is in motion. As soon as the robot has stopped, the ambiLED
switches to lightblue.

4. Safety door is open: The ambiLED lights up

permanently in red. An alarm is active.

2.4.3 Safeguarding
This consists of safety door and safeguarding elements.

These safeguarding elements are available as an option in the following sizes (width *
height):

- 1000 mm * 2000 mm
- 500 mm * 2000 mm

These provide complete safeguarding of the work envelope of the robot and/or the entire
automated system.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 42

2.5 Pneumatics

2.5.1 Compressed Air Connection

This connection is made on the service unit with a 1/2" hose. A shutoff valve (ball cock
or quick connection coupling) should be installed at the point of connection to the main
compressed air line.

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

Air consumption per robot cycle:

The air consumption depends on the optional equipment installed on your robot.

Air consumption of the robot may be calculated from the following table:

Consumption per stroke * Cons. per sec. **

CNC Robots C axis A axis Vacuum per circuit
W811 0.3 0.4 0.4
W813, W823 0.2 0.2 0.4
W821, W831 1.3 0.4 0.4
W832, W833 1.1 1.3 0.4
W843 1.1 1.3 0.4
W853 6.4 8.3 0.4
W873 6.6 4.5 0.4

*: In ft³ at 90 psi (6 bars)

**: For venturi vacuum circuits only

Example of calculation of compressed air consumption:

W833CNC: with X, Y, Z axes motor driven

A and C axes pneumatic
2 vacuum circuits, operated 10 sec. each

1) A axis:
moved twice per cycle: 2 x 1.3 = 2,6 dm³
2) C axis:
moved twice per cycle: 2 x 1.1 = 2.2 dm³
3) 2 vacuum circuits:
each one operated for 10 sec./cycle: 2 x (10 x 0.4) = 8,0 dm³
4) Total consumption: 2.6 + 2.2 + 8 = 12.8 dm³

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 43

3 Operating Instructions for R8.3 Control

3.1 Basic Operation

3.1.1 Introduction
The R8.3 control unit is a high-performance control system with a teach programming
interface for the robot and peripheral equipment.

Before starting up the robot for the first time, review the manual thoroughly and
familiarize yourself with the operation of the robot, to avoid improper use or
programming.

Improper use or programming may result in injury to personnel and damage to the robot,
gripper, mold or injection molding machine. Programming of the robot must be carried
out only by trained personnel who are fully familiar with the operation of the robot.

We offer training sessions at our service centers. Do not hesitate to contact us.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 44

3.1.2 Robot Axes

Fig.: Standard Linear Robot

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 45

3.1.3 Emergency Stop Block

The buttons on the Emergency Stop Block are used for basic operation of the robot.

This buttons work regardless whether the Teachbox is connected or disconnected.

Depending on the mode of operation the LED of the corresponding button is lit.

Fig.: Emergency Stop Block

Reference travel
Performing the reference travel. Possible in the mold area only when the
loaded teach program contains a reference travel.

IMM: Operation with robot

Enables operation of IMM with robot. In shut-off state the IMM can be
operated without robot. The LED will flash, when turned on while mold,
ejectors or core pullers are not in a defined position. In this case the
function will be turned on with a delay, in order to allow reaching such a
position.

Automatic-Start
Start of automatic operation. The robot must be in reference mode, the
IMM must be in automatic mode and operation with robot must be on.

Block Stop
Ends automatic operation after complete execution of the currently
processed instruction or group of instructions. Automatic operation may
be continued by pressing the Automatic Start button again.

Manual operation / Stop

Causes an immediate stop and switches to manual operation.

Control Voltage On
Press to switch on the control voltage after the mains switch has been
turned on, or after an emergency stop.

EMERGENCY STOP
Causes the robot to stop immediately. Relevant outputs are disabled
through hardware, the EMERGENCY STOP circuit to the IMM is

interrupted and the LED of the button is lit.

The error message EMERGENCY STOP appears on the display.

See also: 3.3.4.21 Virtual Sub Pendant

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 46

3.1.4 Numerical Input

This window is used to input numbers when necessary.

Fig.: Numerical Input

The title bar displays the name of the parameter. The minimum and maximum values for
the parameter are shown left and right of the current value and on the status bar at the
bottom of the window.

Input the digits using the numeric keys.

discards the changes.

and move the Cursor to the desired direction.

deletes from the current cursor position to the right.

deletes from the current cursor position to the left.

discards the changes and closes the window.

confirms the value and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 47

3.1.5 Text Input

This window is used to input text when necessary.

Fig.: Text Input

The name of the parameter is shown on the status bar at the bottom of the window.

Input is done using the alphanumeric keys that are positioned like on a typewriter.

discards the changes.

and move the Cursor to the desired direction.

deletes from the current cursor position to the right.

deletes from the current cursor position to the left.

discards the changes and closes the window.

confirms the value and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 48

3.1.6 Operating Modes

Operation of the robot requires knowledge about the various operating modes of the
robot.

These divide to the following:

Reference Missing
Status of the control unit after activation. All manual functions are available, but
the numerical axis positions shown on the Teachbox display are invalid. In
order to be able to use all functions of the robot, a reference travel must be
performed.

Manual
All functions of the robot are available; the Teachbox displays valid position
values. In order to be able to start automatic operation, a reference travel must
be performed.

Reference
All axes, vacuum and gripper circuits are in their respective reference positions.
The taught reference programs have been executed. It is possible to start
automatic operation.

Automatic
The Teach program loaded to the robot is being executed.

Blockstop
End of automatic operation after complete performance of the currently
processed instruction or group of instructions. Automatic operation can be

resumed at the next program line by pressing the button

Wait IMM
The robot is waiting for the injection molding machine.

The robot will switch from Automatic to Wait IMM:

 When the machine changes to Manual.
 When the machine is not in Automatic and the robot reaches a
command that waits for a signal of the machine.
 When the machine is not in Automatic or Operation With Robot is not
on when the robot executes the command
WAIT OP. WITH IMM = ON.

The robot will continue automatic operation automatically once the machine
changes to Automatic or when Operation With Robot is being switched on.

See also:
3.1.7 Operating Mode Reference

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 49

3.1.7 Operating Mode Reference

The Reference travel brings the robot and any peripheral equipment present into a
defined home position in order to enable operating mode Automatic. The reference
positions of the gripper and vacuum circuits are selectable.

As long as no reference travel has been successfully executed after powering up the

unit, only the operating mode Reference Missing will be available.

Depending on the current operating mode of the robot, two different types of reference

travel are executed when the button is pressed:

 Reference travel in the operating mode Reference Missing

 Reference travel in the operating mode Manual

3.1.7.1 Reference travel in the operating mode Reference Missing

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

the mold area. First, the axes have to be moved out of the mold area using manual
functions; furthermore the B-axis (if present) must be moved to its 0-position.

Press and hold the button to start the initial standard reference travel for the robot.

The axes will be traveled to their reference positions using the sequence Y-X-Z-C-A.

Pneumatic axes simply travel to their 0-position limit switch.

Also the numerical axes travel to their 0-position limit switch at first. Axes with an
incremental encoder then travel to the reference mark of the encoder. After that the
respective axis travels to its configured reference position. In standard configuration this
is 10.0 mm (0.04") in plus direction from the 0-position limit switch. After reaching this
reference position the numerical position of the axis is set to zero.

If the button is released before the reference position of the robot is reached, the
movement is stopped immediately.

When you press the button again, the sequence will continue.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 50

When all axes have reached their reference position, the robot switches to operating
mode Manual.

The Icon is shown at the status bar in the upper left corner of the display; the LED

of the button is lit.

If no corresponding reference travel (ROBOT-REF) has been programmed, now the

grippers have to be brought to their defined reference position. At last the reference travel
in the operating mode Manual has to be carried out, in order to enable automatic
operation.

3.1.7.2 Reference travel in the operating mode Manual

Press and hold the button to start the reference travel.

If reference teach programs for the robot (ROBOT-REF) and the peripheral equipment
(PERI-REF) are programmed, at first these sequences are carried out simultaneously
(!). This makes it possible to reference the robot from inside the mold area, and to bring
peripheral equipment to its home position at the same time. Furthermore the vacuum
and gripper circuits can be switched to their reference states by the reference teach
programs.

If no reference travel for the robot has been programmed, or if after carrying out the
reference teach programs individual axes have not yet reached their 0-position, these
axes are moved into their reference position in the sequence Y-X-Z-C-A.

When the button is released, the movement is stopped immediately. When the
button is pressed again, the reference travel will start from the beginning.

When the reference position is obtained, the robot switches to operating mode
Reference.

The Icon is shown at the status bar in the upper left corner of the display; the LED

of the button is lit.

See also: 3.5.9.6 Teachcommand Operating Mode

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 51

3.1.8 Override
This function is used to set the travel speeds of the motor axes in connection with the
maximum speed (VMAX) set in the teach program.

The key can be used in every operating mode to open the override window.

Here you can use the sliders to change the Overrides for the numerical axes of the robot.

Fig.: Sliders

When the option locked is activated with a all sliders are moved together. When the
option locked is deactivated, the overrides of the axes can be altered individually.

The keys and are used to change the Overrides in steps of 1%.

The key can be used to set the Overrides of all axes to 30% simultaneously.

Use the option ECO-mode to turn the mode for economic travel on or off.

is used to exit the override window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 52

Preferably the speeds of the numerical axes should be set in the Teach programm using
VMAX and VABS commands. This should happen in a way that the Overrides of the
axes can be set to 100% when the robot is executing the standard production cycle.

Depending on the robot settings the Overrides are automatically reduced to 30%,
when:
- a new teach program is started.
- the robot is being powered up.

Example:

In the teach program a maximum speed of 80% of the maximum design speed (design
Vmax) was programmed for the Z axis (Vmax=80%).

The manual override is set at 50% (of Vmax).

Therefore the drive speed is 40% of the maximum design speed.

Fig.: VMAX and Override

Refer to: VMAX, VABS

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 53

3.1.9 ECO-Mode
The function ECO-Mode adapts speed and acceleration of the numerical axes while
traveling outside the mold in a way that the robot arrives at its waiting position outside
the mold at ECO-Buffer time before the next mold opening starts. The movements inside
the mold remain unchanged by the ECO-Mode. This way - without changing the overall
cycle time - a more economic operation of the robot is achieved, compared to running
the robot with full speed and acceleration outside the machine.

You can turn the ECO-Mode on and off in the Override window, using the option ECO-
Mode.

With the ECO-Mode turned on, the robot is calculating the optimum setting during the
first few cycles after starting automatic mode. Only after this the robot will execute the
placing motion with constant low speed and acceleration. The settings made by the ECO-
Mode will be shown with the small sliders in the Override window.

Fig.: Override window with ECO-Mode active

Should the robot out of any reason be too late (mold opens before the robot arrives at
the waiting position), the rest of the cycle will be executed with full speed and
acceleration. During the next cycles the robot will then retry to find the correct settings.

For alternative routines executing special motions (that take significantly longer or
shorter to finish than the standard motion) the ECO-Mode can be deactivated for the
current cycle using the Teach command ECO MODE. The robot will then use the settings
done with VMAX, VABS, AABS and the Override for the current cycle. The ECO-Mode
will be automatically re-activated with the next cycle. Furthermore the ECO-Mode can be
turned on by the command automatically and can be reset.

For permanent irregular travel times, the ECO-Buffer time should be increased to cover
the time difference between the longest and shortest trip, and thus to achieve a better
control behavior.

In order for the ECO-Mode to work, use a compatible sequence to wait for the open
mold or Smart Removal: In.

Refer to: 3.5.9.7 Teach command ECO MODE

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 54

3.1.10 Safety System

3.1.10.1 Startup with Safety System

3.1.10.1.1 Manual Setup Mode

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

3.1.10.1.2 Automatic Mode, Step Mode, Reference Travel

After the control unit has been activated, safety must be ensured, since otherwise the
AUTOMATIC, STEP and REFERENCE TRAVEL modes cannot be used with the robot.

To ensure safety:
1.) Open safety door
2.) Close safety door
3.) Press outside acknowledgment key
4.) Set key switch to position Auto-Step-Reference

The period between opening and acknowledgment outside may be as long as desired
(no time monitoring features are in place).

3.1.10.2 Selection of Operating Modes

3.1.10.2.1 Manual Setup Mode

If the key switch is in the position MANUAL SET UP, each axis can be moved for 30
seconds while actuating one of the permit keys on the bottom of the teachbox. If you
release the permit key, the selected function will be stopped immediately (software axis
stop function; power supply 24 V for outputs will be disconnected through hardware).

After 30 seconds as well as during each change of function (e.g., X axis to Y axis) the
permit key must be released and then pressed again. In order to enter the teach mode,
you must first perform referencing (ensure safety - set key switch to position Auto -
Stepping - Reference). Then call up the teach mode and set the key switch to position
MANUAL SET UP. Now the safety door can be opened and it will be possible to teach
the positions inside the protective guarding using the permit key.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 55

3.1.10.2.2 Automatic Mode, Step Mode, Reference

In order to travel to the reference position, all doors must be checked for safety. The key
switch must be set to AUTOMATIC - STEPPING - REFERENCE position. This applies
to the automatic and stepping modes as well. Should it be necessary to access the

machine during the automatic cycle, press the key first in order to unlock the door.
The door will be unlocked when all axes have completed their motions. If the door is not

opened, automatic operation can be continued with the key. However, if the door
is opened, safety must be ensured after the intervention and the removal cycle will be

continued with the key. If Safety ensured is shown on the input, the reference
position may be approached and automatic operation started. Safety must also be
ensured for the STEP mode.

3.1.10.3 Monitoring of the Safety Gate

The safety gate monitoring system is active only when the key switch is in the
AUTOMATIC - STEP - REFERENCE position.

Safety Gate:
The safety gates are electrically monitored by a safety module which ensures that the
robot can be used only in manual operation when someone is within the safeguarded
area, and that no one can accidentally enter the hazardous area of the plant while the
robot is used in the automatic mode. In addition, it is verified that no switches have been
bridged or other interventions made in the safety circuits.

3.1.10.4 Error Effect Analysis

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

- The safety gate is opened during the block stop mode

-> The safety contactor circuit disconnects all outputs from the power supply by
means of hardware. At the same time, the software does not permit start of a
new function. Hence a defective output or a faulty program will not lead to an
undesirable motion.

- In the MANUAL SETUP MODE (safety gate not monitored) an axis motion can
be executed only with the permit key. If this key is pressed for a longer period
(30 sec.) without a motion being performed, no new travel instruction may be
executed (by the software). The entire system will go into a failure state (time
monitoring permit key).

- In addition, in an unsafe state all motor axes will be disconnected

by means of hardware from the frequency converter/servo module
feeder line through contactor disconnects.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 56

3.1.11 User Administration and Passwords

User administration makes it possible to assign different rights of access to fifteen
different users for operation of the robot. For example, operators may be authorized only
for robot operation, shift supervisors for manual functions as well, while machine
programmers could also be allowed to load and change programs, and so forth.

User's rights may be freely specified in 8 different user profiles. Profile 7 defines what
can be accessed without entering a password. The eighth profile (profile 0) is
permanently defined and is reserved for the administrator (Admin) of the system. The
administrator is assigned all rights; as sole user authorized to do so, he may also create
profiles and change passwords. Each user receives a personal password and is
assigned one of the user profiles 1 to 6.

The user administration of the R8.3 control is always active, and cannot be
deactivated. In order to enable operation without a password, enable read/write access
for all functions in profile 7. Thus only the settings reserved for the Administrator will
require a login.

Write down the passwords, especially the administrator password and keep them in a
suitable safe place.

If you lose the administrator password the functions reserved for the administrator
(Changes in the password system and several other base settings) will be no longer
accessible! In this case contact our nearest service center.

3.1.11.1 Administrator
In order to be able to manage users with their profiles and passwords, and for some
other base settings you will have to login as administrator.

The user name for the administrator is always ADMIN.

The password for the administrator is 1234 at delivery.

For real use of the user administration the password of the administrator must be
changed in order to avoid unauthorized access.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 57

3.1.11.2 Users
Creating, changing and deleting of users is only possible if you login as administrator.

In the menu Init select User Administration, and switch to the tab Users.

Here you can assign User Profiles to existing users by activating the desired option in
the line with the user by tapping the option.

is used to create a new user.

is used to delete the highlighted user.

is used to edit the highlighted user

discards the entries and closes the window.

confirms the new user data.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 58

3.1.11.2.1 User (create, change)

Here you can create a user or change the data of a user.

Fig.: Window to edit a user

After tapping the respective input field, the desired value can be entered using the
dialogue for text input.

discards the entries and closes the window.

confirms the new profile data.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 59

3.1.11.3 Profiles
You have to login as administrator to access the user profiles.

In the menu Init select User Administration and switch to the tab Profiles.

Here you can set up user profiles 1 to 7 to suit your needs.

is used to lock the highlighted function in the respective profile. This will be
indicated by an x in the table.

is used to give a "read only" permission for the highlighted function in the
respective profile. This will be indicated by an r in the table.

is used to give a "read and write" permission for the highlighted function in the
respective profile. This will be indicated by an r/w in the table.

discards the entries and closes the window.

confirms the new profile data.

Profile 7 is used to permit functions for use without password!

If a "read and write" permission is given for the Text Editor, automatically a "read and
write" permission is given for the Manual Functions.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 60

3.1.11.4 Login
With user administration activated in the logged out state (e.g. after powering up the unit)
only the buttons to change the mode of operation, the help function and the functions
activated in profile 7 are available. All other functions are deactivated.

The icon will be displayed in the status bar.

Each user has to login with name and password to access the functions attached to his
profile. Tap the menu Init and there Login to do so.

You then can login using the following window:

Enter your user name after tapping the input field Insert Username using the dialogue
for Text Input.

Enter your user password after tapping the input field Insert User Password using the
dialogue for Numerical Input.

discards the entries and closes the window.

will confirm the entries and log you in.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 61

3.1.11.5 Logout
With user administration activated, one should logout when leaving the Teachbox, in
order to avoid misuse of the appliance.

Tap the menu Init and Logout to do so.

The Icon will be displayed in the status bar.

Only the buttons to change the mode of operation, the help function and the functions
activated in profile 7 will be available. All other functions will be deactivated.

3.1.11.6 Forgot Password

In case you forgot the administrator password, you can press the button Forgot
Password in the Login window to get the passwords encrypted to a code:

With this code you can contact our local service center to help you.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 62

3.1.12 Manual Functions

3.1.12.1 Numerical Axes

This function is used to manually move the selected numerical axis in the operating

modes Manual, Reference and Reference Missing. Furthermore

the current position of the axis is displayed in all operating modes.

At robots with secondary axes press the axis button longer, if you want to display the
buttons for toggling between main axis and secondary axis.

Whether the numerical axes can be moved using variable or fixed manual speeds is
being set in the Init Menu Setup: Robot Settings.

Fig.: Numerical axis with variable manual speed

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 63

Fig.: Numerical axis with fixed manual speeds

moves the axis into plus direction with variable speed.

moves the axis into plus direction with high manual speed.

moves the axis into plus direction with low manual speed.

moves the axis about 0,1mm into plus direction.

moves the axis about 0,1mm into minus direction.

moves the axis into minus direction with low manual speed.

moves the axis into minus direction with high manual speed.

moves the axis into minus direction with variable speed.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 64

3.1.12.2 Axis Release in Manual Mode (optional)

When horizontal, numerical axes are equipped with the optional feature of Axis Release,
it can also be activated in operating mode Manual. Releasing an axis in manual mode
will open the brakes of the respective axes, which results in the possibility to shift those
axes by hand.

Activation is done in the View Menu Axes Positions:

Fig.: View Menu Axes Positions with Release

With a at the option Release the respective axis will be released immediately.

The release can be switched off manually tapping the option Release again. Additionally
the release will be switched off automatically, if any other drive command is sent to the
axis.

is used to release all releasable axes.

is used to deactivate all releases.

See also: 3.5.1.3.7 Teach command Axis Release

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 65

3.1.12.3 Pneumatic Axes

This function is used to manually move the selected pneumatic axis in the operating

modes Manual, Reference and Reference Missing. Furthermore

the current position of the axis is displayed in all operating modes.

At robots with secondary axes press the axis button longer, if you want to display the
buttons for toggling between main axis and secondary axis.

Fig.: Window for pneumatic axes

moves the axis directly to the endposition in plus direction.

moves the axis to the next intermediate position in plus direction.

moves the axis to the next intermediate position in minus direction.

moves the axis directly to the endposition in minus direction.

The number of positions depends on the type and equipment of the selected axis.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 66

3.1.12.4 Digital (B-) Axes

This function is used to manually move the selected digital axis in the operating modes

Manual, Reference and Reference Missing. Furthermore the

current position of the axis is displayed in all operating modes.

At robots with secondary axes press the axis button longer, if you want to display the
buttons for toggling between main axis and secondary axis.

Fig.: Window for digital axes

moves the axis 90° into plus direction.

moves the axis 60° into plus direction.

moves the axis 15° into plus direction.

moves the axis 15° into minus direction.

moves the axis 60° into minus direction.

moves the axis 90° into minus direction.

When traveling a digital axis, the respective button should be held until the control unit
has finished the selected movement. Otherwise the axis may stop between two positions
and cause an error message.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
R8.3 USER MANUAL Page 67

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 68

3.1.12.5 Counters

This function is used to display, reset or set the 64 counters of the Teach program in any
mode of operation.

Primus Robot: 10 counters available

Fig.: Counter window

is used to set the selected counter to a desired value. The numeric value is entered
using the dialogue for numerical input.

is used to reset the selected counter to zero.

is used to reset all 64 counters to zero.

Depending upon the application of the counter in the teach program, modifying counters
(especially in automatic mode) can result in serious changes in execution of the
program, as well as in damage due to collisions! Therefore, counters should (especially
in automatic mode) be modified only with caution by persons who are familiar with the
effects of such modification on the teach program.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 69

3.1.12.6 Placing Counters

This function is used to display the current values of the counters of the 16 placing
programs of the teach program in all operating modes. In operating modes

Manual, Reference and Reference Missing it is furthermore possible

to reset the counters to zero.

Primus Robot: 2 placing counters available

Fig.: Window for placing counters

Name
Shows the name of the respective placing program.

Used Axes
This shows which axes are used in the respective placing program.

1. - 2. - 3.
This shows the current values of the placing counters of the respective placing program.

Part Counter
This shows the current value of the part counter of the respective placing program.

is used to reset the counters of the selected placing program.

is used to reset the counters of all 16 placing programs.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 70

3.1.12.7 Conveyors

This function is used to manually switch the conveyors during operating modes

Manual, Reference and Reference Missing. Furthermore the

current states of the conveyors are displayed in all operating modes.

Fig.: Window for conveyor belts

means the respective conveyor is OFF.

means the respective conveyor is ON.

is used to switch the selected conveyor on.

is used to switch the selected conveyor off.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 71

3.1.12.8 Peripheral Outputs

This function is used to manually switch the peripheral outputs during operating modes

Manual, Reference and Reference Missing. Furthermore the

current states of the peripheral outputs are displayed in all operating modes.

Fig.: Window for peripheral outputs

means the respective peripheral output is OFF (LOW).

means the respective peripheral output is ON (HIGH).

is used to switch the selected peripheral output on.

is used to switch the selected peripheral output off.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 72

3.1.12.9 Vacuums

This function is used to manually switch the vacuum circuits during operating modes

Manual, Reference and Reference Missing. Furthermore the

current states of the vacuum circuits are displayed in all operating modes.

Fig.: Window for vacuum circuits

means the respective vacuum is OFF.

means the respective vacuum is ON.
means the respective vacuum is blowing off (optional).

is used to switch the selected vacuum on.

is used to switch the selected vacuum off.

is used to switch the selected vacuum to blow off (optional).

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 73

3.1.12.10 Grippers

This function is used to manually switch the grippers during operating modes

Manual, Reference and Reference Missing. Furthermore the current

states of the grippers are displayed in all operating modes.

Fig.: Window for grippers

means the respective gripper is OPEN.

means the respective gripper is CLOSED.
indicates that the gripper is RELEASED.
indicates that the state of the gripper is UNKOWN.

is used to switch the selected gripper on.

is used to switch the selected gripper off.

is used to release the selected gripper.

The state RELEASED is only available at gripper circuits equipped with the required
valves.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 74

3.1.12.11 Cylinders

This function is used to manually switch the Cylinders defined within the teach program

during operating modes Manual, Reference and Reference

Missing. Furthermore the current states of the cylinders are displayed in all operating
modes.

Fig.: Window for cylinders

indicates that the cylinder is in OFF position.

indicates that the cylinder is in ON position.
indicates that the cylinder is RELEASED.
indicates that the state of the cylinder is UNKOWN.

is used to switch the selected cylinder to its ON position.

is used to switch the selected cylinder to its OFF position.

is used to release the selected cylinder.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 75

3.2 Using the Quick New Wizard and the Quick Edit
Using the Quick New Wizard and the Quick Edit you can create simple pick and place
programs. No programming skills are necessary.

First the Quick New Wizard will ask you some questions about the requirements for the
program to be created. According to your answers the wizard will then create the desired
program and open it in the Quick Edit. Finally you will use the Quick Edit to input the
required values for positions, times and speeds.

Proceed as follow:

1) Press to start the Quick New Wizard.

2) In the first step you define whether you want to takeout the parts using vacuum
suction cups or grippers. Gripper-01 is reserved for the sprue, but can be used for
parts nevertheless, if you do not take out sprue. Decide if you want to take out
sprue using Gripper-01, and if you want to place the sprue before or after placing
the parts.

Press to enter the next step of the wizard.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 76

3) Define the number of placing positions per cycle that the robot has to travel to.
Additionally define which vacuum / gripper circuits shall be used to carry the parts
to the different placing positions.

Press to enter the next step of the wizard.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 77

4) Decide if rejects shall be placed separately. This functionality uses the reject part
signal of the injection molding machine. Activating this option additionally gives you
the possibility to separate an adjustable number of parts as startup rejects.

Press to enter the next step of the wizard.

5) Decide for the possibility of using a button on the screen of the Teachbox to request
a quality sample to be placed on a dedicated position.

Press to enter the next step of the wizard.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 78

6) Decide if the robot shall bring the removed parts to a device for cutting sprue, and
define how many cutting positions shall be used. The cutting device will be
triggered using peripheral output PO-001.

Press to enter the next step of the wizard.

7) Decide if the ejectors shall move parallel to the in and out movements of the robot
in order to save cycle time. Activate a softer, slower departure at the beginning of
the out movement of the robot, if the parts have to be separated from the mold
slowly.

Press to enter the next step of the wizard.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 79

8) Decide if the program shall use the EcoMode for automatic adaption of the speed
of the placing travel to the requirements of the machine cycle.

Press to enter the next step of the wizard.

9) Name your new program, and add a comment, if necessary.

Press for the wizard to create your program and to open it

in Quick Edit.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 80

10) Work through the displayed parameter values from top to bottom, and set the
desired values. Use the display- and editing functions of the Quick Edit for this.

11) Test your program with reduced velocity using the Dry Cycle function of the virtual
sub pendant, or use the Step functionality of the Text Editor.

12) Use the File menu Save as to store your new program on a storage medium. This
is possible in the Quick Edit and in the Text Editor.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 81

3.3 FILE Menu of the main screen

3.3.1 Properties
Here the properties of the Teach program of the robot are displayed. That is the program
which is executed when the robot is in automatic operation.

Fig.: Window for properties of the CPU program

Name of Teach program
Shows the name of the teach program of the robot. This name is not necessarily the
same as the file name of the program.
CPU = Teachbox or CPU <> Teachbox
Displays whether the teach programs in the robot (CPU) and the Teachbox are equal or
unequal.
Tooldata
Displays the Tooldata text of the teach program of the robot. The text for Tooldata can
only be edited in the properties window of the text editor.
Size
Displays the size of the teach program in the robot. The maximum size of a teach
program is limited to 32.768 bytes.
Primus Robot: max. 1000 lines possible

Number Part Programs

Shows the number of part programs of the teach program in the robot: ROBOT-PRG,
PERI-PRG, ROBOT-REF, PERI-REF, ALLMODE-PRG and up to 120 additional part
programs.
Primus Robot: only ROBOT-PRG. And ROBOT-REF Prg. available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 82

Number Placing Programs

Shows the number of placing programs used in the teach program in the robot. The
maximum number of placing programs available in a teach program is limited to 16.
Primus Robot: 2 Placing Programs available

If a picture has been associated with the selected teach program, can be used to
open the picture viewer.

can be used to email the Teach program as an email attachment (*.wip, *.htm
and *.txt file) using the manual email function of the robot.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 83

3.3.2 System Backup/Restore

At the R8.3 control you have to backup certain settings onto the System USB Stick
(“Boot” USB stick) once the robot is completely set up.
Especially at robots equipped with absolute encoders, it is absolutely essential to save
their Reference position values as well as the positions of the emulated mold safety
switches, as these values will be lost e.g. due to a low battery in a Sanyo-R inverter or
after a software-update.

For the backup the following steps are necessary:

1) Plug the System USB Stick (“Boot” USB stick) into the Teachbox.
2) Login as Administrator.
3) Open the menu File – System Backup / Restore.
4) In the tab Backup activate the desired options:

Fig.: Window for System Backup

The option Absolute encoder is only available at robots equipped with absolute
encoders.
5) Press the button [Backup] to start the automated backup process.

6) If you are asked about overwriting, confirm with .

7) Press [Close] to exit the menu.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 84

3.3.2.1 Backup stored Teachprograms

The R8.3 control offers you the possibility to store Teachprograms on the internal
storage medium of the robot control unit. Nevertheless you should regularly backup the
stored programs externally, in order to avoid data loss.

Everything you store on the internal storage medium of the robot will end up in the
folder C:\PUBLIC and its subfolders. Therefore use the backup function for the public
folder to backup your data on an USB stick.

Proceed like this:

1) Plug in your backup-USB-stick to the Teachbox.

2) Login as Administrator.

3) Open the menu File – System Backup/Restore and select the tab .

Fig.: Selection for backup of the Public folder

4) Activate only the option Public folder and press .

5) Answer the questions about overwriting. At the end of the backup process you will
have the possibility to display a report about the copied files.

6) Close the window with .

7) Logout as Administrator.

Storage location for the backed up files on the USB stick is the folder Backup. Each
robot will add its own subfolder inside that folder. The name of the subfolder will consist
of the respective robot type and serial number using the format Wxxx-xxxx. Thus you
can use one USB stick to backup data from several robots.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 85

3.3.3 INIT Menu

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

3.3.3.1 Stroke Limits

The stroke limits are software limit switches to limit the maximum travel range of an axis.

In operating mode Reference Missing the stroke limits are not active, the axes
travel is limited by the hardware limit switches. If a stroke limit is reached in manual
mode, the robot will stop at the position value of the stroke limit without an error message.
In automatic mode the error message 004-007 STROKE LIMIT will be shown.

Axes commands in a Teachprogram will be checked already during transfer to the CPU.
If an axis command targets a position outside the stroke limits, the error message 160-
005 TARGET OUT OF STROKE LIMITS including the affected line number and axis
will be shown.

Fig.: Window for stroke limits

After tapping the respective input field, the desired axis value can be input using the
dialogue for numerical input. The title bar of the dialog box will show which axis value is
to be entered while doing so.

discards the entries and closes the windows.

changes the stroke limits to the entered values.

The respective stoke limit of a numerical axis will be set automatically, when a position

limit switch is approached while the robot is not in operating mode Reference
Missing.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 86

3.3.3.2 Roller Switches

The roller switches are used for mold monitoring.

Refer to chapter 2.3.4 Mold Monitoring S5/S6

3.3.3.3 Absolute Encoders (Admin only)

The menu Init – Absolute encoders serves for setting the zero points of axes with
absolute encoders.

Setting the zero points of axes with absolute encoders will be necessary at initial startup
in the factory; after installing a new drive belt, motor, gearbox, etc.; and after a battery
failure of the Sanyo R drive.

Caution! Changing the zero points will lead to severe danger of collisions, because
all positions in your Teachprograms will be invalid!

See also:
6.5.2 Battery replacement at Sanyo R inverters.

3.3.3.4 Setting the zero points at a PRO-series Robot

At Wittmann PRO -series robots setting the zero points with the feeler gauge block will
be unnecessary. The procedure will be done by the software of the robot’s control.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 87

3.3.3.5 Deactivate Monitoring

This function is only available for users with write permission for the text editor.

In the selection window Init / Deactivate monitoring you can disable various
monitoring functions temporarily. Thus you can manually move the robot out of
hazardous areas, after one or more of the monitoring functions were triggered.

Fig.: Selection window for Deactivate Monitoring

The following monitoring functions can be deactivated:

 Mold Monitoring
 Safety Areas (if present)
 Collision Monitoring (if present)

The selection window only shows monitoring functions which are currently present.

A deactivates the respective monitoring.

When monitoring functions are deactivated, the icon for the mode of operation changes
its color to yellow.

The monitoring functions remain deactivated until one of the following events:
 A reference travel is executed.
 The users logs out or is being logged out.
 The monitoring functions are re-activated manually.

Press to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 88

3.3.3.6 Maintenance - Lubrication Interval

This function was introduced in order to call the user's attention to regular lubrication of
the guides.

Fig.: Window for lubrication

In the line Configured Interval the configured lubrication interval in kilometers is shown.

At the axes the distances traveled since the last lubrication are shown.

If the distance traveled by one axis exceeds the configured interval, the symbol will
be shown in the status bar, to remind that lubrication is needed.

After the robot has been lubricated, the traveled distances can be reset to zero using the

button .

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 89

3.3.3.7 Setup: Robot Settings

Fig.: Window for robot settings

Set Service Signal when Lubrication Interval is reached

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

Switch POs in Editor On

This function is used to configure whether or not peripheral outputs and conveyors are
turned on or off during teaching when the corresponding function is programmed. I.e., if
this option is activated and the command to turn on peripheral output 2 is entered in the
editor, output 2 will in fact be turned on immediately. This will not happen if the option
Switch POs in Editor On is deactivated.

Step speed
Speed setting in percent of the configured maximum axis speed used for axes
movements in step mode and while executing programmed reference travels. After
tapping the input field the desired value can be entered using the dialogue for numerical
input. Value range is from 1 to 30%.

Clear Counters
This is to determine if and when the counters of the teach programs are to be cleared
automatically or after request.

Clear Placing Programs

This is to determine if and when the placing programs of the teach programs are to be
cleared automatically or after request.

Override
The two options are to determine the automatic behavior of the Override. When none of
the options is activated, the Override is automatically reduced to 30% when a new teach
program is started or the robot is being powered up.

Axes Speeds
This is to determine if numerical axes use variable or fixed speeds for manual
movements.

Units
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 90

This is to determine if distances and positions are displayed in Millimeters or Inches.

End-Of-Arm-Tooling by RFID
Use this option to determine the behavior when the optional RFID End-Of-Arm-Tooling
recognition loads teach programs automatically.
Primus Robot: RFID not available

Show mouse cursor

Use this option to display a mouse pointer at the coordinates of the last registered
touch at the touch screen.

Work cell
This name will be used to identify the robot in the WIBA Quicklook App and in Emails.

discards the entries and closes the window.

confirms the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 91

3.3.3.8 Setup: Date / Time

Here you can set date and time.

Fig.: Window for date and time settings

discards the entries and closes the window.

confirms the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 92

3.3.3.9 Setup: Language

This is to change the display language of the Teachbox.

Fig.: Window for language setting

First select the desired language from the list by tapping it.

Then press to load the selected language.

During the loading process a window with a progress bar is shown.

is used to close the window without changing the language.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 93

3.3.3.10 Setup: Custom FTP-Server (only Admin)

This is to determine the settings for the connection of a robot to a Custom FTP-Server.
This server can be used as a central Data Pool for one or more robots in a network to
save e.g. teach programs, backups and further robot relevant data.

Fig.: Window for FTP-Server settings

Server Name
Distinct name of the server in the network

IP Address
Distinct, static address of the server in the network.

Start Directory
Directory, where the data shall be stored or loaded from.

User Name
Name the user takes to connect to the FTP-server.

User password
Indivivdual, alphanumeric password to identify the user when connecting to the server.

Transfer mode
Choose passive for a succesfull connection.

Server-name IP-Address etc. are assigned by the administrator of your network.

After tapping the respective input field use the dialogue for numerical input or text input
to enter the desired value.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 94

establishes the connection to the FTP-server.

discards the entries and closes the window.

confirms the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 95

3.3.3.11 Setup: Network Settings (Admin only)

This is to do the settings for the network connection of a robot.

Fig.: Window for network settings

IP-Address
Distinct, static network address of the robot.
Subnet Mask
Mask for limiting the number of participants in the local network.
Default Gateway
Address for establishing connection with participants outside the own local network
segment.
DNS Server
Address of the server for name resolution.
Mailserver
Address of the server handling email traffic.
UDP Port
Local port for UDP traffic. Use the standard setting.
VNC Logout Time
Time of inactivity after which (remote-) users automatically loose access to the
Teachbox.

The values for IP-Address, Subnet Mask, Default Gateway, DNS Server and Mailserver
have to be assigned by the network administrator.
After tapping the respective input field use the dialogue for numerical input to enter the
desired value.

discards the entries and closes the window.

confirms the entries and closes the window.

The current network settings can be viewed in View / Operating Systems also.
R83_V8_32_00_WIT_EN / 01.10.2020
R8.3 USER MANUAL Page 96

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 97

3.3.3.12 Setup: Remote Users Settings (Admin only)

This is to do the settings necessary for VNC remote users access.

Using VNC (Virtual Network Computing) and a VNC viewer software the Teachbox can
be displayed on a remote PC via a network and the robot being remote controlled
respectively. At integrated solutions with injection molding machines VNC is used to
enable accessing the functionalities of the Teachbox also on the panel of the injection
molding machine.

For using this function it is required that the robot is attached to a network. Furthermore
the Network Settings must be correct and Licenses for VNC access must be available.

Fig.: Window for remote users settings

Press to open the window for creating a new remote user.

Press to open the window for editing the selected remote user.

Press to delete the selected remote user.

discards the entries and closes the window.

confirms the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 98

3.3.3.12.1 Create / Edit Remote Users (Admin only)

Type
A remote user of the type IMM can access all functions of the Teachbox, if his assigned
local user has the respective permissions. This is used for IMM integrations. Also a
remote user of the type Remote User can only access functions, his locally assigned
user has permissions for – additionally he can neither use manual functions nor perform
changes of the operating mode. The type IMM is only available at integrated solutions.

Username
Here you choose a user from the local User Administration to be used for the remote
user. The remote user will always be automatically logged in with the user name of the
selected user, and will have the respective permissions.

IP-Address
The IP-Address of the remote users computer. The remote user will be identified with his
IP-Address, and will be given access with that address only.

Online Users
This displays a list of IP-addresses of remote computers that are requesting VNC access
successfully or unsuccessfully.

discards the entries and closes the window.

confirms the entries and closes the window.

3.3.3.13 Licenses (Admin only)

This window displays the number of available VNC licenses for remote users.
Furthermore this is where you activate additionally acquired licenses.

In case you should need additional licenses, contact our service office responsible for
you.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 99

3.3.3.14 Setup: Email Settings

This is to do the settings for the manual and automatic email functions of a robot.

3.3.3.14.1 Tab Basic

Here you input the E-mail sender address for the robot and the contact email address
of our technical support facility responsible for you, using the dialogue for text input.

After selecting the desired entries with a you can press to use the default
addresses.

3.3.3.14.2 Tab Content

Select the content to be included in automatically generated emails.

You can add description text for the work cell of the robot using the dialogue for text
input after tapping the input field.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 100

3.3.3.14.3 Tab Timeouts

Set the timeout for the automatic email function. In case of the robot stopping with an
error message (switching from automatic mode to manual mode) and nobody confirming
the error message(s) within this timeout, the robot will send emails with the selected
content to the selected recipients.

3.3.3.14.4 Tab Recipients

Create, change or delete possible recipients for the automatic email function.

Press to open the window for creating a new recipient.

Press to open the window for editing the selected recipient.

Press to delete the selected recipient.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 101

3.3.3.14.5 Tab Events

Select the recipients to sent an email to with the automatic email function. You can create
additional recipients on the tab Recipients.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 102

3.3.3.15 Setup: Screensaver Properties

Fig.: Window for the properties of the screensaver

Start screensaver after inserted time

This is used to activate or deactivate the screensaver.

Activation Timeout
This is the time to pass after the last touching of the touchscreen, before the screensaver
starts. After touching either the minutes or seconds field, values are input using the
dialogue for numerical input.

Switch Time
This is the time the screensaver uses to show each picture. After touching either the
minutes or seconds field, values are input using the dialogue for numerical input.

is used to start the screensaver immediately for testing purposes.

discards the entries and closes the window.

confirms the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 103

3.3.3.16 Setup: Calibrate Touch

This function is used to calibrate the touchscreen of the Teachbox. This is necessary for
the Teachbox to correctly calculate digital X/Y coordinates from the two analogue
resistance values supplied by the touchscreen. Only then it is possible for the Teachbox
to react correctly when the touchscreen is tapped on.

Calibrating the touchscreen is only necessary when pressed buttons are not interpreted
correctly.

After calling the function follow the instructions on the screen. Tap the center of the
displayed crosses as exactly as possible.

3.3.4 View Menu

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

3.3.4.1 Operating Systems

This window displays the versions of software loaded to the robot and the network
settings.

Fig.: Window for Operating Systems

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 104

3.3.4.2 Operating Data

This window displays operational data of the robot.

Fig.: Window for Operating Data

Cycletime
Displays the time between the last but one and the last positive slope of the signal "Mold
Open" from the IMM. This is the time needed to produce one part (round).

Cyclecounter
The cycle counter counts the positive slopes of the signal "Mold Open" from the IMM
during automatic operation of the robot. The cycle counter is only reset by using the boot
medium.

Withdrawaltime
Displays the time between the positive slope of the signal "Ejector is forward" of the IMM
and the moment when the robot is travelling onto the bar of the S5 rollerswitch of the Y-
arm. This is the time the robot needs to get out of the mold with the part on the gripper.

Mold open time

Displays the time between the positive slope of the signal "Mold Open" of the IMM and
the positive slope of the permit signal "Close mold" of the robot to the IMM. This is the
time the IMM has to wait for the robot before it can mold the next part.

Operating Hours
Displays the overall time the robot worked in automatic mode. The operating hours are
only reset by using the boot medium.

Lubrication
In the first line the lubrication interval is displayed, in the following lines the kilometers
travelled by the linear axes since the last lubrication are shown.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 105

3.3.4.3 Axes positions

This window displays the current positions of the robot axes and their drive type.

Fig.: Window for axes positions

The number and type of the axes shown is depending on the configuration of the actual
robot.

The positions are shown in millimeters for linear axes and in degrees for rotary axes. The
resolution of the values displayed is always one tenth.

is used to close the window.

See also: 3.1.12.2 Axis Release in Manual Mode

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 106

3.3.4.4 I / O
This window displays the current states of the inputs and outputs of the robot control unit.

Fig.: Window for inputs and outputs

Tap one of the tabs Input or Output to select if either the inputs or the outputs are to be
shown.

All 512 theoretically possible inputs and outputs of a robot are shown. If any input or
output is displayed in this window, it does not indicate that this input or output is really
existent on the actual robot. If (NC) is displayed right next to the name, the respective
input or output is not configured on the current robot.

indicates that the input/output is OFF (LOW).

indicates that the input/output is ON (HIGH).

The four buttons on the right are shortcuts to certain function groups:

inputs and outputs of the IMM interface

peripheral inputs and peripheral outputs

inputs and outputs of the grippers

inputs and outputs of the vacuum circuits

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 107

3.3.4.5 Safety Areas

Here you can view the settings of the current safety areas.

Fig.: View Menu safety areas with working area and example areas

The Working Area is always present. It is defined by the Stroke Limits of the robot.

is used to open a window showing the coordinates of the selected safety area.

When you press with the working area selected, the window for setting the
visibility of the working area in the graphical display will be opened.

is used to open the graphical display of the safety areas.

is used to close the window.

See also:
3.4.6.3 Setup Menu: Safety Areas
3.4.6.3.3 Graphical display of the safety areas

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 108

3.3.4.6 Counters
This window displays the current values of the 64 counters of the teach program.
Primus Robot: 10 counters available

Fig.: Window for counters

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 109

3.3.4.7 Placing Counters

This window displays the current counter values of the 16 placing programs of the teach
program.
Primus Robot: 2 placing counters available

Fig.: Window for placing counters

Name
Shows the name of the respective placing program.

Used Axes
This shows which axes are used in the respective placing program.

1. - 2. - 3.
This shows the current values of the placing counters of the respective placing program.

Part Counter
This shows the current value of the part counter of the respective placing program.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 110

3.3.4.8 Conveyors
This window shows the current state of operation of the conveyor belts.

Fig.: Window for conveyors

indicates that the respective Conveyor is OFF.

indicates that the respective Conveyor is ON.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 111

3.3.4.9 Cylinders
This window shows the current state of the cylinders defined in the teach program.

Fig.: Window for cylinders

indicates that the cylinder is in OFF position.

indicates that the cylinder is in ON position.
indicates that the cylinder is RELEASED.
indicates that the state of the cylinder is UNKOWN.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 112

3.3.4.10 POs - Peripheral Outputs

This window displays the current states of the peripheral outputs of the robot control unit.

Fig.: Window for peripheral outputs

indicates that the peripheral output is OFF (LOW).

indicates that the peripheral output is ON (HIGH).

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 113

3.3.4.11 PIs - Peripheral Inputs

This window displays the current states of the peripheral inputs of the robot control unit.

Fig.: Window for peripheral inputs

indicates that the peripheral input is OFF (LOW).

indicates that the peripheral input is ON (HIGH).

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 114

3.3.4.12 IMM I / O
This window displays the current states of the signals of the IMM interfaces.

Fig.: Window for IMM interfaces

If the robot is equipped with 2 interfaces for injection molding machines, tap one of the
options IMM 1 or IMM 2 to select the interface to be displayed.

indicates that the interface signal is OFF (LOW).

indicates that the interface signal is ON (HIGH).

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 115

3.3.4.13 AutoSwitches
This window displays the current states of the 32 AutoSwitches.

Fig.: Window for AutoSwitches

indicates that the AutoSwitch is OFF.

indicates that the AutoSwitch is ON.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 116

3.3.4.14 Stopwatches
This window displays the values measured by the four stopwatches available in the teach
program.

Fig.: Window for stopwatches

The minimum value, maximum value and average value calculated from the
measurements done, as well as the current value are displayed for each stopwatch.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 117

3.3.4.15 Vacuums
This window shows the current state of operation of the vacuum circuits.

Fig.: Window for vacuum circuits

indicates that the vacuum circuit is OFF.

indicates that the vacuum circuit is ON.
indicates that the respective vacuum is blowing off (optional).

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 118

3.3.4.16 Default Vacuum Level

This window shows the current pressure values and states of the analogue vacuum
circuits.

Fig.: Window for vacuum pressure values

indicates that the vacuum circuit is OFF.

indicates that the vacuum circuit is ON.
The big bar and the first field below the scale show the current under-pressure, the small
bar and the number right next to it display the set default vacuum level. The field Warning
is optional and acts as deterioration signal for the vacuum circuit.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 119

3.3.4.17 Grippers
This window shows the current state of the grippers.

Fig.: Window for grippers

indicates that the gripper is OPEN.

indicates that the gripper is CLOSED.
indicates that the gripper is RELEASED.
indicates that the state of the gripper is UNKOWN.

The state RELEASED is only available at gripper circuits equipped with the required
valves.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 120

3.3.4.18 Alarms
This window displays all occurring operational error messages in plain text, each with a
specific error number.

Fig.: Error Window

The error messages are displayed in two colors:

Red
Error and cause currently exist. The error is active. The cause of the error has to be

eliminated, before the error can be confirmed. The icon will be displayed in the
status bar if one or more errors are active.

Gray
The error occurred, but the cause no longer exists. The error is inactive and can be
confirmed.

is used to confirm inactive errors.

Press to display a help text for each error message. Press to turn off the
help texts again.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 121

3.3.4.19 Error Buffer

This window displays the last 500 operational error messages in chronological order.

Fig.: Error Buffer

is used to refresh the list.

can be used to email the contents of the error buffer by means of the manual
email function of the robot. This requires the robot being connected to a network.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 122

3.3.4.19.1 Export the Error Buffer

The contents of the error buffer can be stored to a UNICODE text file *.TXT on the USB
stick. Path and name of the file are selectable. The default folder is
D:\ROBOT\LOG\ERRORS. The generated file can be opened, displayed and printed
with a PC, or can be forwarded to our service department if needed.

Press to open the dialogue for exporting the error buffer:

Fig.: Dialogue for exporting the error buffer

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a text file *.TXT

After tapping the field Filename you can use the dialogue for text input to input the
desired filename. By tapping on it in the display of the current folder, you can also use
the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 123

is used to delete the selected file or folder.

is used to rename the selected file or folder.

is used to optimize the display of the contents of the current folder for either short
or long file names.

is used to open the selected folder.

is used to save the file to the current folder, applying the name from the field
Filename.

is used to abort the function and to close the window.

Before the file is actually stored, the Teachbox checks if a file with the same name is
already stored in the selected folder, and a check back message may appear.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 124

3.3.4.20 Command Buffer

This window displays the last actions (operating steps) executed in chronological order.

Fig.: Command Buffer

is used to refresh the list.

can be used to email the contents of the command buffer by means of the manual
email function of the robot. This requires the robot being connected to a network.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 125

3.3.4.20.1 Export the Command Buffer

The contents of the command buffer can be stored to an UNICODE text file *.TXT on the
USB stick. Path and name of the file are selectable. The default folder is
D:\ROBOT\LOG\COMMANDS. The generated file can be opened, displayed and printed
with a PC, or can be forwarded to our service department if needed.

Press to open the dialogue for exporting the command buffer:

Fig.: Dialogue for exporting the command buffer

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a text file *.TXT

After tapping the field Filename you can use the dialogue for text input to input the
desired filename. By tapping on it in the display of the current folder, you can also use
the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 126

is used to delete the selected file or folder.

is used to rename the selected file or folder.

is used to optimize the display of the contents of the current folder for either short
or long file names.

is used to open the selected folder.

is used to save the file to the current folder, applying the name from the field
Filename.

is used to abort the function and to close the window.

Before the file is actually stored, the Teachbox checks if a file with the same name is
already stored in the selected folder, and a check back message may appear.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 127

3.3.4.21 Virtual Subpendant (Emergency Stop Block)

The buttons on the Emergency Stop Block are used for basic operation of the robot. The
virtual Subpendant displays these buttons on the touch screen of the Teachbox.

Touch the icon for the operating mode at the upper left corner of the touch screen to
access the virtual Subpendant directly.

3.3.4.21.1 Tab Standard

Fig.: Tab Standard of the virtual Subpendant (Emergency Stop Block)

Reference travel
Press and hold to execute the reference travel. In the mold area this is possible only
when a reference program has been programmed.

IMM: Operation with robot

This enables operation of IMM with robot. In shut-off state the IMM can be operated
without robot.

Automatic-Start
Start of automatic operation. The robot must be in reference position and operation with
robot must be activated.

Block Stop
Press to stop automatic operation after complete execution of the currently processed
instruction or group of instructions. Automatic operation can be continued by pressing
the Automatic Start button again.

Manual operation / Stop

Causes an immediate stop and switches to manual operation.

See also: 3.1.3 Emergency Stop Block

R83_V8_32_00_WIT_EN / 01.10.2020
R8.3 USER MANUAL Page 128

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 129

3.3.4.21.2 Tab Easy

Fig.: Tab Easy of the virtual Subpendant (Emergency Stop Block)

Here, the buttons of the Subpendant and some additional functions for easy operation of
the robot are collected in the groups Prepare, Start and Stop.

Dry Cycle
Use this function to test a Teachprogram, without producing parts with the IMM. When
the Teachprogram runs on to decisions that would account for the IMM to run in full
automatic mode, a dialogue will be displayed, where the user can decide how the robot
shall continue.

One Cycle
Use this function to make the robot take out and place one shot only. The mold of the
IMM will remain open. The robot will travel back above the IMM and will switch to

Blockstop mode at the command that waits for the opening of the mold. Only after

or being pressed again, the mold of the IMM will be closed, and the next cycle will
start.

EOAT Change
Use this to execute the EOAT change program
Primus Robot: EOAT not available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 130

3.3.4.22 Memory State

This window displays information about the memory load of the Teachbox. For service
purposes only.

Fig.: Window for Memory State

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 131

3.3.5 System Report

The System Report is useful for simple and effective transmission of all data out of the
robot control unit that might be helpful for the service department to do a remote
diagnosis in case of a problem.

When creating a system report, plug a USB stick into the Teachbox first. Then open the
Help menu "?" and start the function System Report.

The dialogue for text input will appear, and a comment about the report can be entered.

After this the System Report will be stored on the USB stick using the following file name
and path: ..\ROBOT\LOG\SYSTEM\Wxxx-xxx_sys.zip

After a successful completion of the storage process, a window like this will appear:

can be used to email the system report file by means of the manual email function
of the robot. This requires the robot being connected to a network.

is used to close the window.

The System Report can now be loaded from the USB stick to a PC, and can be forwarded
via email, for example.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 132

3.3.6 Email Functions

3.3.6.1 Manual Email Function

By means of the manual email function the user can send the current Teach program,
the error buffer, command buffer or system report to any choice of recipients directly
from the robot.

For using this function it is required that the robot is attached to a network and has access
to a mail server. Furthermore the Network Settings and the Email Settings in the menu
Init/Setup must be correct.

After accessing the function with , the window for selecting email recipients will
appear:

Fig.: Window for selecting email recipients

Add recipient
Tap this field to enter a new recipient with the dialogue for text input.

Select recipient
Tap to select an existing recipient and press to add this recipient to the list of
recipients for the current email.

Recipients
This field displays the list of recipients chosen for the current email. Press if you
want to remove all entries from this list of recipients.

is used to send the email to the chosen recipients.

is used to cancel the function without sending an email.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 133

3.3.6.2 Automatic Email Function

By means of the automatic email function the user can receive automatically generated
emails from the robot in case it has stopped with an error message and nobody confirmed
the error within a set timeout.

For using this function it is required that the robot is attached to a network and has access
to a mail server. Furthermore the Network Settings and the Email Settings in the menu
Init/Setup must be correct.

The email generated by the robot will have the subject Alarms/Errors from
control cabinet

With all possible content activated, the message text of the email will look somehow like
this example:

This E-mail was automatically created by the robot.

Control No.: 4711

Teachbox-Version: 8.02
Master-Version: 8.02
Operating Mode: Manual
Work cell: MY TEST ROBOT

Alarms/Errors from control cabinet

active: 0
inactive: 1
006-000-000 Vacuum-01 PART LOST inactive

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 134

3.3.7 RFID / Digital EOAT (optional)

Primus Robot: not available

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

3.3.7.1 Link a Teach Program with an EOAT

If a gripper is present on the EOAT recognition system, the dialogue for linking the teach
program with an EOAT-ID will be shown when storing the teach program using the menu
File – Save As.

Fig.: Dialogue for linking a teach program with an EOAT-ID

Press if you want to link the program with the EOAT.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 135

3.3.7.2 EOAT Change

Primus Robot: not available

When the EOAT recognition system recognizes a newly attached gripper, the dialogue
for selecting one of the teach programs linked with the EOAT will appear.

Fig.: Dialogue for selecting a linked teach program

Highlight the desired program and press to load it.

You can use to unlink the highlighted teach program.

Press if you don't want to load a program.

With the corresponding setting made in the menu Init – Setup – Robot Settings the
program will be loaded automatically, if only one single program is linked with the EOAT.
In this case the selection dialogue will not be shown.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 136

3.4 Teach-Mode using the Text Editor

Teach-Mode is used to create a Teach program for the robot and the attached peripheral
equipment. This program contains all procedures and movements necessary for
automatic operation and reference travel. In general the text editor is used for this, in
order to be able to use the full functionality of the R8.3 control unit.

3.4.1 Operation of the Text Editor

3.4.1.1 Entering the Text Editor

The text editor can be called up in all operating modes using the button .

If the text editor is entered in the operating mode Reference Missing, the Offline
Editor will be activated automatically, because no valid positions are available for the
numerical axis in this operating mode.

If the text editor is entered in one of the operating modes Automatic or

Blockstop, only times, speeds and positions of numerical axes (+/- 10mm) can
be adapted. Adding or deleting of commands will not be possible, except the Offline
Editor is activated.

Only if the text editor is entered in one of the operating modes Manual or
Reference, the full functionality of the Online Editor will be available.

See also:
3.4.3 Part Programs

3.4.1.2 Exit the Texteditor and transfer the program to the CPU

Exit the Text Editor by using the button or by using the option Exit to Main of
the File menu.

Refer to: 3.4.4.11 File Menu: Exit to Main.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 137

3.4.1.3 Editing Functions

The most common editing functions of the text editor can be accessed using the buttons
on the bottom of the editor window:

takes you to the first line of the Teach program.

takes you to the last line of the Teach program.

deletes the highlighted line(s).

adds an empty line before the highlighted one.

opens a window to edit the highlighted command.

See also:
3.1.6 Selection Mode

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 138

3.4.1.4 Online Editor

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

3.4.1.5 Offline Editor

The offline editor can be turned on in the teach editor using the option OfflineEditor of
the Setup menu. This puts the Text Editor offline, but following features will stay active:

 The Emergency-Stop-Block with the buttons for basic operation of the appliance
 The menu View in the Text Editor (View signal states, counter values)
 The Quick Editor to make changes of parameters in the running program.
The teach program is created or edited without travelling the robot, while the robot
processes another program in the Master CPU. However, no axis positions can be
entered.
The turned-on offline editor is indicated by a flashing on the status bar at the upper
left of the display. If a numerical axis is selected, the characters " ?????.?" are shown

instead of the current axis position. Upon acknowledgment with the axis
command is added to the teach program with the undefined position. Predefined
positions are taken over correctly.

For a program edited or created offline, all axis instructions created offline must be
converted online, before the program can be transferred to the master CPU and before
it can be executed.

3.4.1.6 Online Conversion

The Online Conversion is started by selecting the option OnlineEditor in the Setup
menu.

After a successful conversion the following notice will appear:

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 139

3.4.2 Step Operation

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

 Step operation in Block Stop mode

 Step operation in Reference and Manual modes

To do this, the one must be in the editor, and the program in the editor must be already
transferred to the CPU. The highlighted instruction is executed by holding down the

key. Execution of the instruction may be aborted at any time by releasing the
key.

Step Operation in Block Stop Mode

The program is stepped through chronologically according to the automatic sequence.
All travel instructions of the numerical axes are executed at the full speed of the
automatic sequence.

Step Operation in Reference and Manual Modes

The speeds of travel motions of the numerical axes can be set from 1 to 30% of the
maximum speed.

For safety reasons, a newly created program must be run through in Step operation
before the first automatic operation.

The branch to the alternative sequence when a monitoring triggers will not be executed
in step operation.

3.4.2.1 Procedure Step

By tapping the menu point Edit-Debug-Step is Procedure Step the user can activate
or deactivate Procedure Step.

Procedure Step means, that when a CALL command is being stepped, not only the CALL
command is executed, but the whole subroutine called up by the CALL command.

In this case the cursor remains on the CALL command, until the execution of the
subroutine is finished.

A subroutine may only be tested using a procedure step, when it has already been tested
with "normal" step operation.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 140

3.4.3 Part Programs, PROGRAM Menu

3.4.3.1 Part Programs

Primus Robot: not available

A complete standard teach program consists of the following part programs:

 Robot Program (ROBOT-PRG)

 Peripheral Program (PERI-PRG) Primus Robot: not available

 Robot Reference Program (ROBOT-REF)

 Peripheral Reference Program (PERI-REF) Primus Robot: not available

 All Modes Program (ALLMODE-PRG) Primus Robot: not available

Up to 115 additional part programs can be added.

Each of these additional part programs can be a Sub-Allmodes Part Program.

One of the additional part programs can be used as EOAT Change Program.

After opening the editor the robot program ROBOT-PRG will be displayed for editing. To
switch the editor to a different part program, simply select the desired program from the
Menu Program. The status field on the bottom left corner of the editor window indicates,
which part program is currently shown in the editor.

Fig.: Indication of current part program

3.4.3.1.1 Robot Program (ROBOT-PRG)

This program is used to program all movements and procedures the robot has to execute

together with the IMM in Automatic mode.

The robot program is executed cyclically. After execution of the last command line of the
robot program or an END command within, the execution of the robot program will
continue at its first line.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 141

3.4.3.1.2 Peripheral Program (PERI-PRG)

Primus Robot: not available

This program is used to control all sequences (in peripheral equipment) that have to be
executed independently from the movements of the robot.

The program must be started in the robot program or in one of the 115 additional part
programs. After that it will be executed in parallel to (at the same time as) the other part

programs running in Automatic mode.

The Peripheral Program will not be executed cyclically. After execution of the last
command line of a peripheral program or an END command within, the execution of the
peripheral program will be stopped. If the peripheral program should be executed
permanently (cyclically) this feature has to be programmed accordingly (using a Jump
command).

3.4.3.1.3 Robot Reference Program (ROBOT-REF)

This program is used to control all movements and procedures executed by the robot

during the reference travel in operating mode Manual.

3.4.3.1.4 Peripheral Reference Program (PERI-REF)

Primus Robot: not available

This program is used to control all movements and procedures executed by peripheral

equipment during the reference travel in operating mode Manual. This program
will be executed in parallel to the robot reference program. The two reference programs
can perform coordinated sequences using handshakes with counters.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 142

3.4.3.1.5 115 additional Part Programs

Primus Robot: not available

Like the peripheral program the additional part programs are used to control all
sequences (in peripheral equipment) that have to be executed independently from the
movements of the robot.

The programs must be started in the robot program or in one of the other additional part
programs. After that they will be executed in parallel to (at the same time as) the other

part programs running in Automatic mode.

Additional part programs will not be executed cyclically. After execution of the last
command line of an additional part program or an END command within, the execution
of the additional part program will be stopped. If the additional part program should be
executed permanently (cyclically) this feature has to be programmed accordingly (using
a Jump command).

3.4.3.1.6 All Mode Program (ALLMODE PRG)

Primus Robot: not available

The ALL MODES program (ALLMODE-PRG) is executed by the R8.3 control unit in the
background, regardless of the current mode of operation the robot is in. Meaning this

program is not only executed in the operating mode Automatic, but also in the

operating modes Manual, Reference and Blockstop.

The ALL MODES program cannot be executed in the operating mode

Reference Missing.

This program is used to control movements and procedures, which have to be executed
in every operating mode of the robot (except Reference Missing).

The ALL MODES program does not start automatically. Like the peripheral program, it
has to be started either from a different part program using the respective Teach
commands; or it is started manually using the function "START/STOP ALLMODE-PRG."
of the INIT menu.

Once the ALL MODES program is activated, it is executed cyclically. After execution of
the last command line of the ALL MODES program or an END command within, the
execution of the ALL MODES program will continue at its first line.

The Icon is shown in the status bar of the Teachbox right next to the operating
mode, to indicate that the ALL MODES program is running. Changes of the mode of
operation will not interrupt the ALL MODES program. Only the respective STOP-
command, or an emergency stop or powering down the robot will stop the ALL MODES
program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 143

Even more flexibility can be added to ALL MODES programs using the event Mode. This
gives the possibility to react on the actual robot mode.

3.4.3.1.7 Sub-Allmode Part Program

Primus Robot: not available

Sub-Allmodes Part Programs are additional part programs which, like the ALL MODES

program are not only executed in operating mode Automatic, but also in the

operating modes Manual, Reference and Blockstop.

Sub-Allmodes Part Programs do not start automatically. They also do not start
automatically, when the ALL MODES program is started. Sub-Allmodes Part Programs
must be started from within the ALL MODES program or from within another Sub-
Allmodes Part Program using the respective start teach command.

Sub-Allmodes Part Programs will not be executed cyclically. After execution of the last
command line of a Sub-Allmodes Part Program or an END command within, the
execution of the Sub-Allmodes Part Program will be stopped. If a Sub-Allmodes Part
Program should be executed permanently (cyclically) this feature has to be programmed
accordingly (using a Jump command).

Once the ALL MODES program is stopped, all Sub-Allmodes Part Programs will be
stopped as well.

3.4.3.1.8 EOAT Change Program

Primus Robot: not available

The EOAT Change Program is used for moving to an EOAT changing position, or to
change the EOAT automatically.

The EOAT Change Program has to be programmed in the text editor. All functions of the
robot can be used.

When the button on the virtual Subpendant is pressed one time during operating
modes Manual or Reference, first a reference travel (according to the reference program)
will be executed. After this the EOAT Change Program will run.

If the button should be released and pressed again during execution of the EOAT
Change Program, the EOAT Change Program will not start all over, but will continue
working at the current program line.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 144

3.4.3.2 Manage Part Programs

Primus Robot: not available

This function is used to manage the part programs of the teach program.

Fig.: Window to manage part programs

The Part Program Information Table shows information about the part program
selected in the list of Existing Part Programs.

is used to create a new part program.

is used to edit the settings of the part program selected in the list of Existing Part
Programs.

is used to delete an additional part program selected in the list of Existing Part
Programs. The standard programs ROBOT_PRG, PERI-PRG, ROBOT-REF, PERI-
REF and ALLMODE-PRG cannot be deleted.

is used to close the window, and to discard the entries.

is used to confirm the entries, and to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 145

3.4.3.2.1 Edit a Part Program

Primus Robot: not available

This function is used to create a new additional part program, or to edit the settings for
an existing part program.

Fig.: Window to edit part program settings

After tapping the field Part program name you can change the name of an additional
part program using the dialogue for text input. The names of the standard programs
ROBOT_PRG, PERI-PRG, ROBOT-REF, PERI-REF and ALLMODE-PRG cannot be
altered.

The button Teachable Axes is used to open the dialogue for axes definition. Here you
can assign axes to the part program.

Use one of the three options on the left bottom of the window to define the type of the
new part program:

Standard Program
Use this option to create a standard additional part program.

Allmode Program
Use this option to create a sub-allmodes part program.
Primus Robot: not available

Use part program as End-Of-Arm-Tooling change program

Primus Robot: not available

Use this option to create an EOAT change program. The default name EOAT Change
is assigned to this program automatically.

is used to close the window, and to discard the entries.

is used to confirm the entries, and to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 146

3.4.4 FILE Menu of the text editor

3.4.4.1 New
This function is used to create a new empty teach program in the Teachbox.

Fig.: Options window for a new teach program

The window Options for new Teach program is used to select which elements from
the existing program are kept with the new teach program. This is possible for:

 Names
 Positions
 Axis Definitions
 Cylinders
 Reference settings for vacuum and gripper circuits
 AutoSwitches
 Safety areas

The different elements are selected or deselected by tapping the respective option. A
means, that the element is selected to be taken over to the new program.

is used to select all elements.

is used to deselect all elements.

is used to cancel the process.

is used to create a new empty teach program.

The program currently loaded in the Teachbox will be irretrievably deleted. The program
in the robot remains unchanged.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 147

3.4.4.2 Open
This function is used to load a teach program from a storage medium to the Teachbox.

Fig.: Window to open a file

The field Search in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a teach program file *.WIP

for a teach program file *.ZIP

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 148

is used to open the properties window of the selected program.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to load the selected program to the Teachbox.

is used to abort the function and close the window.

The program stored in the teachbox will be irretrievably deleted by loading another teach
program.

Before the program can be executed, it has to be transferred to the robot.

Every newly loaded teach program must be run through at least once in step mode before
automatic operation.

The file name of a stored teach program is not necessarily the same as the teach
program name.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 149

3.4.4.3 Import Macro

A macro is a file *.WIM which contains one or more program lines, that were exported
from a (different) teach program previously.

The function Import macro is used to insert a macro *.WIM from a storage medium to
the teach program before the current position of the cursor.

Abb.: Window to import a Macro

The field Search in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a macro file *.WIM

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 150

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to load the selected macro to the Teachbox, and to insert it to teach
program before the selected line.

is used to abort the function and close the window.

If labels or subroutines whose names already exist in the teach program are loaded, they
are automatically renamed to LABEL_xxx or SUBR_xxx. "xxx" represents a 3 digit
number.

If an associated JUMP instruction is loaded together with an already existing label, the
JUMP instruction will also be changed to the new label name. The same applies to CALL
instructions that are loaded together with their subroutines.

If a placing program, which has the same name as an existing placing program in the
teach program but otherwise differs from the latter in some way, it will automatically be
renamed with the name of the first unused placing program.

If a macro that does not correspond to configured robot hardware (e.g., an axis not
present) is loaded, a flag will appear and the offline editor will be activated. The
corresponding instructions will now have to be changed or removed manually, after
which the program can be switched back ONLINE again with the function ONLINE
EDITOR of the Setup menu.

If an axis instruction with a reference to a previously defined position, which has the
same name as a previously defined position existing in the teach program but otherwise
differs in some way from the latter, is loaded, it will be automatically renamed to
POSITION_xxx. "xxx" represents a 3 digit number.

When a macro is loaded, axis positions of configured axes will be transferred without
comment. However, this does not mean that they can be approached without risk.
Programs expanded by macros must therefore always be tested in STEP mode.

When a macro is loaded, instructions with configured peripheral input/outputs are

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 151

3.4.4.4 Load Program from CPU

This function is used to load the teach program from the robot to the Teachbox.

The teach program loaded in the Teachbox including all names, cylinder definitions and
position definitions will be irreversibly deleted.

3.4.4.5 Save (NAME.ZIP)

This function is used to save the teach program from the Teachbox to a storage medium
as a *.ZIP file. Both name and path of the file will be the ones used before. The name of
the target file is shown in brackets right next to the menu entry Save. If no name is
displayed, Save will call the function Save as instead.

The previous version of the program stored on the storage medium with the same name
will be deleted irretrievably.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 152

3.4.4.6 Save As
This function is used to save the teach program from the Teachbox to a storage medium
as a *.ZIP file. Path and name of the file are selectable.

Fig.: Window to save a teach program

The field Save in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a teach program file *.WIP

for a teach program file *.ZIP

The field Filename suggests the last filename used or the teach program name as
filename. After tapping the field you can use the dialogue for text input to change the
filename as desired. The extension will always be ZIP. By tapping it in the display of the
current folder, you can also use the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

is used to create a new folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 153

is used to delete the selected file or folder.

is used to rename the selected file or folder.

is used to open the properties window of the selected program.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to save the teach program to the current folder, applying the name
from the field Filename.

is used to abort the function and close the window.

Before storing is executed, a check is made to see whether a program of the same name
is already stored in the selected folder, and a check back message may appear.

If a coded gripper is present on the optional RFID / Digital-EOAT gripper recognition

system, you will be asked if you want to assign the program to that gripper.
Primus Robot: RFID / EOAT not available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 154

3.4.4.7 Export Selection

This function is used to save previously selected lines from the teach program to a
storage medium as a macro *.WIM. Path and name of the file are selectable.

Fig.: Window to save a macro

The field Save in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a macro file *.WIM

After tapping the field Filename you can use the dialogue for text input to enter the
desired filename. The extension will always be WIM. By tapping it in the display of the
current folder, you can also use the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 155

is used to rename the selected file or folder.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to save the macro to the current folder, applying the name from the
field Filename.

is used to abort the function and close the window.

Before storing is executed, a check is made to see whether a macro of the same name
is already stored in the selected folder, and a checkback message may appear.

See also:
3.4.4.3 File Menu: Import Macro
3.4.5.1 Edit Menu: Selection Mode

3.4.4.8 Transfer program to CPU

This is used to transfer the teach program from the Teachbox to the robot. This is
necessary to enable execution of the program.

A progress bar is shown during the process.

With the appropriate setting of the option Clear counters in the Init Menu
Setup: Robot Settings a request about resetting counters and placing programs will pop
up:

The program previously stored in the robot will be irretrievably overwritten.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 156

3.4.4.9 Properties
Here the properties of the teach program in the text editor of the Teachbox are displayed.
That is the program which can be edited. Before this program can be executed in
automatic operation, it has to be transferred to the robot.

Fig.: Window for properties of the program in the texteditor

Name of Teach program

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

CPU = Teachbox or CPU <> Teachbox

Displays whether the teach programs in the robot (CPU) and the Teachbox are equal or
unequal.

Tooldata
Displays the Tooldata text of the teach program in the text editor. After tapping the input
field, the Tooldata text can be edited using the dialogue for text input.

Size
Displays the size of the teach program in the text editor. The maximum size of a teach
program is limited to 32.768 bytes.
Primus Robot: max. 1000 lines possible

Number Part Programs

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

Number Placing Programs

Shows the number of placing programs used in the teach program in the text editor. The
maximum number of placing programs available in a teach program is limited to 16.
Primus Robot: 2 Placing Programs available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 157

can be used to open the picture viewer. There you can either associate a picture
with the teach program, or watch the picture associated with the teach program.

can be used to email the teach program by means of the manual email function
of the robot as an email attachment (*.wip, *.htm and *.txt file).

is used to discard the entries and to close the window.

is used to confirm the entries and to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 158

3.4.4.10 Print
This function is used to print the teach program loaded in the Teachbox to either a
UNICODE-textfile *.TXT or an HTML-file *.HTM on the USB stick. Path and name of the
file are selectable. The default folder is D:\ROBOT\PRINT. The generated file can be
opened, displayed and printed with a PC.

Fig.: Window to print a teach program to a file

The button right next to the field for the filename is used to select the type of file for
printing:

activates printing to a textfile

activates printing to an HTML-file

The field Save in displays the path of the current folder.

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a textfile *.TXT

for an HTML-file *.HTM

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 159

Only files of the same type as selected for the printout will be displayed.

The field Filename suggests the last filename used or the teach program name as
filename. After tapping the field you can use the dialogue for text input to change the
filename as desired. By tapping it in the display of the current folder, you can also use
the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to save the printout to the current folder, applying the name from the
field Filename.

is used to abort the function and close the window.

Before storing is executed, a check is made to see whether a file of the same name is
already stored in the selected folder, and a checkback message may appear.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 160

3.4.4.11 Exit to Main

This function can also be called with the button , and is used to exit the editor.

If the teach program in the editor is different than the one in the robot, then it is possible
to select whether or not the program shall be transferred from the Teachbox to the robot:

This is necessary to enable execution of the program.

A progress bar will be shown during the process.

With the appropriate setting of the option Clear counters in the Init Menu
Setup: Robot Settings requests about resetting counters and placing programs will pop
up:

The program previously stored in the robot will be irretrievably overwritten, if the program
from the Teachbox is transferred to the robot.

See also: 3.4.6.6 Counter Definition

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 161

3.4.4.12 Properties Window of the File Dialogue

Here the properties of the teach program selected in the file dialogue are displayed.

Fig.: Window for properties of a stored program

Name of Teach program

Shows the name of the selected teach program. This name is not necessarily the same
as the file name of the program.
CPU = Teachbox or CPU <> Teachbox
Displays whether the selected teach program and the one in the robot (CPU) are equal
or unequal.
Tooldata
Displays the Tooldata text of the selected teach program. The text for Tooldata can only
be edited in the properties window of the text editor.
Size
Displays the size of the selected teach program. The maximum size of a teach program
is limited to 32.768 bytes.
Primus Robot: max. 1000 lines
Number Part Programs
Shows the number of part programs of the selected teach program: ROBOT-PRG, PERI-
PRG, ROBOT-REF, PERI-REF, ALLMODE-PRG and up to 115 additional part
programs.
Primus Robot: only ROBOT-PRG and ROBOT REF PRG available
Number Placing Programs
Shows the number of placing programs used in the selected teach program. The
maximum number of placing programs available in a teach program is limited to 16.
Primus Robot: 2 Placing Programs available

If a picture has been associated with the selected teach program, can be used to
open the picture viewer.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 162

can be used to email the teach program by means of the manual email function
of the robot as an email attachment (*.wip, *.htm and *.txt file).

is used to exit the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 163

3.4.4.13 Picture Viewer

Here the picture associated with the teach program can be viewed, provided that the
storage medium containing the associated picture is available.

The picture viewer can be accessed in the properties windows of the teach program

using the button .

Fig.: Picture viewer showing a picture

If the picture is too big, it can be moved horizontally and vertically using the sliders.

Associating a picture to a teach program is only possible, if the respective properties

window has been opened with the menu File / Properties inside one of the editors.

is used to return to the properties window.

3.4.4.13.1 Associate a picture with a Teach program

In order to be able to associate a picture to a teach program, first the properties window

must be opened with the menu File / Properties inside one of the editors. Now the
is used to open the picture viewer.

Here the button opens the file dialogue for selecting a picture.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 164

Fig.: Dialogue for selecting a picture

The following file formats are supported:

 BMP files with 256 colors
 BMP files with 24 bits color depth
 GIF files with 256 arbitrary colors
 JPG files (not all compression rates and color depths)

The icons used by the display of the contents of the current folder include the following:

for a sub-folder

for supported picture files.

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 165

associates the selected picture with the teach program.

is used to abort the function and to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 166

3.4.5 EDIT Menu

3.4.5.1 Selection Mode

The option Selection Mode On/Off is used to switch on or switch off the selection mode
of the text editor. The selection mode is needed to mark several program lines.

When the selection mode is off, single program lines can be selected by tapping on them
in the editor window. The currently selected line is displayed on a gray background.

Fig.: a single selected line

If the selection mode is activated now, the selection can be expanded to several lines,
by tapping the last line to be included to the selection.

Fig.: several selected lines

The block of lines being selected this way, can now either be moved or copied via the
clipboard, or can be exported to a storage medium as a macro.

could be used to delete the selected lines.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 167

3.4.5.2 Copy, Cut, Paste

Using these functions of the Edit menu you can copy or move previously selected
program lines to a different location in the program via the clipboard.

Copy
The function Copy copies the selected lines to the clipboard.

Program Clipboard

Fig.: Copy

Cut
The function Cut moves the selected lines to the clipboard and deletes them at their
original position in the program.

Program Clipboard

Fig.: Cut

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 168

Paste
The function Paste copies the lines, which were previously put to the clipboard, from the
clipboard to back to the program just before the selected line. In the example shown
below, the block of lines 2 has been previously cut out between blocks 1 and 3, and is
now inserted behind block 3.

Program Clipboard

Fig.: Paste

If labels or subroutines are copied, they are automatically renamed to LABEL_xxx or

SUBR_xxx. "xxx" represents a 3 digit number.

If an associated JUMP instruction is copied together with its label, the JUMP instruction
will also be changed to the new label name. The same applies to CALL instructions that
are copied together with their subroutines.

If a placing program is copied, it will automatically be renamed with the name of the first
unused placing program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 169

3.4.5.3 Search-Toolbar
Use the option Show Search-Toolbar of the EDIT menu to activate or deactivate the
display of the Search-Toolbar of the text editor. The Search-Toolbar is used to search
for arbitrary text in the Teach program.

Fig.: Search-Toolbar

After tapping the input field use the dialogue for text input to input the desired search
text.

Use to access a list with previously used search texts.

Use to find the next occurrence of the search text before the current cursor position
in the Teach program.

Use to find the next occurrence of the search text after the current cursor position
in the Teach program.

Use to remove the Search-Toolbar from the display.

Use to open the window for the settings of the Search Toolbar.

Fig.: Window for the settings of the Search Toolbar

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 170

Search through entire program

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

In all part programs

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

Start search at begin of program

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

Direction upwards / downwards

The search will be performed in the selected direction.

Press to recall the standard settings.

3.4.5.4 Show Prefixes

Use the option Debug - Show Prefixes of the EDIT menu to activate or deactivate the
display of prefixes before the names of elements in Teachcommands. Displaying
prefixes can increase the readability of a teach program, especially if the user has given
similar or equal names to different kinds of elements.

Example:

As they deal with the same function, an Autoswitch, a peripheral output and a counter
have been given the same custom name "EXAMPLE".

Without prefixes a snippet of that Teach program would be displayed by the text editor
like this:

IF EXAMPLE = ON
EXAMPLE: ON
EXAMPLE = EXAMPLE + 1
ENDIF

With prefixes, the same snippet would result in this display:

IF ASW_EXAMPLE = ON
PO_EXAMPLE: ON
CNT_EXAMPLE = CNT_EXAMPLE + 1
ENDIF

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 171

3.4.5.5 Show Default Names

Use the option Debug - Show Default Names of the EDIT menu to activate or deactivate
the display of standard names in parentheses after the current names of elements in
Teachcommands. Displaying standard names can increase the readability of a teach
program, especially if the user has given similar or equal names to different kinds of
elements.

Example:

As they deal with the same function, an Autoswitch, a peripheral output and a counter
have been given the same custom name "EXAMPLE".

Without standard names a snippet of that Teach program would be displayed by the text
editor like this:

IF EXAMPLE = ON
EXAMPLE: ON
EXAMPLE = EXAMPLE + 1
ENDIF

With standard names, the same snippet would result in this display:

IF EXAMPLE(Autosw-01) = ON
EXAMPLE(PO-001): ON
EXAMPLE(Counter-001) = EXAMPLE(Counter-001) + 1
ENDIF

3.4.5.6 Show Internal IDs

Use the option Debug - Show Internal IDs of the EDIT menu to activate or deactivate
the display of internal IDs in parentheses after the current names of Placing Programs.

Example:

Without internal ID a Placing Program with the name EXAMPLE will be displayed in the
text editor like this:

Placing Program: EXAMPLE

With internal ID the same Placing Program will be displayed in the text editor like this:

Placing Program: EXAMPLE(ID 000)

3.4.5.7 Show Line Numbers

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 172

3.4.5.8 Show Execution Times

Use the option Debug - Show Execution Times of the EDIT menu to activate the display
of the actually measured execution times of each command of the teach program.

Fig.: Display of execution times

The times displayed are being refreshed with every execution of the respective command
line.

t=??????? indicates that the respective command line has not been executed yet.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 173

3.4.6 Teach program Settings in the SETUP Menu

3.4.6.1 Online / Offline Editor

This is to switch between Offline and Online Editor.

The Offline Editor is used to edit a teach program without the robot.

See also:
3.4.1.4 Online Editor
3.4.1.5 Offline Editor
3.4.1.6 Online Conversion

3.4.6.2 Axes Definition

Primus Robot: not available

Here you can assign the axes controlled by the robot control unit to the different part
programs and paths for automatic operation.

Fig.: Window for axes definition

Using the selection field Part Program the respective axis can be assigned to a specific
part program. The movements of that axis are then controlled by this part program only.

With a at the option Included in path the respective (numerical) axis is included to
the path calculation. This enables the axis to be moved coordinated together with the
other path axes of the respective part program using 3D and Curve movements.

discards the entries and closes the window.

confirms the settings and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 174

3.4.6.3 Safety Areas

Fig.: 3d view of a typical simple safety area configuration

including the working area

The R8.3 gives the possibility of setting up Teach program specific safety areas to
prevent the robot from crashing obstacles in all operating modes, except Reference
Missing. This is achieved by creating several overlapping, box-shaped, inclusive areas,
in which the robot can move safely. Every attempt to exit the resulting safety area will
make the robot stop at the border of the area and trigger an error message.

Furthermore, there is the possibility to use exclusionary areas to exclude box shaped
regions from the working area of the robot.

Individual safety areas can be activated dependent on the state of an input or output of
the robot.

A peripheral output can be switched on, when the robot is situated inside or outside a
certain safety area.

All settings for the safety areas of the robot are done in the Setup menu Safety Areas.
The safety areas will be automatically stored and loaded as part of the respective Teach
program. When you create a new program, you can choose to keep the safety areas of
the currently loaded program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 175

Fig.: Setup menu safety areas with working area and example areas

The Working Area is always present. It is defined by the Stroke Limits of the robot.

is used to create a new safety area.

is used to edit the selected safety area.

When you press with the working area selected, the window for setting the
visibility of the working area in the graphical display will be opened.

is used to delete the selected safety area.

is used to copy the selected safety area. The dialog for editing the new safety
area will pop up.

is used to open the graphical display of the safety areas.

is used to close the window.

The safety areas of the R8.3 are Teach program specific. A new safety area or changes
to an existing safety area will only become valid after the Teach program has been
transferred to the CPU!

The safety areas of the R8.3 are inoperative in operating mode Reference Missing!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 176

3.4.6.3.1 Create / Edit Safety Areas

Fig.: Window to edit safety areas

Activate each single axis coordinate From / To with a , and approach them one after
the other to create the desired box-shaped safety area.

The desired name for the safety area can be entered after tapping the field Name using
the dialogue for text input.

The safety areas of the R8.3 are inclusive by default. This means, that as soon as at
least 1 area has been defined, the robot is only allowed to travel within the defined areas.
With a at the option exclusionary you can also define exclusionary areas. The robot
is not allowed to enter exclusionary areas.

Use the option Activate on to activate the safety area dependent on the state of an input
or output of the robot.

Use the option Set Output to switch on a peripheral output, when the robot is situated
inside or outside the safety area.

discards the entries and closes the window.

confirms the safety area and closes the window.

The safety areas of the R8.3 are Teach program specific. A new safety area or changes
to an existing safety area will only become valid after the Teach program has been
transferred to the CPU!

The safety areas of the R8.3 are inoperative in operating mode Reference Missing!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 177

3.4.6.3.2 Properties of the Working Area

Here you can set the visibility of the working area in the graphical display of the safety
areas.

Fig.: Window for properties of the working area

Working Area Color

Shows the color of the working area.

Working Area Transparency

With the dialogue for numerical input enter the percentage of transparency used for the
working area in the graphical display of the safety areas. The higher the value, the more
transparent the working area will be; and the more clearly visible the safety areas will be,
when displayed together with the working area.

Visible
Use this option to decide whether the working area will be shown in the graphical display
of the safety areas or not.

discards the settings and closes the window.

confirms the settings and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 178

3.4.6.3.3 Graphical Display of the Safety Areas

The graphical display of the safety areas can be opened either in the View menu Safety

Areas or in the Setup menu Safety Areas using the button .

It graphically displays the safety areas and the working area of the robot.

Fig.: Window showing the 3D view

Fig.: Window showing the projected views

Press to turn the transparency of the areas on or off.

Press to toggle between 3D view and projected views.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 179

Press to reset the 3D view.

Press , or to select the action to be carried out, when dragging on

the display area or when pressing or .

Press followed by , or to define in which axes the previously

selected action will work, when triggered with or . Multiple selections are
possible.

Press to quit the graphical display.

See also:
3.4.6.3 Setup Menu: Safety Areas
3.3.4.5 View Menu: Safety Areas

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 180

3.4.6.4 Cylinder Definition

The cylinder function is useful to ease the teaching of pneumatic cylinders by combining
two peripheral outputs to a cylinder. Additionally you can use two peripheral inputs and
a time limit to monitor the correct function of the pneumatic cylinder. Does the cylinder
not approach the respective target position within the set time limit an error message will
be displayed on the teachbox.

Up to 255 such cylinders are possible in one teach program.

A cylinder consists of:

 1 to 2 peripheral outputs (O1, O2).
O2 is optional, and negates the status of O1.
 0 to 2 peripheral inputs (I1, I2) for acknowledging or
monitoring the action controlled by O1/O2 (optional),
where I1 always acknowledges O1 and I2 always acknowledges O2.
 A limit for the time that is allowed to elapse between
setting of Ox and acknowledgment of Ix.
Only if inputs are used.

If no cylinders have been defined previously, the editor will directly jump to the function
to edit cylinders. If any cylinders are defined already, the dialogue Cylinder Definition
will be shown.

Fig.: Dialogue Cylinder Definition

is used to create a new cylinder.

is used to edit the selected cylinder.

is used to delete the selected cylinder, if it is not applied in the teach program.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 181

3.4.6.4.1 Create / Edit Cylinders

This is to edit an existing cylinder or to create a new one.

Fig.: Window to edit a cylinder

After tapping the respective input fields you can pick the desired peripheral outputs and
peripheral inputs from selection windows.

If any conflict happens to occur because of some PO or PI being already used by the

current or any other cylinder, the icon will be shown next to the affected input or
output. The status field on the left bottom of the window will contain a description of the
conflict.

If inputs for position feedback are defined, it is possible to enter a time limit for the
movements of the cylinder after tapping the input field Timeout. The desired time is
entered using the dialogue for numerical input. If no inputs are defined, the timeout must
be set to zero.

A name for the cylinder can be entered after tapping the input field Name using the
dialogue for text input.

discards the entries and closes the window.

confirms the cylinder and closes the window.

See also:
3.5.5.3.1 Applying cylinders in a teach program
3.5.5.3 Cylinder function

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 182

3.4.6.5 Auto Switch Definition

Here the basic settings for the AutoSwitches can be done:

Fig.: Setup Menu - AutoSwitch Definition

and are used to define if the selected AutoSwitch has to act like a switch
(maintained contact) or like a key (momentary contact).

is used to reset the selected AutoSwitch to the factory settings.

is used to reset all AutoSwitches to the factory settings.

is used to open the setup window of the selected AutoSwitch:

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 183

Fig.: Setup window of an AutoSwitch

Current Name
This is the name of the AutoSwitch. That name is not only displayed on the AutoSwitch,
but also used as an identifier for the AutoSwitch in the Teach program. After tapping the
input field, the name can be altered using the dialogue for text input.

Current Type
Activating the desired option selects whether the AutoSwitch has to act like a switch
(maintained contact) or like a key (momentary contact).

Current Image
This is the picture that will be shown on the AutoSwitch. Tapping the input field will
display a list with the available pictures already stored in the Teachbox:

Fig.: selection list for AutoSwitch pictures

Tap on the name of the desired picture to select it.

can be used to import pictures from the USB stick for display on the
AutoSwitches. Once imported, the pictures are available for all AutoSwitches in all Teach
programs permanently.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 184

Imported pictures not exceed a width of 190 pixels and a height of 64 pixels. The
recommended size is 64 x 64 pixels - as the standard picture. The following file formats
are supported:

 BMP files with 256 colors (recommended)

 BMP files with 24 bits color depth
 GIF files with 256 arbitrary colors
 JPG files (not all compression rates and color depths)

can be used to remove the current picture from the memory of the Teachbox.

discards the entries and closes the window.

confirms the settings and closes the window.

An AutoSwitch will be displayed only if it is actually used in the Teach program in the
robot.

See also:
3.5.10 AutoSwitches
3.5.7.8.6 Jump condition AutoSwitch
3.3.4.13 View Menu: AutoSwitch

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 185

3.4.6.6 Counter Definition

Here you can set for the 64 counters of the Teachprogram, whether they will be visible
in the WIBA QuickLook App, and if they are “permanent“.
Primus Robot: 10counters available

Fig.: Window for Counter Definition

indicates that for the respective counter the setting is inactive.

indicates that for the respective counter the setting is active.

Use to decide whether the selected counter will be shown as a Program Value in
the WIBA QuickLook Smartphone App or not.

Use to decide whether the selected counter shall be “permanent” or not.

Permanent means that this counter will neither be cleared when powering up the robot,
nor when transferring a program – regardless of the settings in Init – Setup: Robot
Settings. The value of a permanent counter can also not be manipulated using the
manual function for counters.

discards the settings and closes the window.

confirms the settings and closes the window.

See also:
3.5.6 Counters
3.5.7.8.1 Condition: Counters

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 186

3.4.6.7 Counter Names

Here you can rename the 64 counters of the teach program. The name of a counter
should describe its function as good as possible, in order to ease understanding the
teach program.
Primus Robot: 10 Counters

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the counters can be different in every program.

Fig.: Window for counter names

is used to rename the selected counter. The name is entered using the dialogue
for text input.

renames the selected counter to its standard name.

renames all 64 counters to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.6 Counters
3.5.7.8.1 Condition: Counters

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 187

3.4.6.8 Conveyor Names

Here you can rename the conveyors controlled by the robot control unit. The name of a
conveyor should describe its function as good as possible, in order to ease reading the
teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the conveyors can be different in every program.

Fig.: Window for conveyor names

is used to rename the selected conveyor. The name is entered using the dialogue
for text input.

renames the selected conveyor to its standard name.

renames all conveyors to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.5.1 Conveyor

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 188

3.4.6.9 Peripheral Output Names

Here you can rename the peripheral outputs controlled by the robot control unit. The
name of a peripheral output should describe its function as good as possible, in order to
ease reading the teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the peripheral outputs can be different in every program.

Fig.: Window for PO names

is used to rename the selected peripheral output. The name is entered using the
dialogue for text input.

renames the selected peripheral output to its standard name.

renames all peripheral outputs to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.5.2 Peripheral Outputs

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 189

3.4.6.10 Peripheral Input Names

Here you can rename the peripheral inputs used by the robot control unit. The name of
a peripheral input should describe its function as good as possible, in order to ease
reading the teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the peripheral inputs can be different in every program.

Fig.: Window for PI names

is used to rename the selected peripheral input. The name is entered using the
dialogue for text input.

renames the selected peripheral input to its standard name.

renames all peripheral inputs to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.7.8.3 Condition: Peripheral Inputs

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 190

3.4.6.11 Stacking Sensor Names

Here you can rename the stacking sensors used by the robot control unit. The name of
a stacking sensor should describe its function as good as possible, in order to ease
reading the teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the stacking sensors can be different in every program.

Fig.: Window for stacking sensor names

is used to rename the selected stacking sensor. The name is entered using the
dialogue for text input.

renames the selected stacking sensor to its standard name.

renames all stacking sensors to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.7.8.11 Condition: Stacking Sensor
3.5.1.3.8 Axis Command: Stacking Sensor

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 191

3.4.6.12 Stopwatch Names

Here you can rename the 4 stopwatches of the teach program. The name of a stopwatch
should describe its function as good as possible, in order to ease reading the teach
program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the stopwatches can be different in every program.

Fig.: Window for stopwatch names

is used to rename the selected stopwatch. The name is entered using the dialogue
for text input.

renames the selected stopwatch to its standard name.

renames all 4 stopwatches to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.9.5 Stopwatch

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 192

3.4.6.13 Vacuum Names

Here you can rename the vacuum circuits controlled by the robot control unit. The name
of a vacuum circuit should describe its function as good as possible, in order to ease
reading the teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the vacuum circuits can be different in every program.

Fig.: Window for vacuum names

is used to rename the selected vacuum circuit. The name is entered using the
dialogue for text input.

renames the selected vacuum circuit to its standard name.

renames all vacuum circuits to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.5.4 Vacuum

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 193

3.4.6.14 Gripper Names

Here you can rename the grippers controlled by the robot control unit. The name of a
gripper should describe its function as good as possible, in order to ease reading the
teach program.

The names are always valid for the teach program loaded in the Teachbox. This means
the names of the grippers can be different in every program.

Fig.: Window for gripper names

is used to rename the selected gripper. The name is entered using the dialogue
for text input.

renames the selected gripper to its standard name.

renames all grippers to their standard names.

For easier distinction of different kinds of elements you can activate the display of
prefixes or default names.

is used to close the window.

See also:
3.5.5.6 Gripper

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 194

3.4.6.15 Vacuum Reference States

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

Fig.: Window for vacuum reference states

means the reference state of the vacuum circuit is ON.

means the reference state of the vacuum circuit is OFF.
means the reference state of the vacuum circuit is not checked.

changes the reference state of the selected vacuum to ON.

changes the reference state of the selected vacuum to OFF.

sets the reference state of the vacuum to NOT CHECKED.

, or are used to set the reference states of all vacuum circuits to the
state of the selected one.

discards the entries and closes the window.

confirms the settings and closes the window.

See also:
3.5.5.4 Vacuum

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 195

3.4.6.16 Gripper Reference States

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

Fig.: Window for gripper reference states

means the reference state of the gripper is OPEN.

means the reference state of the gripper is CLOSED.
means the reference state of the gripper is RELEASED.
means the reference state of the gripper is not checked.

changes the reference state of the selected gripper to CLOSED.

changes the reference state of the selected gripper to OPEN.

changes the reference state of the selected gripper to RELEASED.

sets the reference state of the selected gripper to NOT CHECKED.

, , or are used to set the reference states of all grippers to the

state of the selected one.

discards the entries and closes the window.

confirms the settings and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 196

See also:
3.5.5.6 Grippers

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 197

3.4.6.17 Setup Standard Vacuum Pressure

Here you set the threshold under-pressure that is used by the vacuum monitoring and
the condition vacuum to determine whether the parts on the respective vacuum circuit
are sucked on or not. This threshold must be set for every product or Teach program.
The settings for vacuum pressure will be automatically stored and loaded as part of the
respective Teach program.

This setting is not valid, when the threshold has been set to a different value than
STANDARD with the Vacuum Level command in the Teach program.

The suggested method for doing the pressure setting is:

1) Select the desired vacuum circuit by tapping on the respective scale, then switch it

on using the button .

2) Put all parts onto all suction cups of the vacuum circuit.

3) Use the slider and the up/down buttons on the right side of the window to set the
threshold to a value just smaller than the displayed value of the current under-
pressure.
4) Tap the field Warning and enter a value for the warning threshold (deterioration of
the vacuum cup) using the dialogue for numerical input.

Fig.: Display with part on the vacuum and the

threshold set

The big bar and the field below the scale show the current under-pressure, the small
bar and the number right next to it display the set threshold. At a correct setting the big
bar must be located in the green area of the scale, when all parts of the vacuum circuit
are sucked on.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 198

5) Remove one part from one suction cap of the vacuum circuit.

Fig.: Display with a part missing on the vacuum and

the threshold set

At a correct setting, now, the big bar must be located in the red area of the scale, and
the field below the scale must be red, too. If this does not apply, the setting of the
threshold under-pressure must be adapted accordingly.

Fig.: Display with a part on the vacuum and

the threshold in the warning range

In case the vacuum suction cup can due to deterioration not reach the required vacuum
level, the value will drop into the yellow area of the scale and the pressure field will
become yellow as well. When the vacuum valve has done 10 cycles of operation
without reaching the required pressure the following error message will pop up:

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 199

Fig.: Error vacuum cap leaky

This error will disappear as soon as the correct vacuum level can be reached again.

After a successful setting you can switch off the vacuum circuit using the button .

discards the entries and closes the window.

confirms the settings and closes the window.

See also:
Vacuum
Vacuum monitoring
Condition: vacuum

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 200

3.4.7 Part program Settings in the PART PRG SETUP menu

3.4.7.1 Positions
Up to 255 different axis positions for the robot can be predefined here in each part
program. This is especially advisable for positions that are approached fairly often at
various locations in the teach program. In addition, offline teaching is made easier.

The predefined positions can be called up later using the selection field Position in the
windows of the axis commands.

If no positions have been defined previously, the editor will directly jump to the function
to Create New Positions. If any positions are defined already, the dialogue Positions will
be shown.

Fig.: Dialogue for Positions

is used to create a new position.

is used to edit the selected position.

is used to delete the selected position, if it is not applied in the teach program.

After activating an axis with a this selected axis can be moved to its target within the
selected position.

is used to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 201

3.4.7.1.1 Create / Edit Positions

Here you can edit an existing position or create a new one.

Fig.: Window to edit positions

Each single axis is activated with a and is moved one after the other until the robot is
on the desired position.

The desired name for the position can be entered after tapping the field Position name
using the dialogue for text input.

discards the entries and closes the window.

confirms the position and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 202

3.4.7.2 Labels and Subroutines

This displays a list of all the labels and subroutines that exist in the respective part
program.

Fig.: Window for labels and subroutines

For each label (subroutine) the line number is displayed and the number of references
to it.

is used to rename the selected label (subroutine). The desired name is entered
using the dialogue for text input. Commands accessing the renamed label (subroutine)
are changed accordingly automatically.

is used to close the window.

See also:
3.5.7.2 Label
3.5.7.4 Call - Subr - Ret

3.4.7.3 Placing Program

Refer to Placing Programs.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 203

3.5 Teach Commands Of The Texteditor

3.5.1 Axes

3.5.1.1 Axes Selection

At robots with secondary axes press the axis button longer, if you want to display the
buttons for toggling between main axis and secondary axis.

3.5.1.2 Terminology

3.5.1.2.1 Pneumatical Axes

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

3.5.1.2.2 Numerical Axes

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

3.5.1.2.3 Path Axes

Path axes are numerical axes which are included in a path axes calculation of a part
program. Path axes of the same part program can be move coordinated with each other
using 3D and Curve movements.

The main axes X, Y, Z of a standard robot are included in the path axes calculation of
the robot program Robot Prg. by default.

You can assign numerical axes to the path axes calculations of the different part
programs of the current Teachprogram using the Setup menu Axes Definition.
Primus Robot: Menu Axes Definition not available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 204

3.5.1.3 Move

This tab provides teach commands to teach movements of the selected axes.

What kinds of movements are available is depending on the kind of drive of the axis and
if it is a path axis.

After selecting the kind of movement, the axis is moved to the desired target position
using the drive keys.

Fig.: Buttons for moving axes

If there are predefined positions available, alternatively one of these positions can be
picked from the selection list. In this case the axis is taken to the selected positions using
the buttons shown below. The axis will stop automatically when it has reached the
position.

Fig.: Buttons to move axes to predefined positions

Whether the numerical axes can be moved using variable or fixed manual speeds is
being set in the Init Menu Setup: Robot Settings.

is used to confirm and write the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 205

3.5.1.3.1 Absolute Movement

Absolute

This instruction is used to approach a particular position with the corresponding axis.

3.5.1.3.2 Relative Motion

Relative

If a position was approached with a numerical axis, this function can be used to move
the axis relative to this position. This instruction is identified by the letter " R" after the
position entry.

Example:
Z: 500.0
X: 100.0
Z: 100.0R

With the Z axis, move to position 500.0 mm, and with the X axis, to position 100.0 mm.
Starting from this position, move the Z axis to position Z = 600.0 mm. Now if the first Z
position is modified, the second Z position will also shift by the same value, but the
distance between the two positions will remain constant and exactly 100.0 mm.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 206

3.5.1.3.3 Parallel Movements

A parallel movement is the simultaneous motion of several axes.

As a parallel command simply causes command processing to acknowledge the

command before its execution is finished, for a coordinated ending of all previously
started commands you have to use a WAIT SYNC command after every parallel
movement. This ensures that all previously started commands have to be finished before
the next command is executed.

The parallel commands are not available for path axes. You have to use 3D movements
to execute simultaneous movements with several path axes.

Two kinds of parallel movements are available:

 Synchronous
 Parallel At

3.5.1.3.3.1 Synchronous

Synchronous

When this instruction is started, the following (travel) instruction is also started
simultaneously.

Synchronous parallel motion is identified by the symbol " *" after the position to be
approached.

Example:
C: 0.0*
A: 0.0
WAIT SYNC

The A and C axes are started simultaneously and are moved to their 0 position. The
instruction WAIT SYNC ensures that both axis motions are completed before the
program is continued.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 207

3.5.1.3.3.2 Parallel at

Parallel

This function is used to drive the respective axis alone to an intermediate position
(Intermediate Pos.). When this intermediate position has been passed, the next (travel)
instruction is started, while the axis continues traveling to its target position (Final
position) in parallel.

Fig.: Parallel at

To teach this command, first the Intermediate Pos. is activated by tapping it. Now the
axis is moved to the position, where when passing it in automatic mode, the next
instructions shall be started.

The next step is to activate the Final position by tapping it, and to move the axis to its
target position.

Now the command can be added to the teach program using .

is used to exit without changing the teach program.

Example:
Z: 500.0* 200.0
C: 90.0
WAIT SYNC

The Z axis will travel to the position 500.0, and from position Z = 200.0 the instruction C:
90 will be processed in parallel. The instruction WAIT SYNC ensures that both axis
motions will be carried to the end before processing of the program is continued with the
next instruction.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 208

3.5.1.3.4 Curve

Curve

With the curve function, the relevant position of a path axis is not approached, but is
passed using an adjustable radius R3D. The function is identified by the symbol "*"
before the respective axis.

Example:
*Z: 500.0
Y: 200.0

The position with the coordinates Z = 500.0 and Y = 200.0 is approached in one motion.
The Y axis is started around R3D before reaching the position Z = 500.

The curved movement can also be used to start a parallel motion of a non path axis
during the motion of a path axis when the path axis moves past a given position.

Example:
*Z: 500.0
C: 90.0*
Z: 1000.0
WAIT SYNC

The Z axis travels in one motion to the position 1000.0. When the Z axis travels past the
position 500.0, pivoting of the C axis is started in parallel. Parallel travels have to be
completed with a WAIT SYNC command.

Similarly, peripheral outputs for example can also be switched when a given position is
passed, without the motion of the axis concerned being affected.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 209

3.5.1.3.5 Stop

Stop

Processing of this instruction in automatic mode produces an immediate stop of the

selected numerical axis.

See also:
3.5.5.7 Vacuum Monitoring

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 210

3.5.1.3.6 Soft Torque Push

The Soft Torque Push function enables the robot to take out long parts with the
respective axis being pushed by the ejector.

The EOAT is moved to the piece and the piece is being fixed on the gripper already
before the ejector starts moving forward.

The PUSH command is used to start the ejector and to let the respective axis being
pushed by the ejector. This is done with adjustable torque assistance, thus eliminating
the resistance of the robot mechanicals.

From the Intermediate Position given by the command, the axis will use either
maximum velocity or the last measured velocity to travel to the target position. In the
second case, regarding the braking ramp of the ejector, the Intermediate Position
should be placed in a way to let the robot continue its travel with sufficient speed.

The permit for Ejector Forward must be turned off in the Teach program by the user.

The sequence for teaching (shown for the X-axis) is:

1) Use Absolute to select the X-axis.

2) Travel to the part removal position.

3) Confirm the command with .

4) Program everything that is necessary to take the part
(switch on vacuums, close grippers).

5) Use to select the Soft Torque Push function.

The following window will appear:

Fig.: Window for the Soft Torque Push function

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 211

6) Activate the option Intermediate Pos. and move the X-axis to the end position
of the ejector.
7) Activate the option Final position and move the X-axis to the final kick stroke
position in the mold, from which the vertical arm can be moved up and out of
the mold.
8) Use the value Assistance to set the amount of torque assistance from 0 to
120% of the base settings.
9) Use the options Vmax and Uniform velocity to decide whether the movement
from the intermediate position to the target position shall be carried out with
either maximum speed or the last measured (ejector-) speed.

10) Press to add the command to the program.

Example:

...
*Y: 1000.0 travel to the part
Vacuum-01 = ON
X: 600.0
WAIT Vacuum-01 = ON fix the part
X: 100.0 PUSH 300.0 (100%) travel synchronously with the ejector
PERMIT IMM:EJECTORS FORWARD!=OFF switch off Ejector Forward
...

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 212

3.5.1.3.7 Release (optional)

Release

The use of this function requires that the respective axis is equipped with a suitable
gearbox.

and are used to determine whether the command shall switch the axis
release on or off.

is used to add the command to the Teach program.

When the release is activated, the respective axis can be moved by auxiliary force.

After deactivating the axis release, the position of the axis will be controlled actively
again.

Example:

X: RELEASE = ON
FUNCTION IMM: EJECTORS FORWARD! WAIT
X: RELEASE = OFF

Here the X-axis is pushed by the ejector. The ejector is started after the axis has been
released. When the ejector has arrived at its most forward position, the axis release is
being deactivated again.

See also: 3.1.12.2 Axis Release in Manual Mode

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 213

3.5.1.3.8 Stacking Sensor (optional)

This function makes it possible to react to obstacles in travel of an axis by means of a

stacking sensor. The axis is traveled until either the stacking sensor is actuated or a
teachable maximum position is reached.

Fig.: Stacking Sensor

At first the desired Stacking Sensor is selected from the list box on the upper left of the
tab.

From Position: is the position that is first approached absolutely at the current speed;
this is where travel to the stacking sensor starts.

To Position: is the position at which stacking sensor travel ends when the stack sensor
is not activated during travel.

Each position has to be selected by tapping on it, and has to be approached with the
axis using the drive keys. Alternatively predefined positions can be selected.

Vabs: Absolute speed in mm/s, by which travel to the stacking sensor is carried out
between From Position and To Position. (is not affected by the override)

Current: shows the current position of the axis.

discards the changes and closes the window.

writes the command to the teach program and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 214

3.5.1.3.9 Find ´n´ Pick

With this function the axis will use one of the analogue vacuum monitors to search for
the part to take or for any other obstacle. This may be useful when approaching the
takeout position in molding machines with big tolerances on the mold open position. The
function is also an alternative for a “real” stacking sensor.

Fig.: Find ´n´ Pick

Use the list box on the upper left corner of the window to select the desired vacuum
circuit. During automatic operation the selected vacuum circuit will be automatically
switched on when execution of the teach command begins.
Vabs
Determines the absolute speed in mm/s used for the search movement.
(Not influenced by the Override)
Vac. Level
This is the trigger level used for the vacuum monitor of the selected vacuum circuit. When
the vacuum under pressure exceeds this level, the robot recognizes the part/obstacle
and stops the search movement. In order for the robot to recognize the part/obstacle as
early as possible, the value should be set as closely as possible above the value shown
for the empty vacuum circuit shown in the View menu Vacuum Pressure.
End position
Use the input box on the bottom of the window to determine the position where the
movement ends, if the trigger level of the vacuum monitor has not been exceeded during
the search. After tapping the input box, you can use the drive buttons to move to the
desired position. Alternatively you can select a predefined position.
Current
This shows the current position of the axis.

discards the entries and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 215

adds the command to the teach program and closes the window.

Example:
…
*Y: 567.8
*X: 234.5
X: 345.6 Vacuum-01 VABS = 100 Vacuum Level = 34%
Wait Vacuum-01 = ON
X: 123.4 PUSH: 200.0 (100%)
…

In this example the robot tries to find the part in a mold with a varying open position. It
uses the Find ´n´ Pick command to search for the part between X=234.5 and X=345.6.
After the robot has sucked on to the part (Wait Vacuum), it lets itself being pushed back
by the ejector using the Push command.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 216

3.5.1.3.10 Insert

This function makes it easier to insert parts into the mold. It is put into practice as the
axis is moved towards its insert-position with reduced velocity and less torque.

Vmax
From the Intermediate Position determined by the command, the axis will travel further
with reduced velocity to the determined target position. Insert-speed can be set from
1% to 20% of Vmax.

Reduced torque
Use the pull-down menu with its 4 predefined modes to adapt the torque value to your
application. Basis for these modes are the settings of the Softtorque ACD function,
which is active only in manual mode.

 Extra-Soft: equal to the settings of the Softtorque ACD function

 Soft: basic settings +10%
 Standard: basic settings +25%
 Powerful: basic settings +50%

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 217

Intermediate position
From the Intermediate Position given by the command, the axis will travel to its defined
target position with the prior defined parameters.

Target position
Use the input box on the bottom of the window to determine the position where the
insert-movement ends. After tapping the input box, you can use the drive buttons to
move to the desired position. Alternatively you can select a predefined position.

The parameters for the softtorque ACD-function are stored in a separate menu,
accessable only with an additional password. Changes to these parameters have to be
done ONLY by a Wittmann service technician or qualified technical staff.

discards the entries and closes the window.

adds the command to the teach program and closes the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 218

3.5.1.4 Enhanced Conveyor control

3.5.1.4.1 Follow Conveyor (optional)

Primus Robot: not available

Additional hardware for measuring the velocity of the conveyor is required for the Follow
Conveyor function.

The Follow Conveyor function enables the robot to follow a conveyor synchronously.
Thus the robot can place products on a moving conveyor, or take them away from there.

Abb.: Window for the Follow Conveyor commands

After opening the window in the text editor you can use the buttons and to
determine whether you want to create the command for starting the conveyor following
movement or the command for stopping the conveyor following movement.

discards the entries and closes the window.

adds the command to the teach program and closes the window.

The indications in parentheses (1, 2, 3, 4, 5, ALT) in the description of the Follow

Conveyor commands relate to the schematic of a conveyor following movement in the
figure further down this chapter.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 219

FOLLOW Conveyor-xx ON ALT Label

This command starts the conveyor following movement. The command will “wait” until
the robot moves synchronously with the conveyor (1 to 2). From this moment on, the
program will be executed parallel to the conveyor following movement (2 bis 5). For the
axes only relative movements are allowed during the conveyor following movement, they
will be executed additionally.

The robot will not travel to the positions P1 and P2 during the actual conveyor following
movement. The line between the coordinates of P1 and P2 only serves as a vector for
the direction of the conveyor following movement.

In order to teach program the positions P1 and P2, open the window for the Follow
Conveyor commands and activate every single axis position one after the other with a
. Use the axes drive buttons to move the currently activated axis until you reach the
desired position. Us two distant points for P1 and P2, located close above the same
border of the conveyor, in order to make the vector as parallel to the actual moving
direction of the conveyor as possible.

The normal plane of this vector at P2 is used as a limit for the conveyor following
movement. If the position of the robot touches this limit during the conveyor following
movement, the alarm 019-001-xxx Conveyor-xx FOLLOWING TARGET POSITON
REACHED will be triggered and the program will continue at the label for the alternative
routine. This will not stop the conveyor following movement; you will rather have to
program an escape movement in the alternative routine in order to make stopping
possible (ALT).

Thus the position of P2 should selected to enable the planned conveyor following
movement (1 to 5) to be finished before reaching the normal plane, and on the other side
leave enough space for the escape movement (ALT) of the alternative routine to be
finished before reaching the stroke limits.

For the label of the alternative routine you can either tap the input field Enter label to
input a new label using the dialogue for text input, or you can select an existing label
using the selection field Select Label.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 220

FOLLOW Conveyor-xx OFF

This command ends the conveyor following movement (5, ALT).

Fig.: Schematic of a conveyor following movement

Example:

A part is taken away from a continuously moving conveyor. The indications in

parentheses relate to the schematic of a conveyor following movement in the figure.

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

TOO_FAR: In case the conveyor following movement did

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 221

3.5.1.4.2 Conveyorbelt tact extension

Here, the settings, use and programming of the enhanced conveyorbelt control will be
explained. This feature is part of the robot since software-version R8.23.02.

To ensure complete functionality of this feature, changings in the parameter

settings have to be done by a Wittmann service-technician on site.

3.5.1.4.2.1 Requirements
Robot Software version R8.23.02 or higher, as well as Wittmann Configuration
software version 8.8.0.12, writing version Configuration file 21 or higher.

3.5.1.4.2.2 Function
The control of a conveyorbelt works independently and without a teach program.

In case an external button is connected, the conveyor will be operated every time the
button is pressed. The button – and further the operation of the conveyor – can be
locked or unlocked via a teach command. When switching to operating mode
MANUAL, the latch will be released automatically. This realease can also be
deselected. Furthermore it is possible to realize the button as illuminated pushbutton
and indicate the latch by a light-signal.

In case a light barrier is installed at the end of the conveyor, the belt can be stopped as
soon as a part treaches the end of the conveyor. This affects both, operating the
conveyor manually and via teach commands. When the light barrier is free again, the
conveyor will run as well. In case the conveyor is controlled by time, the time will be
halted. Using an output, it is possible to turn on a signal light as indication for the Stop-
status.

In the parameter settings it is possible to determine a conveyors behavior in case the

operating mode changes – regardless a button, light barrier etc. is installed or not. The
conveyor can be stopped, when switching into operating mode MANUAL. When
switching into BLOCKSTOPP, the conveyor can be stopped, also. The settings can be
determined for each conveyor separately and independently from the teach program.

These parameter settings have to be carried out by a Wittmann service-

technician on site.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 222

3.5.1.4.2.3 Manual Operation

Choose on the mainscreen the button Conveyor to show the state and also operate the
conveyor manually.
In the menu Info – I/O the physical signal states are indicated.

The different states will be shown by following indication – icons:

Symbol conveyor state:

Conveyor is OFF
Conveyor is ON

the conveyor has been stopped during BLOCKSTOPP - mode

the conveyor has been halted, because of parts interrupting the light barrier

Symbol Conveyor button state:

conveyor pushbutton is not operated

conveyor pushbutton is operated

conveyor pushbutton is latched by Teachcommand

3.5.1.4.2.4 Teachcommands
According to the conveyor and the configuration of In- and Outputs, following
commands are available.

3.5.1.4.2.5 Conditions
Conditions will be realized using the commands WAIT, IF,ELSEIF, JMP and CALL.

Conveyor belt: The condition indicates whether the conveyor is running or not. This is
a logical signal, which also shows an operation of the conveyor, in case it had been
stopped by the input Conveyor light barrier interrupted, but should be running.

Syntax:
{WAIT | IF | ELSEIF | JMP Label | CALL Subr} Conv-01 = {ON | OFF}

Example:
Wait at the placing position until the conveyor has stopped completely, especially in
case the conveyor had been stopped by an interrupted light barrier.

*X: 275.0 Z: 60.0

WAIT Conv-01 = OFF
Y: 460.0
Vacuum-01 = OFF
*Y: 0.0

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 223

Pushbutton: The condition indicates an operated conveyor pushbutton. This is the

direct input-signal. The pushbutton’s state can be requested in a part program – no
matter is it latched or not.

Syntax:
{WAIT | IF | ELSEIF | JMP Label | CALL Subr} Conv-01 BUTTON = {ON |
OFF}

Example:
Open Stopp-cylinders in MANUAL mode in the Allmode-program in order to completely
clear the conveyor.

WAIT Conv-01 BUTTON = ON

Cylinder -01: OFF

Light barrier: The condition indicates an interrupted light barrier at the end of the
conveyor belt (CLEAR = Signal ON, FULL = Signal OFF). It is the direct Input-Signal.

Syntax:
{WAIT | IF | ELSEIF | JMP Label | CALL Subr} Conv-01 CONV.END = {CLEAR
| FULL}

Beispiel:
WAIT Conv-01 CONV.END = CLEAR
Y: 460.0
Vacuum-01 = OFF
*Y: 0.0
Conv-01: BUTTON = CLEAR

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 224

3.5.1.4.2.6 Program sample:

Complete teachprogram including conveyor pushbutton and placing program.

0001 REM Drive to the IMM

0002 C: 0.0*
0003 X: 115.0 Z: 1832.3
0004 WAIT SYNC
0005 -
0006 REM Takeout of the IMM
0007 WAIT SGM: MOLD OPEN = ON
0008*Y: 403.0
0009 X: 193.3
0010 Vacuum-01 = ON
0011 FUNCTION IMM: EJECTOR FORWARD! WAIT
0012 WAIT Vakuum-01 = ON
0013 FUNCTION IMM: EJECTOR BACK!
0014*X: 115.0
0015 Y: 0.0
0016 PERMIT IMM: MOLD CLOSE! = ON
0017 -
0018 REM Drive to Placing Area
0019 C: 90.0*
0020 Z: 820.0
0021 WAIT BAHNSYNC
0022 Z: 737.2
0023 -
0024 REM Placing
0025 WAIT Conv-01 = OFF Wait until the conveyor has finished turning.

0026 Conv-01: Button = LATCH Conveyor must stand still.

0027 Placing program: Placingprg-001

0028 Vacuum-01 = OFF
0029 TIME = 0.50s
0030 Y: 0.0
0031 IF Placingprg -001 ZXY STACK READY Placing program is ready.
Conveyor pushbutton can be activated.
0032 Conv-01: Button = CLEAR Turn on conveyor at least until next position.
0033 Conv-01: ON 2.00 s
0036 ENDIF Start program from beginning.
0037 -

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 225

3.5.1.4.2.7 Renaming:

When renaming a conveyor, all related commands will be named accordingly:

{WAIT|IF|ELSEIF|JMP Label|CALL Subr} ConvLeft = {OFF|ON}

{WAIT|IF|ELSEIF|JMP Label|CALL Subr} ConvLeft BUTTON = {OFF|ON}
{WAIT|IF|ELSEIF|JMP Label|CALL Subr} ConvLeft CONV.END =
{CLEAR|FULL}
ConvLeft: BUTTON = {SPERREN|FREIGEBEN}
ConvLeft = {OFF|ON} [<Time> s]

Hardware

Necessary components besides the conveyor for complete implementation:

Illuminated pushbutton „Conveyor forward“ with red lamp and white calotte
at the end of the conveyor.

Yellow light indicator for indication „Conveyor full“ as sign to clear the
conveyor.

Light barrier at the end oft he conveyor. Output OFF when light barrier
interrupted.

3.5.1.4.2.8 Versions
The minimal version contains a normal pushbutton at the input “Conveyor-Button”.
Better will be an illuminated pushbutton. Without any pushbutton, the output “Conveyor
pushbutton blocked” will make no sense.
A light indicator for “Conveyor full” is an option, but will make the light barrier at the end
of the conveyor necessary.
The light barrier at the end of the conveyor can be implemented without pushbutton
and light indicator as well.

3.5.1.4.2.9 Wiring
Relating to the already existing connection for conveyor belts (PI-021 until PI-024 and
PA-021 until PA-025), which is wired to the plug A1+CON-X6, the mentioned plug can
be used for the signals described in chapter 6.1 and 6.2. For details refer to the relating
wiring diagram.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 226

3.5.1.4.2.10 Reverse Operation

In case the conveyor shall be operated in both directions, for reverse operation a
second conveyor has to be configured. This easy solution provides for each conveying
direction one Conveyor clear button, two Light indicators and one Light barrier. All
devices can be controlled and latched independently from each other.

3.5.1.4.2.11 Programming a conveyor pushbutton

In case the installed software version does not provide the conveyor pushbutton-
function, it can be realized in a teach program as well.
In this case, please note:

- Light barrier, light indicator and signal lamp cannot be implemented easily.
Complex programming will be necessary.

- Latching the pushbutton without any additional hardware can only hardly be
realized.

- The implementation of the conveyor pushbutton must not have an impact on

any other ON/OFF-commands concerning the conveyor.

- An Allmode-program will be necessary to provide the feature permanently.

Example for an Allmode-Programm:

0001 REM Conveyor pushbutton

0002 Loop:
0003 WAIT A(CONV 01) = ON Wait for sthg. relevant to happen.

0004 OR PO-001 = ON
0005 JMP Conv A(CONV 01)= OFF
0006 WAIT A(CONV 01) = OFF Wait for the conveyor to stop.
0007 JMP Loop
0008 -
0009 Conv:
0010 Conv-01: EIN 0.10 s
0011 TIME = 0.05 s
0012 JMP Conv PI-001 = ON
0013 JMP Loop

Necessary commands in the main program:

0025 WAIT A(CONV 01) = OFF Wait until the conveyor has stopped
turning.
0026 Placing program: Placingpr-001
0027 Vacuum-01 = OFF
0028 TIME = 0.50s
0029 Y: 0.0
0030 IF Placingpr -001 ZXY STACK READY
0031 Conv -01: ON 2.00 s
0032 ENDIF

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 227

It is NOT recommended to realize the above mentioned solution. The explained

example is suitable only for standard situations. A running conveyor during part placing
will not be preventable. To avoid this, complex programming will be necessary.

Solution with Allmode-program without any regard on the main program

0001 REM Conveyor pushbutton

0003 WAIT PI-001 = ON
0010 Conv -01: ON 0.10 s
0011 TIME = 0.05 s

All other conveyor commands will be terminated, when pushing the button!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 228

3.5.1.4.3 Mold Opening Synchronization (optional)

Mold Opening Synchronization (MOS) enables the robot to enter the mold during its
opening movement, thus saving valuable time.

A way measuring system the opening width of the mold of the IMM is necessary for this
feature.

The command WAIT MOLDPOSITION is used to wait until the mold has opened wide
enough for the robot to enter.

Now (normally) the X-axis can follow the moveable plate of the mold with a teachable
distance using the MOS command. The MOS command behaves like a synchronous
command (the respective axis is taken out of the pre-calculated path), enabling the
robot to enter the mold with the Y-axis simultaneously. The MOS command is
terminated by the signal Mold Is Open of the IMM.

Finally a WAIT SYNC command must be introduced to end the parallel movement.
This also includes the MOS-axis to the pre-calculated path again.

The two commands for mold opening synchronization are added to the program like
this:

WAIT MOLD POSITION

This is used to wait until the mold is opened wide enough for the robot to enter. After

accessing the command with Mold Position you have to

pick one of the operators <=, >=, <, >, <>, = to select whether you want to wait until the
actual position of the mold is equal, below or above the selected value. Move the Mold
of the IMM to the desired position to select the value for the command.

Press to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 229

RELATIVE TO MOLD
This axis command lets a robot axis (most likely X) follow the mold in a teachable
distance.

In order to teach the command, open the mold and access the command with

R to mold. Now move the robot to the desired distance from

the moving plate of the mold, which the robot should use to follow.

Press to add the command to the teach program.

Example:

...
X: 50.0 travel X to the waiting position over the mold.
WAIT MOLDPOSITION > 400.0 wait until the mold is opened sufficiently for the robot to enter
X: 100.0 R TO MOLD let the X-axis follow the mold with the chosen distance; and at the
same time execute the next commands
(like "synchronous").
Y: 800.0 travel Y to 800.0 mm (while X is following the mold).
WAIT SYNC wait until all axes (X and Y) have finished their movements.
...

The distance displayed within the MOS command does not show the actual value of
the distance between EOAT and mold plate, but shows the calculated difference
between the value measured by the measurement system for the width of the mold
opening and the value of the axis position.

The value displayed within the command WAIT MOLDPOSITION only relates to the
actual value of the width of mold opening, if the MOS-Offset has been adjusted for the
mold currently in use.

The measured value of the mold position must not change, when one of the signals
Mold Is Open or Mold Is Closed is active. This would trigger the error message Mold
Monitoring.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 230

3.5.1.5 3D Motions

In 3D motions, a position is approached simultaneously with the selected path axes.

3D-motions can be executed as

 3D-Absolute Motion
 3D-Curve
 3D-Relative Motion

Fig.: Window for 3D-Motions

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 231

can be used to open the window for selecting the path axes to
participate in the 3D movement.

Fig.: Axes selection for 3D commands

Use to confirm the selection.

Use to close the window and discard the selection.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 232

After selecting the type of motion, the position is approached with the participating path
axes. Use the window for 3D motions to activate every single axis with a and move
one after the other, using the drive keys, until the desired target position is reached.

Fig. Drive keys for numerical axes

When all axes are on target position, use to add the command to the teach
program.

Use to close the window, without changing the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 233

3.5.1.5.1 3D Absolute Movement

Absolute

In automatic mode, when processing this command, the path axes are moved to the
target position simultaneously in a straight movement.

3.5.1.5.2 3D Relative Movement

Relative

In automatic mode, when processing this command, the path axes are moved to the
target position simultaneously in a straight movement.

This function is identified in the teach program by the letter "R" after the axis coordinates.

The axis coordinates in this instruction are added to the axis coordinates of the starting
position of the axes, i.e., motion is executed relative to this starting position.

The position to which the relative motion is to refer must already have been taught before
this function is entered.

When the starting position is changed, the position that is approached with the 3D
relative motion is automatically changed as well. The distances between the two points
remain the same.

3.5.1.5.3 3D Curve

Curve

This function is identified in the teach program by the symbol "*" in front of the axis
coordinates.

In automatic mode, when this command is processed, the indicated position is bypassed
using the adjustable radius R3D and switched to the next instruction.

See also: 3.5.1.3.4 Curve

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 234

3.5.1.6 Velocity

This tab provides teach commands to set velocity and acceleration for subsequently
taught movements of the specific axis.

3.5.1.6.1 VMAX

Vmax

This function is used to set the maximum speed as a percentage of the configured
maximum speed of a numerical axis. The actual axis speed in automatic operation is in
addition affected by the Override. The Vmax instruction remains effective until the next
Vmax or Vabs instruction, and affects all subsequently taught motions of the axis
concerned.

The value of VMAX can be altered by moving the slider, or can be input using the
numerical Input after tapping the input field.

is used to confirm and write the command to the teach program.

3.5.1.6.2 VABS

Vabs

This function permits Override-independent speed setting in mm/s of a numerical axis

for adaptation to secondary motions (for example, ejector motion in piece transfer). The
Vabs instruction is effective until the next Vmax or Vabs instruction, and affects all
subsequently taught motions of the axis concerned.

The value of VABS can be altered by moving the slider, or can be input using the
numerical Input after tapping the input field.

is used to confirm and write the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 235

3.5.1.6.3 AABS

Aabs

This function permits the maximum acceleration or deceleration in mm/s² of a numerical

axis to be adjusted when the configured acceleration (deceleration) is too big for the
application.

This instruction is effective until the next AABS instruction and affects all subsequently
programmed motions of the respective axis.

The value of AABS can be altered by moving the slider, or can be input using the
numerical Input after tapping the input field.

is used to confirm and write the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 236

3.5.1.6.4 R3D

R3D

R3D is the radius for curve motions motion in mm. This is the distance before the taught
end position at which the motion of the next axis instruction is started.

The parameter has to be taught in the program routine before the 3D motion to be
affected.

The value of R3D can be altered either by using the slider, or by typing the value using
the numerical input dialogue after tapping the input field.

is used to confirm and write the command to the teach program.

3.5.1.6.5 V3D

V3D

This parameter limits the resulting path speed of path axes movements. The path speed
is the geometrical sum of the speeds of the involved single axes. The value of V3D is
given in mm/s.

V3D as a limiter overrules the settings performed with VMAX, VABS and the Override.

A limit set with V3D is valid until the next V3D command in the teach program. Without
a V3D command, the path speed in a teach program remains unlimited.

The parameter has to be programmed in the program sequence before the path axes
movement to be affected.

The value of V3D can be altered either by using the slider, or by typing the value using
the numerical input dialogue after tapping the input field.

is used to confirm and write the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 237

3.5.1.7 Wait Sync

Sync

This instruction is used to terminate parallel motions.

Program processing is stopped until all active axis motions have been completed.

3.5.1.7.1 Wait Path Sync

Path Sync

WAIT PATH SYNC is a version of WAIT SYNC especially designed for moving path
axes. The pre-calculation of the path axes is stopped until the last path-movement is
active and all other axes are no longer active.

If at the beginning of the curve radius of the path axes still any other axis is not in its
target position, the path axes will stop at their respective last target positions. The pre-
calculation will be continued after all other axes have reached their target positions.

Example:
*Y: 200.0
C: 90.0*
*Y: 0.0
*X: 0.0
*Z: 2000.0
WAIT PATH SYNC
*Z: 0.0

At Y=200 the synchronous movement to C = 90 is started. If the C-Axes reaches its

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 238

3.5.1.8 Movements and Parameters for Scara Robots

The „normal“ (3D) Motion commands are also available for Scara robots. Those
commands are used to move the robot within the spatial system of coordinates. With the
additional angular movements it is possible to move the axes of the robot outside the
spatial system of coordinates.

3.5.1.8.1 Pathmode

The Parameter Pathmode is used to determine how the robot moves to its target position.

The parameter has to be programmed in the program sequence before the movement
to be affected. A setting made with PATHMODE is valid until the next PATHMODE
command in the teach program.

Linear Mode:
The axes move to the target position coordinated in a way that the resulting movement
draws a straight line in the spatial system of coordinates. The single axes cannot move
with full speed. In linear mode the robot cannot change the bending orientation of its
elbow joint β.

Joint Mode:
The axes move optimized for speed. The resulting movement in the spatial system of
coordinates is not straight. Angular movements („in degrees“) will always be executed in
joint mode.

Select the desired mode by tapping it.

Press to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 239

3.5.1.8.2 Angular Motions - „in degrees“

Absolute in degree

Curve in degree

Use the angular motions to move the axes (joints) α, β, γ of a Scara robot outside the
spatial system of coordinates in angular degrees.

The angular motions are 3D-motions.

Angular motions will always be carried out in joint mode, regardless of the Pathmode set.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 240

3.5.2 Placing Programs

Placing Programs are used for the automatic calculation and approach of several
stacking positions. This makes it possible to stack parts without programming each
position separately.

The R8.3 control offers the following possibilities for this:

 16 freely definable placing programs Primus Robot: 2 Placing Programs

 up to 6 different placing sequences
 up to 6 different axis sequences
 approach of stacking positions with 3D function
 programmable box height
 programmable displacement
 approach stack sensors with adjustable speed
 stacking / un-stacking
 support of double arm robots Primus Robot: not available

Programming a Placing Program has to be done in two steps:

1) Creating the Placing Program.
2) Adding the created Placing Program as a command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 241

3.5.2.1 Create/Edit Placing Programs

For creating and editing of placing programs open the menu
Part Prg Setup – Placing Program. The dialogue for selecting existing placing
programs will be shown.

Fig.: Dialogue for selecting a placing program

In the selection list on the left side of the window you can select one of the existing
placing programs. The table Placing Program Information shows how many positions
in the different axes dimensions the selected placing program will travel to. If no placing
programs have been defined in the current teach program yet, the message "No placing
programs available" will be displayed instead of the selection list.

is used to create a new placing program.

is used to create a new placing program for a double arm robot that additionally
contains the parallel axes X2 and Y2. Prerequisite for this is that the parallel axes have
been added to the path in the current teach program.

is used to edit the selected placing program.

can be used to delete the selected placing program, if it is not used in the teach
program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 242

can be used to create a copy of the selected placing program. The dialogue for
text input will appear. Here you can input a name for the copy of the placing program, or

confirm the suggested standard name with .

When you create a new placing program, first the dialogue for axes selection will be
displayed.

Editing of the other parameters of the placing program will be done using five tabs:

1. ........................... Position of the first piece, Name

2. ........................... Number and distances of the other pieces
Options................... Axis sequence, placing sequence, 3D, box height
STS ........................ Stacking Sensor
Displacement ......... Displacement

The dialogue for axes selection and the tabs for stacking sensor and displacement will
not be displayed at a placing program for a double arm robot.

See also:
3.5.6.2 Reset Placing Counters
3.3.4.7 VIEW Menu: Placing Counters

3.5.2.1.1 Dialogue for Axes Selection

When creating a new placing program, this window is used to select the axes available
for the new placing program.

Fig.: Dialogue for axes selection

Select up to 3 axes to be used with the placing program with a .

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 243

Press to confirm the entries, the tab for the first stacking position will be
displayed next.

Press to cancel the process and discard the entries.

The dialogue for axes selection will not be displayed at a placing program for a double
arm robot.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 244

3.5.2.1.2 Tab 1. - 1st Position, Name

This tab is used to determine the stacking position of the first piece in the placing
sequence; furthermore the name of the placing program can be changed here.

Fig.: Tab for the 1st position

Tap the input field Name of placing program and input a name for the placing program
using the dialogue for text input.

After selecting one of the axes, you can move it to its previously programmed 1st stacking
position using the buttons for moving to an existing position.

If you want to change the axes positions for the first stacking position, first press the

button . Now select each axis and move it to its desired position, until all axes of
the robot are on their first stacking position.

You can also use the selection field on the right bottom of the window to recall a
predefined position for the first stacking position.

When all parameters on this tab are entered, either open the next tab by tapping it, or

accept the placing program by pressing .

Press to cancel the process and discard the entries.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 245

3.5.2.1.3 Tab 2. - Stacking Pattern

This tab is used to determine the stacking pattern.

Fig.: Tab for the stacking pattern

In order to determine the stacking pattern, for each axis the number of pieces to be
placed in the axis direction and the position of either the second or the last piece have
to be specified. The second or last position is calculated as a distance relative to the first
stacking position (this is indicated by the letter R after the positions).

When the first position is changed, the entire placing program will be shifted and the
stacking pattern remains intact.

Choose one of the axes and select whether you want to determine the position of the
second piece (2nd Pos.) or the position of the last piece (End Pos.) in the respective axis
direction.

Now move the axis to its desired position using the drive buttons.

When you activate the option Numeric Input you can input the positions using the
dialogue for numerical input without moving axes.

Finally tap the field Number of parts and use the dialogue for numerical input to input
the number of pieces to be placed in the respective axis direction.

With the option Keep gap constant the distance between stacking positions will be kept
constant automatically, when changing the number of parts in an existing placing
program.

When all parameters on this tab are entered, either open the next tab by tapping it, or

accept the placing program by pressing .

Press to cancel the process and discard the entries.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 246

3.5.2.1.4 Tab Options

This tab is used to set options about approach and placing order for the placing program.

Fig.: Tab for approach and placing order

Axis Order
This sequence will be used during automatic operation to move the axes to the current
stacking position.

Placing Order
This sequence will be used during automatic operation for going to the different stacking
positions.

Fig.: Example - Placing Order ZXY

3D
A at this option activates the 3D approach. The axes will move to their positions
simultaneously by means of a 3D motion. The parameters Box Height and Axis
Sequence make the last axis in the axis sequence end the 3D motion displaced at the
box height, and then travel into position alone. Otherwise, the robot would "move
through" the wall of the crate. R8.3 does not execute the 3D movements as a straight
line, but as a curve to box height. Use the option straight line to get a straight line.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 247

Box Height
This value depends upon the dimensions of the box. Select the axis to be moved into
the box. This has already been done in the Axis Sequence parameter; select an axis
sequence in which this axis is the last to be moved (e.g., ZXY for the Y axis). Move the
selected axis toward a position outside the box that can be approached without collision
(with a 3D motion). Box height will be used during single axis approach also, in order to
trigger the error message 170-007 – BOX CRASH MONITORING. If you do not want to
use box height, deactivate the option.

When all parameters on this tab are entered, either open the next tab by tapping it, or

accept the placing program by pressing .

Press to cancel the process and discard the entries.

3.5.2.1.5 Tab STS - Stacking Sensor

On this tab you can activate that the last axis of the axis sequence uses a stacking sensor
to approach the stacking positions. Above all this is helpful during un-stacking.

Fig.: Tab for a stacking sensor

With the selection field at the right top of the tab you can select which stacking sensor is
to be used. With the selection "000 - none -" the stacking sensor function is
deactivated, the axis will travel to the calculated position directly.

Offset
This is the distance from the calculated stacking position where the search movement to

the stack sensor shall start. After pressing , set the Offset by moving the respective
axis using the drive buttons.

Vabs
This is the absolute speed used for the stacking sensor search movement. After tapping
the input field, input the desired value using the dialogue for numerical input.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 248

When all parameters on this tab are entered, either open the next tab by tapping it, or

accept the placing program by pressing .

Press to cancel the process and discard the entries.

This tab will not be shown at a placing program for a double arm robot.

3.5.2.1.6 Tab Displacement

Certain parts cannot be stacked one over the other (or side by side), but have to be
displaced in relation to the previous layer. Use the parameter Displacement of the placing
program to achieve this for the respective axis direction.

Fig.: Tab for displacement

With every layer change of the last axis in the placing order, the displacement value set
for the respective axis will be added to the stacking positions of that axis.

The displacement value can be set after activating the respective axis by moving the axis
with the drive buttons.

When all parameters on this tab are entered, either open the next tab by tapping it, or

accept the placing program by pressing .

Press to cancel the process and discard the entries.

This tab will not be shown at a placing program for a double arm robot.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 249

3.5.2.2 Add Placing Program Commands to the Teach Program

Before you can add a placing program to the teach program, you have to create it in the
menu Part Prg Setup – Placing Program.

When you have created a placing program in the current teach program already,
and you want to add it as a command, press to open the selection window for adding
placing programs.

Fig.: Selection window for adding placing programs

Select the desired placing program from the list on the left top of the window. The table
Placing Program Information shows how many positions in the different axes
dimensions the selected placing program will travel to. If no placing programs have been
defined in the current teach program yet, the message "No placing programs available"
will be displayed instead of the selection list.

Use the buttons on the right side of the window to decide whether the placing program
shall stack or un-stack:

creates a placing program command for stacking. The counters of the placing
program will be incremented after traveling to a position. Pieces will be “added” to the
stack.

creates a placing program command for un-stacking. The counters of the placing
program will be decremented before traveling to a position. The placing program is
running “in reverse” – pieces will be “removed” from the stack. In the program this will be
indicated by adding the extension UNSTACK to the command.

Use the option Additional Counter and the selection box below to select a counter that
will be incremented when stacking and decremented when un-stacking.

Press to add the command to the teach program.

Press to cancel the action.

R83_V8_32_00_WIT_EN / 01.10.2020
R8.3 USER MANUAL Page 250

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 251

3.5.3 Injection Molding Machine IMM

3.5.3.1 Injection Molding Machine IMM - Standard Functions

Here you can program signals to the IMM.

Fig.: Window for IMM Signals

First pick the desired signal from the selection list.

and are used to select whether the chosen signal is to be turned on or off.

When the robot is equipped with 2 interfaces for injection molding machines, one of the
options IMM 1 or IMM 2 has to be tapped in order to select which Injection Molding
Machine is the targeted by the signal.

is used to add the command to the Teach program.

is used to cancel the entry.

If a signal has been enabled in the teach program, it also has to be disabled again.

These signals are only permits (inhibits) to the injection molding machine. The actual
control of the movements is done by the IMM.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 252

3.5.3.1.1 MOLD CLOSE and FULLY MOLD OPEN

Use the permission signals MOLD CLOSE and FULLY MOLD OPEN to program the
permits for the movements of the mold of the injection molding machine. The signal
FULLY MOLD OPEN is only available with the extended E67 / E12 interface; here the
mold is automatically only opened to an intermediate position. The robot does not control
the standard opening of the mold - the IMM opens the mold when the part is finished.

Furthermore the IMM utilizes E67 / E12 signals to send feedback about the position of
the mold. This is done using the signals MOLD OPEN and MOLD CLOSED. Only when
the mold is fully open, it is possible for the robot to enter the mold.

The extended E67 / E12 interface additionally supplies the feedback signal MOLD
INTERMEDIATE POSITION. Here the robot can already enter the mold, when it is
opened to the intermediate position. According to the mode used at the IMM the robot
then may have to permit the mold to fully open.

Example for standard E67 / E12

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

enter the mold area,

remove the part,
exit the mold area, then...

PERMIT IMM: MOLD CLOSE! = ON close the mold.

Part placement…

Example for extended E67 / E12

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

enter the mold area; fix the part on the EOAT

PERMIT IMM: FULLY MOLD OPEN = O fully open the mold

WAIT IMM: MOLD OPEN = ON wait until the mold is fully open
PERMIT IMM: FULLY MOLD OPEN = OFF switch off permission

exit the mold area

PERMIT IMM: MOLD CLOSE! = ON close the mold.

Part placement…

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 253

3.5.3.1.2 EJECTORS FORWARD/BACK and COREPULLERS PULL/SET

Using the commands EJECTORS FORWARD/BACK and COREPULLERS PULL/SET

the movements of the ejectors and core pullers of the IMM are taught. The most basic
way to do so, is to switch on the permit for the desired movement, then wait until the
target position is reached using a WAIT command, and then to switch off the permit
again.

The following example moves the ejectors forward:

PERMIT IMM: EJECTORS FORWARD! = ON switch on permission

WAIT IMM: EJECTORS FORWARD = ON wait...
PERMIT IMM: EJECTORS FORWARD! = OFF switch off permission

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 254

3.5.3.2 Injection Molding Machine IMM - Automatic Functions

The automatic functions simplify programming the movements of the IMM.

Fig.: Window for IMM signals

First pick the desired movement from the selection list.

The permits are toggled correctly by the commands automatically. When the option Wait
for completion of the command is activated, the command will wait until the movement
is finished. In that case command will have the extension WAIT added in the Teach
program.

When the robot is equipped with 2 interfaces for injection molding machines, one of the
options IMM 1 or IMM 2 has to be tapped in order to select which Injection Molding
Machine is the targeted by the signal.

is used to add the command to the Teach program.

is used to cancel the entry.

These signals are only permits (inhibits) to the injection molding machine. The actual
control of the movements is done by the IMM.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 255

3.5.3.2.1 MOLD CLOSE! WAIT

The command

FUNCTION IMM: MOLD CLOSE! WAIT

eases programming the closing movement of the mold. The command equals the
following sequence of "standard" commands:

PERMIT IMM: MOLD CLOSE! = ON

WAIT IMM: MOLD CLOSED = ON
AND IMM: MOLD OPEN = OFF

3.5.3.2.2 EJECTORS FORWARD/BACK (WAIT) and

CORE PULLERS PULL/SET (WAIT)

The automatic functions will ease the programming of the movements of the ejectors and
core pullers essentially. The respective permits are simply toggled by the commands
automatically.

The automatic function for "ejector back" will look like this:

FUNCTION IMM: EJECTOR BACK!

This equals the following sequence of "standard" commands:

PERMIT IMM: EJECTOR FORWARD! = OFF

PERMIT IMM: EJECTOR BACK! = ON

If additionally the option Wait for completion of command is activated, the extension
WAIT is added to the command, and the command will wait for the respective movement
to be finished.

The Wait function for "ejectors back" will look like this:

FUNCTION IMM: EJECTOR BACK! WAIT

This equals the following sequence of "standard" commands:

PERMIT IMM: EJECTOR FORWARD! = OFF

PERMIT IMM: EJECTOR BACK! = ON
WAIT IMM EJECTOR BACK = ON
AND IMM EJECTOR FORWARD = OFF

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 256

3.5.3.3 Injection Molding Machine IMM - Logical Functions – Mold Was Closed

Here you can program the command for manipulating the latch Mold Was Closed for
the condition with the same name.

This will for example be necessary when at the first cycle the condition Mold Was Closed
has to be overridden for entering the mold, because the mold is going to be closed for
the first time only after inserting inserts.

Fig.: Window for logical IMM commands

and are used to select if the latch shall be set or reset.

When the robot is equipped with 2 interfaces for injection molding machines, one of the
options IMM 1 or IMM 2 has to be activated, in order to select the Injection Molding
Machine, whose latch will the targeted by the action.

is used to add the command to the Teach program.

is used to cancel the entry.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 257

3.5.4 Smart Removal

3.5.4.1 Smart Removal: In

The command Smart Removal: IN is used to program a time optimized movement

into the mold of the IMM in a very simple way. For this purpose the command starts a
curved movement of Y and X during the mold opening movement already, in order to
travel off the Y mold safety switch shortly after full mold opening has been achieved.
Waiting for the mold signals is processed automatically. A distance for X moving in
straight can be set. The integrated "parallel at time" allows pre-triggering of the ejectors.

Use the first window to determine, which axes will be moved in what order by the
Move-In command.

Fig.: Axes selection for Smart Removal In

Use to confirm the selection and to open the dialogue for inputting the other
parameters.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 258

Fig.: Dialogue for Smart Removal In

Start position

This is the position where Smart Removal starts moving in. Is retrieved automatically
from the teach commands before Smart Removal: IN.

Takeoutposition

This is the target position of the Smart Removal movement into the mold. At this position
the gripper of the robot should take over the parts from the IMM. After activation with a
, the participating axes can be moved to their desired positions one by one using the
drive buttons.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 259

Position of the S5 mold safety switch

This is the position where the Y axis travels off the cam of its mold safety switch, thus
entering the mold. It is determined automatically.

Straight movement to takeout position from dx

This is the distance before the X takeout position, where the Y movement must be
finished, in order for X to travel to the takeout position with a straight movement. Input

the desired distance after tapping the input field or after pressing using the

dialogue for numerical input. Furthermore, after tapping the input field you can use

and to tune the distance.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 260

Parallel at time dt before takeout-position

This is the time before the takeout position is reached with Y and X, when the command
Smart Removal: IN acknowledges itself, thus starting the Teach commands after
itself, before it is actually finished. This way you can pre-trigger the ejectors, for example.
The resulting parallel movement has to be completed with a WAIT SYNC command at
an adequate position in the Teach program. Input the desired time after tapping the input

field or after pressing using the dialogue for numerical input. Furthermore, after

tapping the input field you can use and to tune the time.

Mold Intermediate Position

If Smart Removal: IN shall enter the mold already when mold opening reaches the

mold intermediate position, access the tab and activate the option Use
mold Intermediate position there. This option is only available when the optional
signal Mold Intermediate Position is available on the machine interface.

Press to add the command to the Teach program.

Press to discard the entries.

Example:
...
Travel to the start position of Smart Removal over the mold.
*Y: 0.0
*Z: 4711.0
*X: 123.4

Smart Removal: IN

Pre-triggered vacuum and ejectors using the time dt.

Vacuum-01 = ON
FUNCTION IMM: EJECTORS FORWARD! WAIT
WAIT SYNC

WAIT Vacuum-01 = ON
...

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 261

3.5.4.2 Smart Removal: Out

The command Smart Removal: OUT is used to program a time optimized movement
out of the mold of the IMM in a very simple way. For this purpose the command triggers
the closing of the mold already while it moves X and Y out of the mold with a curved
movement. A distance for a straight movement of X can be set. An adjustable time allows
permitting the closing movement of the mold before the Y axis travels onto the cam of its
mold safety switch, thus eliminating any switching delays of the machine interface.

Use the first window to determine, which axes will be moved in what order by the
Move-Out command.

Fig.: Axes selection for Smart Removal Out

Use to confirm the selection and to open the dialogue for inputting the other
parameters.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 262

Fig.: Dialogue for Smart Removal Out

Takeout position

This is the position, where Smart Removal starts moving out. Is retrieved automatically
from the teach commands before Smart Removal: OUT.

Straight movement from takeout position to dx

This is the distance from the X takeout position, where the Y movement is started, after
X has moved away from its takeout position using a straight motion. Input the desired

distance after tapping the input field or after pressing using the dialogue for

numerical input. Furthermore, after tapping the input field you can use and to
tune the distance.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 263

Set close mold before S5 is reached dt

This is the time before the S5 cam is reached, when the command Smart Removal:
OUT already turns on the permit to close the mold, in order to eliminate any switching
delays of the machine interface. Input the desired time after tapping the input field or

after pressing using the dialogue for numerical input. Furthermore, after tapping

the input field you can use and to tune the time.

Position of the S5 mold safety switch

This is the position, where the Y axis reaches the cam of the mold safety switch, i.e.
where it exits the mold. It is determined automatically.

Position over mold

This is the target position of the Smart Removal movement out of the mold. From this
position it should be possible for the robot to move off the machine. After activation with
a , the participating axes can be moved to their desired positions one by one using the
drive buttons.

Press to add the command to the Teach program.

Press to discard the entries.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 264

Example:
...
After the parts have been delivered to the robot gripper using the ejectors.
FUNCTION IMM: EJECTORS BACK! WAIT

Smart Removal: OUT

Travel to the placement position...

Z: 123.4
...

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 265

3.5.5 Peripherals

3.5.5.1 Conveyor

This command is used to control a conveyor.

Fig.: window for conveyors

and are used to select if the command shall switch the conveyor on or off.

When the option Time is activated with a , the selected state is only kept for the
selected time, without interrupting the teach program. The value for the time is input
using the numerical input dialogue after tapping the input field.

is used to add the command to the teach program.

is used to cancel the input.

See also:
3.4.6.8 Setup Menu: Conveyor Names

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 266

3.5.5.2 Peripheral Outputs PO

This command is used to control peripheral outputs (POs).

Fig.: window for peripheral outputs

First, the desired peripheral output is selected.

and are used to select whether the command shall switch the selected
peripheral output on or off.

When the option Time is activated with a , the selected state is only kept for the selected
time, without interrupting the teach program. The value for the time is input using the
numerical input dialogue after tapping the input field.

is used to add the command to the teach program.

is used to cancel the input.

Part monitoring can be activated for peripheral outputs. In monitoring, outputs and inputs
having the same number will always correspond to one another. As an example,
monitoring for peripheral output 1 will be performed through peripheral input 1.

Peripheral outputs will remain set when shifting to manual, block stop or in the event of
an error.

See also:
3.5.5.7 Monitoring
3.5.5.3 Cylinders
3.4.6.9 Setup Menu: PO-Names

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 267

3.5.5.3 Cylinder function

This function is useful to ease the teaching of pneumatic cylinders of some peripheral
equipment, by combining two peripheral outputs to a cylinder. Additionally you can use
two peripheral inputs and a time limit to monitor the correct function of the pneumatic
cylinder. If the cylinder does not reach the respective target position within the set time
limit, an error message will be displayed on the teachbox.

Up to 255 cylinders can be defined. Mapping of the peripheral outputs and inputs, also
setting the time limit is done using the cylinder definition.

After selecting the function, first the desired cylinder is selected from the list.

, and are used to select if the command has to move the cylinder to
either one of its final positions or to release it. Release means, that both outputs are
switched off.

In case of cylinders that are equipped with position limit switches, in automatic operation
the next command is not executed before the desired target position of the gripper is
approached. The option Parallel enables to move several cylinders simultaneously in
that case.

This allows starting additional functions during the motion of the cylinder already.

In order to prevent uncontrolled motions, the instruction WAIT SYNC has to be entered
after every parallel motion. This will ensure that all motions have been completed before
the next instruction is started.

is used to add the command to the teach program.

is used to cancel the input.

Peripheral outputs will remain set when shifting to manual, block stop or in the event of
an error.

See also:
3.4.6.4 Setup Menu: Cylinder Definition

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 268

3.5.5.3.1 Applying cylinders in a teach program

Without using the cylinder function, moving a pneumatic cylinder forward and backward
will be programmed somehow like this:

PO-002: OFF switch off the valve for "backward"

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

...

PO-001: OFF switch off the valve for "forward"

PO-002: ON switch on the valve for "backward"
WAIT PI-002 =ON wait until the limit switch "cylinder backward" is actuated

Using the cylinder function simplifies the example like this:

CYL-01: ON switch off the valve for "backward"

switch on the valve for "forward"
wait until the limit switch "cylinder forward" is actuated

...

CYL-01: OFF switch off the valve for "forward"

switch on the valve for "backward"
wait until the limit switch "cylinder backward" is actuated

If also the time limit is set correctly at the cylinder definition, one benefits a monitoring
function with error message for time limit exceeded without additional programming.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 269

3.5.5.4 Vacuums

This command is used to control vacuum circuits.

Fig.: window for vacuum circuits

First, the desired vacuum circuit is selected.

and are used to select whether the command shall switch the selected
vacuum circuit on or off.

When the robot is equipped with the corresponding valves, a blow-off function will be
available at the turn off command. You can activate the blow off function with a at
Blow out time. After tapping the input field, input the duration of blowing using the
dialogue for numerical input. With the option Infinite the command will switch on blowing
permanently.

is used to add the command to the teach program.

is used to cancel the input.

See also:
3.5.5.5 Vacuum Level
3.5.5.7 Monitoring
3.4.6.13 Setup Menu: Vacuum Names
3.4.6.15 Setup Menu: Vacuum Reference States

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 270

3.5.5.4.1 Switching valve vacuum / gripper

This option is only available for R8 Primus robots

At R8 Primus Series robots it is possible to install a manually operatable selector-

valve in order to switch from vacuum to gripper and vice versa. This optional feature
has been implemented to react to the limited amount of In- and Outputs and therefor
reach a higher level of flexibility in the production.

Fig.: Switching valve vacuum / gripper

For better understanding look at the diagram below.

Fig.: diagram switching valve

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 271

3.5.5.5 Vacuum Level

Use the Vacuum Level command to set the vacuum threshold for vacuum monitoring
and the condition vacuum independent from the preset Standard Vacuum Pressure.
Thus you can use different thresholds in different parts of the Teach program. The
threshold for a specific vacuum circuit set with the Vacuum Level command will be valid
until the next Vacuum Level command for the same vacuum circuit.

Fig.: Window for the Vacuum Level command

After selecting the desired vacuum circuit and tapping the input field Set vacuum level
you can input the desired threshold using the dialogue for numerical input. Alternatively
you can use the slider on the right side of the window.

Select the option Standard with a to generate the command for using the threshold
preset with Setup Standard Vacuum Pressure.

Use to add the command to the teach program.

Use to discard the entries.

See also:
3.5.5.4 Vacuums
3.5.5.7 Monitoring
3.5.7.8.5 Condition: Vacuum
3.4.6.17 Setup Standard Vacuum Pressure

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 272

3.5.5.6 Grippers

This command is used to control gripper circuits.

Fig.: window for gripper circuits

First, the desired gripper circuit is selected.

, and are used to select whether the command shall switch the selected
gripper circuit to opened, closed or released.

The state RELEASED is only available at gripper circuits equipped with the required
valves.

In case of gripper circuits that are equipped with position feedback, in automatic
operation the next command is not executed before the desired target position of the
gripper is approached. The option Parallel enables to move several grippers
simultaneously in that case.

This allows starting additional functions during the closing or opening motion.

In order to prevent uncontrolled motions, the instruction WAIT SYNC has to be entered
after every parallel motion. This will ensure that all motions have been completed before
the next instruction is started.

is used to add the command to the teach program.

is used to cancel the input.

See also:
3.5.5.7 Monitoring
3.4.6.14 Setup Menu: Gripper Names
3.4.6.16 Setup Menu: Gripper Reference States

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 273

3.5.5.7 Monitoring of Vacuum Circuits, Grippers and Peripheral Outputs

Using (part-) monitoring the robot can react on the loss of parts, in order to avoid damage
caused by parts that got stuck, were not taken out or have fallen down.

The monitorings are background functions that from their activation until their
deactivation check, if all parts are still present on the respective vacuum circuit, gripper
or peripheral circuit.

At vacuum circuits part monitoring is done using the analogue vacuum pressure
monitoring. Use the menu Setup Vacuum Pressure to set the trigger value for the current
Teachprogram.

At grippers the state of the respective gripper input Part Monitoring is monitored. This
input must be actuated by a suitable sensor.

At peripheral outputs the state of the peripheral input with the same number is
monitored.

When a monitoring is triggered (by part loss), the action (Stop or Alternative Routine)
selected on activation of the monitoring will be carried out.

Action STOP
When the monitoring is triggered, the robot will switch to operating mode Manual. This
results in an immediate stop of the axes. The error message Element: PART LOST will
be emitted.

Action ALT: label

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

Alternative sequences have to be made dependant on the current position, in order to

avoid collisions.

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

and peripheral circuits; however, it is likewise possible to use a single alternative
sequence for all circuits.

Alternative sequences have to be ended with an unconditional jump and the IMM
signals have to be switched according to the relevant needs. In alternative sequences,
the monitoring system of the addressed circuit or the circuit itself should be turned off;
otherwise the program will jump back to this alternative sequence after having completed
the alternative sequence.

In order to avoid collisions during or after an alternative sequence, the Y-axis should
possibly be moved to its zero position before the other axes are moved.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 274

If an alternative sequence is used by several monitorings, all monitorings must be

disabled at the beginning of the alternative sequence! Otherwise multiple call-ups of the
alternative sequence may occur, and instructions at the beginning of the alternative
sequence will be processed more than once!

After activating the tab in the command window of the element (vacuum circuit,
gripper or peripheral output) to be monitored, you can select the desired monitoring
command:

Fig.: Window for the vacuum monitoring

Use the list on the left side of the window to select the element to be monitored.

Deactivating a monitoring

Deactivation is done automatically when switching off / opening the respective element
or with the monitoring OFF command.

Press to select the command for deactivation of a monitoring:

Element = M-OFF

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 275

Activating a monitoring

Press to select the command for activation of a monitoring.

Without further options the command to activate a monitoring with the action STOP will
be created:

Element = M-ON STOP

Using the option Alternative the command to activate a monitoring with the action ALT
will be created:

Element = M-ON ALT: label

You can either input a new label or select an existing label.

Using the option Smart (only with vacuum) the monitoring will be activated delayed to
let it become active in the moment before the permit to close the mold is being switched
on. This is especially helpful in connection with the Smart Removal: OUT command,
in order to avoid false triggering during acceleration of the exiting (Y-) axis, while making
sure that the mold will not close in case of a part lost inside it.

Example:
…
Smart Removal: IN Y: 678.9 X: 234.5
Vacuum-01 = ON
FUNCTION IMM: EJECTORS FORWARD! WAIT
WAIT Vacuum-01 = ON
FUNCTION IMM: EJECTORS BACK! WAIT
Vacuum-01 = M-Smart ON STOP
Smart Removal: OUT Y: 0.0 X: 123.4
…

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 276

3.5.6 Counters

3.5.6.1 64 freely usable Counters

Primus Robot: 10 Counters available

The primary use of counters is to program repeat functions or to carry out an event count.
Furthermore counters can be used like variables to save e.g. states and settings.
Counters are also useful to interchange parameters and to do handshakes between part
programs. Incorporating Stopwatches makes timer functions possible.

Fig: Window for counters

64 freely usable counters are available.

After entering the counter menu or after tapping the field Result type use the field Select
result type to select the counter to be modified by the operation.

Use the buttons , and to select one of three common cases:

Counter-xxx = 0
Counter-xxx = Counter-xxx + 1
Counter-xxx = Counter-xxx – 1

This selection also defines the basic format of the command (1 or 2 operands).

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 277

Use the field Operator to select one of the operators + (Addition), - (Subtraction),
* (Multiplication), DIV (Division) or REM (Division Remainder).

After tapping one of the fields Left Operand or Right Operand you can choose the
values to be placed right and left of the operator. Possible are:

Value ... a number ranging from -2147483648 to 2147483647

Counter ... the value of a counter
Row Counters X/Y/Z ... the value of one of the row counters of a placing program
Part Counter ... the value of the part counter of a placing program
Stopwatch ... the result of a time measurement of a Stopwatch in 1/100s of seconds
Start Position X/Y/Z ... the starting position of a placing program in 1/10 millimeters
Number of Parts X/Y/Z ... the number of parts of a placing program
End Position X/Y/Z ... the end position of a placing program in 1/10 millimeters

According to the type of the chosen operator, the suitable field for completion of the entry
will be shown on the right side of the window.

For the operand Stopwatch additionally use the buttons , , ,

to select the desired value of the stopwatch.

Use to add the command to the teach program.

Use to close the window without changing the teach program.

Example:

Counter-001 = 0
-
START:
...
Removal process
...
Counter-001 = Counter-001 + 1
JMP QUALI Counter-001 = 50
...
Normal placing
...
JMP START

QUALI:
...
Placing for Quality Control
...
Counter-001 = 0
JMP START
Every 50th piece will be placed on a special position for quality control.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 278

3.5.6.2 Reset / Manipulate Placing Counters

The placing counters are required in the placing program in order to memorize how
many pieces have been already placed for each axis and to approach the next placing
position. Once the placing program is finished (the last piece has been placed), the
associated placing counters for the axes X, Y and Z are reset to zero prior to a new start
of the placing program.

The reading of the number of pieces previously deposited by the respective placing
program is in the part counter. After the placing program has been completed (last piece
has been placed), the value of the part counter remains unchanged until the first part of
the sequence has been placed again.

Placing counters and part counters always change together.

By manipulating the part counter it is possible to let the placing program continue on any
position of the placing sequence.

The teach program function Placingp-XXX RESET can be used to clear the placing
counters and part counter of the placing program XXX at any time.

Fig.: Window for placing counters

After opening the counter menu select PlcProgram-PC as the Result type. Now you
can select the placing program to be manipulated by the command in the field Select
result counter.

The command Placingp-XXX RESET will be offered by default. Tap the field Operand
if you want to select another option for manipulating the part counter.

Press to add the command to the teach program.

Press to close the window without changing the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 279

Example:

SUBR NEW_BOX
Conveyor-01: ON 5.0s
Placingp-001 RESET
RET

The subroutine NEW_BOX executes a box change, when called. The placing program
is being reset, and will continue with the first part in the new box.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 280

3.5.7 Program branching

3.5.7.1 Jump

JMP

Basically a teach program is executed command after command, from top to bottom,
starting at program line no. 0001. If the robot has to be able to react on certain events, a
change in this sequence of execution will be required.

Using the JMP (Jump-) command it is possible not to continue with the next program
line, but to jump to a different location somewhere in the program, and to continue the
execution of the program from there on. The JMP command requires a Label as a target
to jump to.

You can either type in the name of a new label after tapping the input field Enter label,
or choose an existing label from the selection field Select label.

If the jump command is not combined with a condition, the jump to the label will be
executed with every execution of the command. This unconditional jump is referred to
as absolute jump.

is used to generate such an absolute jump.

Example:
JMP START

is used to generate a conditional jump, that is only executed when the selected
jump condition is true.

Example:
JMP QUALI CNT01 = 15

The label QUALI is only jumped to, if counter CNT01 equals 15.

is used to confirm all parameters and to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 281

3.5.7.2 Label

Label

A label is the target for Jump commands.

Tap the input field Input label to enter the alphanumeric name of the label using the Text
input dialogue. The name can be up to 12 characters long.

Example:
BOX_01:

is used to add the label to the program.

A label with a certain name may only exist once in a teach program, but it can be targeted
by any number of Jump commands.

3.5.7.3 If - Elseif - Else - Endif

jump condition

jump condition

Basically a teach program is executed command after command, from top to bottom,
starting at program line no. 0001. If the robot has to be able to react on certain events, a
change in this sequence of execution will be required.

Using the IF - ELSEIF - ELSE - ENDIF commands it is possible to execute or not execute
program parts if jump conditions are true or not true.

You must not exit the program part between IF and ENDIF using a jump command.

There are 3 possible variants.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 282

3.5.7.3.1 Variant 1:
The instruction IF defines a condition for the execution of an alternative program
sequence. This sequence is programmed in the program lines after the instruction IF.
The END IF instruction is programmed at the end of the alternative sequence.

If the jump condition is false, the instructions between IF and END IF will not be carried
out. The program routine will be continued with the first instruction after END IF.

If the jump condition is true, first the instructions between IF and END IF will be carried
out. Only then will the program routine be continued after END IF.

Example:

3.5.7.3.2 Variant 2:
The instruction IF is used to specify a condition for the execution of two alternative
program sequences.

Sequence 1 is to be executed only when the condition is true. Sequence 2 is to be

executed only when the condition is false.

Sequence 1 is programmed in the program lines after the instruction IF. Then the
instruction ELSE and, following that, sequence 2 is programmed. At the end of sequence
2, the instruction END IF is programmed.

If the jump condition is false, the instructions between IF and ELSE will not be carried
out, and the program routine will be continued with the first instruction after ELSE (=
sequence 2).

If the jump condition is true, first the instructions between IF and ELSE will be carried out
(= sequence 1), and then the program routine after END IF will be continued.

Example:

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 283

3.5.7.3.3 Variant 3:
The commands IF and ELSEIF are used to define conditions for the execution of various
program routines; where only one of them has to be executed at a time.

In automatic mode the conditions of the IF command and of the ELSEIF commands are
checked one after the other, following their sequence in the program. The program
routine attached to the first true condition will be executed, after that the execution of
the program will continue behind the ENDIF.

The optional ELSE command is used to define a routine, which will only be executed if
none of the conditions of the IF and ELSEIF commands had been true.

This variant may especially be helpful creating sequencers, where in dependence of the
value of a counter a different step of a sequence has to be executed.

Example:

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 284

3.5.7.4 Call - Subr – Ret

Subroutine Name

Return

Basically a teach program is executed command after command, from top to bottom,
starting at program line no. 0001. If the robot has to be able to react on certain events, a
change in this sequence of execution will be required.

Using CALL-SUBR-RET commands it is possible to structure a Teach program with

subroutines, and to call these subroutines conditional (based on the jump conditions) or
unconditional.

Subroutine callups permit branching into a sequence of instructions. After their

execution, the process will jump back to an instruction located directly after the related
callup. In this way, program sections that are needed more often have to be programmed
only once.

When programming subroutines, the following rules have to be kept in mind in order to
ensure proper execution:

 Subroutines must always be terminated with the instruction RET.

 A subroutine must not be exited with the instruction JUMP.
 A subroutine routine must never be processed without callup with the instruction
CALL.

Instruction CALL
The instruction CALL Name is used to call up the subroutine Name. Execution of the
program will be continued at the subroutine.

Instruction SUBROUTINE
The instruction SUBR Name is used to define the start of a subroutine.

Instruction RETURN
RET is used to terminate a subroutine and to return to the main program. Return is made
to the line after the CALL instruction by which the subroutine was called up.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 285

Example
CALL INIT
START:
CALL REMOVAL
CALL PLACE
JMP START

SUBR INIT
...
RET

SUBR REMOVAL
...
RET

SUBR PLACE
...
RET

This example shows the possibility for structured programming. The first 5 lines form the
main routine, which simply calls the subroutines one after the other, using a sequence
of CALL-commands. The subroutine INIT is only called once when the program is
started, during the further cycles only the subroutines REMOVAL and PLACE are
executed. By using conditional CALL commands, routines for events like reject part or
quality control can be added to the program easily. The advantage of this programming
method is the short main routine, which gives a quick overview of the general sequence
and the functions of the program. The details of the functions are programmed in the
subroutines.

Subroutines can call other subroutines, i.e. they can be nested. Maximum nesting level
is 160.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 286

3.5.7.5 And

Jump Condition

The AND and OR functions allow to execute IF, JMP, CALL and WAIT commands on
the basis of several jump conditions.

First, program the IF or JMP command with the first jump condition. Then, using the
AND/OR function, program the other jump conditions in the following program lines.

Example:
JMP Label Counter-001 = 1
AND Counter-002 = 1

The Jump is only executed when both counters Counter-001 and Counter-002 have the
value 1.

AND and OR instructions must be programmed in the line(s) directly after the instruction
to which they refer. Otherwise logical operation will not take place.

3.5.7.6 Or

Jump condition

The AND and OR functions allow to execute IF, JMP, CALL and WAIT commands on
the basis of several jump conditions.

First, program the IF or JMP command with the first jump condition. Then, using the
AND/OR function, program the other jump conditions in the following program lines.

Example:
JMP Label Counter-001 = 1
OR Counter-002 = 1

The Jump is executed when at least one of the counters Counter-001 or Counter-002
has the value 1.

AND and OR instructions must be programmed in the line(s) directly after the instruction
to which they refer. Otherwise logical operation will not take place.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 287

3.5.7.7 End

End

Every program should be terminated with the instruction END, in order to avoid
unintended processing of additional subroutines.

The robot program and the all modes program will continue their automatic processing
at program line 0001 after processing the END command.

Reference programs, the peripheral program, the additional part programs and also the
EOAT Change program will terminate at the END command.

3.5.7.8 Jump Conditions

Using jump conditions the commands JMP, IF, CALL, WAIT, OR and AND can make the
robot react on internal and external events.

After calling up the above mentioned commands, the following tabs are available to
access the desired event:

 Counter
 Placing Program
 PI
 IMM
 Vacuum
 AutoSwitch
 Misc part program, area, position, mode, stacking sensor, start, production end active
 Input
 Output

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 288

3.5.7.8.1 Jump condition: Counter

The branch is executed dependant on the result of a comparison. The operands for the
comparison can be counters, placing counters, part counters and constant values.

After selecting the event, the desired operands for the left and the right side of the
comparison are picked from the respective lists.

If counters are chosen, a window to select one of the 64 counters is shown.

If pacing counters or part counters are chosen, a window with the available placing
programs is shown.

If value is chosen as an operand, it can be input after tapping the Input value field, using
the dialogue for numerical input.

Additionally, one of the operators <=, >=, <, >, <>, = must be chosen. This is to define
how the numerical value of the left operand must relate to the numerical value of the right
operand in order to trigger the branch.

Example:
IF PLCPRG01-PC = 12
CONVEYOR_01 ON 5.0S
ENDIF
...

The conveyor is switched on if 12 parts have been placed by the placing program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 289

3.5.7.8.2 Jump Condition: Placing Program

The branch will be triggered by events of placing programs.

After selecting the condition, the desired placing program and one out of three events
can be chosen.

Stack ready
The stack is completed. All row counters are zero, the next piece will be the first of the
placing sequence again. This can be used to index the conveyor.

Layer ready
A layer is completed. The row counters of the first two axes of the placing sequence
are zero, the next piece will be the first of the next layer. This can be used to trigger
intermediate layers.

Row ready
A row is completed. The row counter of the first axis of the placing sequence is zero;
the next piece will be the first of the next row.

Example:
…
IF Placingp-001 ZXY STACK READY
Conveyor-01: ON 5.0S
ENDIF
…

The conveyor is switched on every time a complete stack has been placed by the
placing program.

3.5.7.8.3 Jump Condition: PI-Peripheral Input

The branch will be executed if a selectable signal of the peripherals is ON or OFF.

After selecting the event, a list with the available signals is displayed. Select the desired
signal by tapping it.

and are used to specify if the branch has to be executed when the signal is
ON or OFF.

With a at Latch the latch function is activated. At the displayed command an

exclamation mark is added after the peripheral input:
JMP LABEL PIxxx! = ON

With this function activated, the control also triggers on very short ON-impulses of the
input, and memorizes them until the next request occurs in the respective part program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 290

3.5.7.8.4 Jump Condition: IMM - Injection Molding Machine

The branch will be executed dependent on one of the signals of the IMM.

After selecting the event, a list with the available signals is displayed. Select the desired
signal by tapping it.

and are used to determine if the branch has to be executed when the signal
is ON or OFF.

When a signal of the IMM interface is ON, the condition described by the signal is true.

The condition MOLD WAS CLOSED = ON indicates if the mold has been closed since
the last takeout cycle. You can override the automated latch for this condition using its
logical teach command.

The condition WAS REJECT-PART = ON indicates if the reject part signal of the machine
had been set for the last part taken out. When dealing with rejects, you should prefer
checking this latch instead of checking the signal directly, because the reject part signal
may be invalid after switching on the permission to close the mold. The latch will be set
during the execution of the command for switching on the permit Mold Close, and will be
reset next time when entering the mold or at the start of the reference travel.

The condition OP. WITH IMM = ON represents the result of a logical AND operation
with the signals Operation with Robot and Automatic. Both signals must be ON in
order for the condition to be TRUE. If the condition is used in a WAIT command, the
robot will go to operating mode Wait IMM while waiting for the condition to be fulfilled.

When waiting for the mold to open, both signals should be tested. This will detect a
possible failure of the interface, thus avoiding crashing the mold. Additionally, waiting for
Mold was closed inhibits the robot from entering the mold, if no part has been produced
since the last cycle. The first Wait command should wait for the Mold is open signal in
order for the waiting time detection of the speed calculation of the ECO-Mode to work
correctly.

Example:
WAIT IMM: MOLD OPEN = ON
AND IMM: MOLD CLOSED = OFF
AND IMM: MOLD WAS CLOSED = ON

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 291

3.5.7.8.5 Jump Condition: Vacuum

The branch will be executed depending on the feedback of the vacuum pressure
monitoring of one of the vacuum circuits. The state of a vacuum pressure monitor is ON,
when all parts of all suction cups of the respective vacuum circuit are completely sucked
on. Use the Setup menu Vacuum Pressure to set the trigger values of the vacuum
pressure monitors for the current Teachprogram.

This serves to ensure, upon pickup of a piece, that the piece is really held tightly on the
cup before further motions are carried out.

After selecting the event, a list with the available vacuum circuits is displayed. Select the
desired vacuum circuit by tapping it.

and are used to specify if the branch has to be executed when the state of
the vacuum pressure monitor is ON or OFF.

3.5.7.8.6 Jump Condition: AutoSwitch

The branch will be executed depending on the selectable ON / OFF state of an
AutoSwitch.

After selecting the event, a list with the 32 AutoSwitches is displayed. Select the desired
AutoSwitch by tapping it.

and are used to specify if the branch has to be executed whether the
AutoSwitch is ON or OFF.

When AutoSwitches are configured as keys, in many cases the use of the latch function
may prove as useful. With the latch function activated, the control unit will trigger on even
very short ON impulses, memorizing them until the next request occurs in the respective
part program.

The latch function is activated with a at the option latch. At the displayed command
an exclamation mark is added after the AutoSwitch.

3.5.7.8.7 Jump Condition: Part program

Primus Robot: not available

The branch will be executed if a peripheral program is running or ready.
After selecting the event, a list with the available peripheral programs is displayed. Select
the desired program by tapping it.

and are used to specify if the branch has to be executed when the program
is running or not.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 292

3.5.7.8.8 Jump Condition: Area

The branch will be executed dependant on the roller switch S6 of the Z-axis. The jump
conditions Mold Area and Placing Area are used to execute different reference travels
and alternative routines.

Mold Area
The roller switch of the Z-axis(S6) is not actuated. The robot is above or inside the IMM.

Placing Area
The roller switch of the Z-axis(S6) is actuated. The robot is outside the IMM.

3.5.7.8.9 Jump condition: Position

The branch will be executed in accordance with the actual position of one of the robot
axes.

After selecting the event, the desired axis is picked from the list with of available axes. It
is now possible to move the chosen axes to the desired target position by using the drive
buttons on the right side of the window.

At last, you have to select one of the operators <=, >=, <, >, <>, = to define how the
actual position of the axis has to relate to the target position given within the command
for triggering the branch.

Example:
JMP INPERI Z >= 1000.0
AND Z =< 1500.0
AND Y > 350.0
...

Could be part of a reference program. It only jumps to the label INPERI if the Z-axis is
positioned within the range from 1000 to 1500 mm, and at the same time the Y-arm holds
a position bigger than 350 mm.

The operator = should possibly not be used together with numerical axes.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 293

3.5.7.8.10 Jump Condition: Mode

The jump condition Mode is available in an All Modes Program only.

The branch is executed dependent on the mode of operation of the robot.

After selecting the event, the desired mode of operation is chosen from the list Select
mode.

Then select one of the operators <=, >=, <, >, <>, = to define how the attached value of
the actual has to relate to the mode of operation given within the command in order to
trigger the branch.

The attached values of the different modes of operation are:

0 ... Reference missing

1 ... Manual

2 ... Reference

3 ... Blockstop

4 ... Automatic

Use IN BLOCK STOP DRIVE to check if the robot finishes the current block after a block
stop request. The effective mode during this is Automatic still.

Use IN REFERENCE DRIVE to check if the robot is currently executing one of the
reference travels in operating mode Manual. This mode has an attached value of 1,5.
The reference travel in the operating mode Reference Missing will be ignored.

Example:
IF MODE < BLOCK STOP
...
ENDIF

The program part between IF and ENDIF will only be executed during operation modes
Reference missing, Manual, Reference and during the reference travels.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 294

3.5.7.8.11 Jump Condition: Stacking sensor

The branch will be executed if the signal of one of the up to 8 stacking sensors is ON or
OFF.

After selecting the event, a list with the available stacking sensors is displayed. Select
the desired stacking sensors by tapping it.

and are used to specify if the branch has to be executed when the stacking
sensor is actuated or not.

3.5.7.8.12 Jump Condition: Start

The branch is executed when the automatic start button is pressed.

3.5.7.8.13 Jump Condition: Production End Active

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

3.5.7.8.14 Jump Condition: Input

The branch will be executed if a selectable input signal of the robot is ON or OFF.

After selecting the event, a list with the available signals is displayed. Select the desired
signal by tapping it.

For keys on the right side of the window help you to access certain groups of input
signals:

signals of the injection molding machine

signals of the peripheral inputs

signals of the grippers

signals of the vacuums

and are used to specify if the branch has to be executed when the signal is
ON or OFF.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 295

3.5.7.8.15 Jump Condition: Output

The branch will be executed if a selectable output signal of the robot is ON or OFF.

After selecting the event, a list with the available signals is displayed. Select the desired
signal by tapping it.

For keys on the right side of the window help you to access certain groups of output
signals:

signals of the injection molding machine

signals of the peripheral outputs

signals of the grippers

signals of the vacuums

and are used to specify if the branch has to be executed when the signal
is ON or OFF.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 296

3.5.7.9 Start/Stop Part Program

Primus Robot: not available

The commands START part program and STOP part program are used to start or stop
the peripheral program, all modes program or one of the 115 additional part programs
from another part program.

Fig.: Window for the Start/Stop part program commands

First pick the desired part program from the selection list Select part program.

Then use or to determine whether the command shall start or stop the
selected part program.

is used to add the command to the teach program.

is used to discard the entries and to close the window.

Example:

START PERI. PRG.

Starts the peripheral program

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 297

3.5.8 Wait functions

3.5.8.1 Wait

jump condition

The WAIT command is used to halt the execution of the program until the event defined
by the jump condition occurs.

3.5.8.2 Wait Timer

Timer

The command WAIT TIMER is used to link waiting for events with a time (limit).

First the time is set with the command WAIT TIMER, then the other jump conditions are
added using OR and AND commands.

After opening the menu and tapping the input field Time the desired value for the time
can be entered using the dialogue for numerical input.

is used to add the command to the Teach program.

Example:

WAIT TIMER = 3.00s

OR Vacuum-01 = ON

This waits for a part to be sucked on. If the set underpressure is not achieved within the
time limit of 3 seconds, the wait command terminates, and the execution of the program
is continued without the part. Afterwards a service routine for that case could easily be
triggered using a command like JMP label Vacuum-01 = OFF.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 298

3.5.8.3 Time

delay time

If a certain delay in the sequence is required, this can be achieved by means of the time
function. The time function can be used to program time delays from 0.00 to 9999.99
seconds.

After calling up the function, the desired delay time can either be adjusted using the
slider, or after tapping the field input time the desired time can be input using the
dialogue for numerical input.

In the automatic mode, processing of a program will be halted at a time function until the
time has elapsed. Only then will the next instruction be started.

3.5.9 More Commands

3.5.9.1 More

This key opens a window with some additional teach commands.

Those commands are:

 Remark (REM)
 Production end
 Block stop
 Stopwatch
 Operating Mode
 ECO Mode
 Area Switch

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 299

3.5.9.2 Remark (REM)

Remark

In order to facilitate future editing, every program should be provided with a sufficient
number of remarks. Remarks are shown in the teach program preceded by "REM":

0045 REM THIS IS A REMARK

After calling up the function and tapping the input field "Enter remark" use the dialogue
for text input to enter the desired text.

Use to add the command to the teach program.

3.5.9.3 Production End

Production End

This instruction is used for selective stopping of automatic operation at the end of
production, without a part remaining inside the mold or on the EOAT.

Activate this function in automatic operation by actuating the (REFERENCE) key.

The control lamp of the key will begin to flash in confirmation of this function.

The exact sequence is like this:

Automatic operation
During normal automatic operation the command PRODUCTION END is being ignored,
the jump condition Production End Active will be FALSE.

The button REFERENCE is being actuated during automatic operation

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

At the command that switches on the permit MOLD CLOSE

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

After the command that switches on the permit MOLD CLOSE

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 300

At the command PRODUCTION END

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

After the command PRODUCTION END

When automatic operation is continued or restarted, the state of the function Production
End will be normal automatic operation as described above.

Use , and to select the operating mode to be triggered by the

command.

Press to add the command to the Teach program.

3.5.9.4 Blockstop lock/unlock

Blockstop

Normally, if you press the block stop key in automatic operation the currently
processed instruction (axis motion) will be completed and the robot will be halted and
shifted into the block stop mode. The LED of the key will flash during this process.

The instruction LOCK BLOCK STOP allows a block stop to be carried out only after the
UNLOCK BLOCK STOP instruction has been reached and all instructions found before
it in the routine have been processed.

Thus an entire motion sequence (e.g., travel out of the mold area) can be completed with
a block stop.

After calling up the function, use the keys (lock) and (unlock) to select the
desired command.

Use to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 301

3.5.9.5 Stopwatch

The Stopwatch function allows measurement of times that go by during the processing
of arbitrary parts of a teach program. Four such software timers with a resolution of 0,01
seconds are available.

After calling up the function, first select the desired stopwatch, then use the keys on the
right side of the window to select the desired command.

Stopwatch-xx START
Starts the selected stopwatch. The current value of the stopwatch is incremented ins
steps of 0,1 seconds starting from zero while processing the program.

Stopwatch-xx STOP
Stops the selected stopwatch. The measured value is used to recalculate the minimum,
average and maximum values for the Info menu Stopwatch.

Stopwatch-xx RESET
Resets the calculation of the minimum, average and maximum values of the selected
stopwatch.

Use to add the command to the teach program.

The actual measured value can be loaded to a Counter for further processing, even while
the stopwatch is running. 1 in the counter will represent 0,01 seconds.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 302

Example:

-
Vacuum-01 = ON
Enter the IMM, use the ejectors to push the part to the vacuum suction cup(s)
-
Stopwatch-01 START
-
WAIT_VAC:
Counter-001 = Stopwatch-01 CURRENT
JMP TIMEOUT_VAC Counter-001 > 500
JMP WAIT_VAC Vacuum-01 = OFF
-
Standard sequence with part on the EOAT
-
JMP...

TIMEOUT_VAC:
Alternative sequence if the vacuum switch does not detect a part on the suction cups within timeout
-
JMP...

Instead of WAIT VACUUM here a jump back to WAIT_VAC occurs until either the part
is sucked on, or the time set for timeout is over. If the part is sucked on within time (here
5 seconds), the standard sequence is continued. During each run in the jumpback loop,
the actual value of the stopwatch is loaded to Counter-001. If the value is bigger than
500 hundreds of a second, the program will jump to the alternative routine after the label
TIMEOUT_VAC.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 303

3.5.9.6 Operating Mode

Operating Mode

The commands OPERATING MODE BLOCK STOP and OPERATING MODE MANUAL can
be used to interrupt the automatic execution of the teach program, and to switch from

operating mode Automatic to operating modes Block Stop or

Manual. This is useful to stop the robot, especially if the teach program is able to detect
error conditions.

The command OPERATING MODE PRODUCTION END requests Production End. This is

the equivalent of pressing the button during automatic operation.

The command OPERATING MODE REFERENCE can be used in the Robot Reference

Teach program ROBOT-REF to switch the operation mode from Manual to

Reference. This opens the possibility to start automatic execution of the Teach program
at any desired position within the working range of the robot.

When the operating mode is set to Reference by the command OPERATING MODE
REFERENCE, no verification of any kind is performed about axes positions or
vacuum and gripper states. Also the standard reference travel will not be
executed. This implies that if the command OPERATING MODE REFERENCE is
used, any mistake in the Reference Teach program will almost certainly lead to
collisions and damage during automatic operation.

From the command OPERATING MODE ONE- TOUCH REFERENCE on in the Robot
Reference Teach program ROBOT-REF the reference run will continue without the user

keeping on holding the button Reference. In order to terminate the reference run,

the user will now have to press the button Manual.

After selecting the function use , , , or to choose the

desired command.

is used to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 304

3.5.9.7 Eco Mode

Eco Mode

The command ECOMODE is used to control the ECO-Mode from within the Teach
program

Press to select the command ECOMODE ON. The command ECOMODE ON turns
the ECO-Mode on. Thus, there is no need then for the operator to manually turn on the
ECO-Mode with a at the option ECO-Mode in the window Override.

Press to select the command ECOMODE BUFFER-TIME. This command sets

the ECO-Mode buffer time. Thus, there is no need then for the operator to manually set
the ECO-Mode buffer time in the window Override each time when changing programs
with different requirements for that time. After tapping the input field ECO-Buffer (s) you
can input the desired buffer time with the dialogue for numerical input.

Press to select the command ECOMODE INACTIVE. The command ECOMODE

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

Press to select the command ECOMODE RESET. The command ECOMODE

RESET resets the calculations of the ECO-Mode. The robot will use the settings done
with VMAX, VABS, AABS and the Override until it will have determined new values, and
will be able to reduce acceleration and speed again.

Press to add the command to the teach program.

See also: 3.5.9.7 ECO-Mode

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 305

3.5.9.8 Area Switch

This command is only available on robots with absolute encoders.

You can use the command Area Switch to set the switching points of the virtual mold
interlock switches S5 and S6 according to the needs of the respective teach program.
This should be done in the first lines of the robot reference teach program Robot Ref., in
order for the conditions Mold Area and Placing Area to work correctly, when executing
the teach programmed reference travel for the first time.

The new position values for the mold interlock switches will not be set before executing
the area switch commands. While moving manually before executing the teach
programmed reference travel, values may be active, that keep the mold monitoring from
working correctly.

The area switch commands will set the position values for the mold interlock switches
permanently. For the settings to be correct at all times, the commands – once they are
used - have to be used in all Teachprograms of the robot.

Fig.: Window for the Area Switch command

Use the selection field in the upper left corner of the window to select which switch you
want to set with the command.

After tapping a field Switching Point on the right side of the window, you can set the
selected switching point by either travelling there with the connected axes, or by inputting
it numerically.

Use the options on the left bottom of the window to select the state of the switch on the
0 Position of the connected axis. Mold Area means off; Placing Area means on.

Press to add the command to the teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 306

3.5.10 AutoSwitches
AutoSwitches are virtual switches and keys, that are displayed on the main screen of the
Teachbox, when they are used in the Teach program. They serve as a replacement for
real switches, which would have to be connected using peripheral inputs in order to use
them in a Teach program. The AutoSwitches can be accessed directly by means of their
jump condition.

Fig.: Main screen with AutoSwitches

Up to 32 AutoSwitches are possible in one Teach program. If all the AutoSwitches used
cannot be displayed in one line, a scroll bar for shifting to the desired line is shown.

The button in the bottom right corner is used to select whether the AutoSwitches
are displayed or not.

Settings in the Setup Menu

The basic settings for the AutoSwitches are made using the Setup menu AutoSwitch
Definition.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 307

3.5.10.1 The Teach command AutoSwitch

The Teach command AutoSwitch is used to switch on or off an AutoSwitch that is

configured as a switch from within a Teach program.

After calling the function and selecting the desired AutoSwitch, the buttons and

are used to define if the AutoSwitch shall be switched on or off.

discards the entries.

adds the command to the Teach program.

See also:
3.4.6.5 Setup Menu: AutoSwitch Definition
3.5.7.8.6 Jump condition AutoSwitch
3.1.15.13 View Menu: AutoSwitch

Example: Part for quality control

The Autosw-01 has been renamed to CHECKPART and has been configured as key.

...
START: cycle start (label START)
...
Removal from IMM
...
JMP CONTROL CHECKPART!=ON Branch to the label CONTROL, if the key CHECKPART has
been pressed previously (latch!)
...
Placement, etc.
...
JMP START Jump to the cycle start
-
CONTROL: Label CONTROL
...
Deliver the part to the control station
...
JMP START Jump to the cycle start
-

After the key CHECKPART has been pressed shortly, the next part is delivered to the
quality control station.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 308

Example: start-up-parts

The Autosw-01 has been renamed to STARTUP, and has been configured as switch.

...
STARTUP = ON Switch on the switch STARTUP
...
STARTUPCYCLE: Start of the startup cycle - IMM "without" robot
PERMIT IMM:MOLD CLOSE! = ON
WAIT IMM:MOLD CLOSED = ON
JMP START STARTUP = OFF If the switch STARTUP is off, and the mold is closed, branch to
the start of the normal cycle
WAIT IMM:MOLD OPEN = ON
FUNCTION IMM:EJECTORS FORWARD! WAIT
FUNCTION IMM:EJECTORS BACK! WAIT
JMP STARTUPCYCLE Jump to the start of the startup cycle
-
START: Start of the "normal" cycle (label START)
...
Robot moves over the IMM, waits for the mold to open, etc. ...
...

The robot and the IMM are started together. The robot automatically switches on the
AutoSwitch STARTUP at the beginning of the program. The sequence between the label
STARTUPCYCLE and JMP STARTUPCYCLE toggled the permits for the IMM in a way
to let the machine produce parts "without" the robots (and let them fall down). When the
switch STARTUP has been switched off, the normal production cycle at the label START
will be executed after closing the mold.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 309

3.5.11 User Defined Error Messages

3.5.11.1 Introduction
At the R8.3 control you can use the teach command Alarm to emit individual error
messages.

Prerequisite is that a message table UserErr.txt is stored in the robot. Without this file,
the teach command Alarm will not be offered by the Teachbox.

Before you start with the steps explained below, it is obligatory to make a backup of the
current settings, as they will be gone when this process is finished.
For further information see 3.1.13.2 System Backup/Restore

3.5.11.2 Creating and Storing the File UserErr.txt

The file Usererr.txt is a Unicode text file. The columns of the contained table are
separated by tab stops. Use spreadsheet software like Microsoft Excel to create it, and
save it as Unicode text.

Use ISO 639-2 language codes to define messages in up to 40 languages. The file must
contain at least 3 columns (i.e. at least 1 language).

Fig.: Example for a UserErr.txt with 2 messages in 2 languages

In row 1 you define the columns for the different languages.

In column A you define error group 126 of the error number 126-XXX-YYY.

In column B define the unique error XXX inside of group 126. XXX can be any number
from 0 to 255.

Write the message texts for the different languages into the other columns.

If a language is set on the Teachbox which is not available in the table, the texts from
the first defined column will be displayed. In the example shown above this would be
English from the column ENG.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 310

The supplemental number YYY will be set by the teach command Alarm. You can
display the contained information in the message texts using escape sequences:

\U … 3-digit number with leading zeros. It shows the number YYY+1.

\N … 3-digit number with leading zeros. It shows the number YYY.
\I … 3-digit number no leading zeros. It shows the number YYY.
\i … 3-digit number no leading zeros. It shows the number YYY. 0 displays nothing.
\J … 3-digit number no leading zeros. It shows the number YYY. 0 displays nothing.
If this results in two spaces in a row, only one will be shown.
\A … axis designation: 0=X, 1=Y, 2=Z, 3=A, 4=B, 5=C, 6=X2, 7=Y2, 8=Z2, 9=A2, 10=B2,
11=C2
\V … vacuum name (current name of vacuum YYY+1)
\G … gripper name (current name of gripper YYY+1)
\O … peripheral output name (current name of peripheral output YYY+1)
\Y … cylinder name (current name of cylinder YYY+1)
\C … conveyor name (current name of conveyor YYY+1)
\S … stacking sensor name (current name of stacking sensor YYY+1)
\R … safety area, 3 digits, YYY+1.
\E … peripheral input name (current name of peripheral input YYY+1)
\Z … counter name (current name of counter YYY+1)
\M … IMM Name (current name of IMM YYY+1)

\K … Autoswitch Name (current name of Autoswitch YYY+1)

\W … stopwatch name (current name of stopwatch YYY+1)
\P … placing program name (current name of placing program YYY+1)
\p or \T … part program name
\H ... mode of operation: 0=Reference missing, 1=Manual, 2=Reference, 3=Block stop,
4=Automatic

If you actually want to show a „\“ in your text, you’ll have to write „\\“ instead.

Store the finished table as a Unicode text file with the name UserErr.txt into the folder
..\robot\tablo\language on the system USB stick of the robots and use this to boot the
robot. The file UserErr.txt will automatically be stored in the robot during the boot
process.

Once the file has been stored on the robot, the included error messages will be available
for all teach programs on that robot.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 311

3.5.11.3 The Teach Command ALARM

Alarm

Using the teach command Alarm you can emit your own error messages.

Prerequisite is that a message table UserErr.txt is stored in the robot. Without this file,
the teach command Alarm will not be offered by the Teachbox.

Fig.: Window for the teach command ALARM

After selecting the command, you select the desired message in the selection field
Number.

Use the field Info to input the desired supplemental number. If the supplemental number
is used in the message text, you can see the result already in the command display at
the top of the window.

With the buttons , and you define to which mode of operation the
robot shall switch when the error message is triggered.

With the button you define that the mode of operation of the robot will not change,
when the error message is triggered.

With the options for State you select whether the error shall be displayed as active (red)
or inactive (gray):

Off (inactive) results in the error being shown in the state inactive permanently, or that
an active error changes its state to inactive.

On (active) results in the error being shown in the state active permanently.

Momentary results in the error being shown in the state active for some seconds, and
then changing to the state inactive automatically.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 312

Press to add the command to the teach program.

3.6 Quick Editor

3.6.1 Introduction
The Quick Edit gives the possibility to display (even complex) Teach programs in a way
that makes it easy to do simple program changes and adaptations.

Therefore only those parameters are displayed, which have been released for possible
editing in the Teach Program.

3.6.2 Operation of the Quick Edit

3.6.2.1 Entering the Quick Edit

Use the button on the main screen to enter the Quick Edit.

This is not only possible in Manual and Reference modes, but also when the robot is
working in Automatic mode. In Automatic mode the same limitations as in the Text Editor
apply; meaning that positions of numerical axes can only be changed within
+/- 10mm.

3.6.2.2 Display and Editing Functions

The Quick Editor always shows the parameters of the Teach program currently loaded
in the robot.

Changings to parameters will also be applied, in case the Text Editor had been switched
to offline before.

Use Buttons on the right side of the screen select what types of parameters to display:

displays percentage parameters only (speed, acceleration, vacuum level).

displays time parameters only.

displays absolute speed parameters only.

displays position parameters only.

displays counter value parameters only.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 313

displays placing program parameters only.

displays distance parameters only.

displays all parameters.

The parameters out of the Teach program are displayed in numbered fields:

Fig.: Fields in the Quick Edit

The upper part of a field contains explanations of what the displayed parameter is used
for in the program sequence. The quality of those explanations strongly depends on the
skills of the creator of the respective Teach program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 314

The lower part of a field displays the parameter with its name and its changeable values.
Tap the respective display field to open a pop up that you can use to edit the respective
value.

Abb.: Pop-Up in the Quick Edit to change a Position

Changes will be transferred to the Teach program in the robot immediately

If the alternations are intended to be permanent ones, the Teach program has to be
stored to a storage medium using the functions of the File menu.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 315

3.6.2.3 Exit the Quick Edit

Use the button or the option Exit to Main of the File menu to exit the Quick
Edit.

3.6.3 FILE Menu of the Quick Edit

3.6.3.1 Open
This function is used in the Quick Edit to load a teach program from a storage medium
to the robot.

Fig.: Window to open a file in the Tooling Editor

The field Search in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a teach program file *.WIP

for a teach program file *.ZIP

is used to step up one folder.

opens the standard folder for this file operation.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 316

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

is used to open the properties window of the selected program.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to load the selected program to the robot.

is used to abort the function and close the window.

The program stored in the robot will be irretrievably deleted by loading another teach
program.

Every newly loaded teach program must be run through at least once in step mode before
automatic operation.

The file name of a teach program is not necessarily the same as the teach program
name.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 317

3.6.3.2 Open Template

Use this function to open Teachprogram Templates. Templates are programs prepared
for certain standard applications in a way that you only need to parameterize them in the
Quick Edit.

Teachprogram Templates are stored in a Read-Only location, where you can only load
them from, but not overwrite. The Teachprogram you create from the template, you can
store to any location available for storing Teachprograms using the function Save As.

The rest of the functionality of the menu Open Template is the similar to the menu Open.

3.6.3.3 Save (NAME.ZIP)

This function is used to save the teach program from the Teachbox a storage medium
as a *.ZIP file. Both name and path of the file will be the ones used before. The name of
the target file is shown in brackets right next to the menu entry Save. If no name is
displayed, Save will call the function Save as instead.

The previous version of the program stored on the storage medium with the same name
will be deleted irretrievably.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 318

3.6.3.4 Save As
This function is used to save the teach program from the Teachbox to a storage medium
as a *.ZIP file. Path and name of the file are selectable.

Fig.: Window to save a teach program

The field Save in displays the path of the current folder. By touching the field you can
select one of the standard folders C:\PUBLIC (internal storage medium of the Teachbox)
or D:\ROBOT\TEACHPRG (USB-Stick).

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a teach program file *.WIP

for a teach program file *.ZIP

The field Filename suggests the last filename used or the teach program name as
filename. After tapping the field you can use the dialogue for text input to change the
filename as desired. The extension will always be ZIP. By tapping it in the display of the
current folder, you can also use the name of an existing file.

is used to step up one folder.

opens the standard folder for this file operation.

is used to create a new folder.

is used to delete the selected file or folder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 319

is used to rename the selected file or folder.

is used to open the properties window of the selected program.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to save the teach program to the current folder, applying the name
from the field Filename.

is used to abort the function and close the window.

Before storing is executed, a check is made to see whether a program of the same name
is already stored in the selected folder, and a checkback message may appear.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 320

3.6.3.5 Properties
Here the properties of the teach program in the robot are displayed. That is the program
which is executed when the robot is in automatic operation.

Fig.: Window for properties of the CPU program

Name of Teach program
Shows the name of the teach program of the robot. This name is not necessarily the
same as the file name of the program. After tapping the input field, the name can be
edited using the dialogue for text input.
CPU = Teachbox or CPU <> Teachbox
Displays whether the teach programs of the robot (CPU) and the Teachbox are equal or
unequal.
Tooldata
Displays the Tooldata text of the teach program of the robot. The text for Tooldata can
only be edited in the properties window of the text editor.
Size
Displays the size of the teach program of the robot. The maximum size of a teach
program is limited to 32.768 bytes.
Primus Robot: max. 1000 lines
Number Part Programs
Shows the number of part programs of the teach program of the robot: ROBOT-PRG,
PERI-PRG, ROBOT-REF, PERI-REF, ALLMODE-PRG and up to 11 additional part
programs.
Number Placing Programs
Shows the number of placing programs used in the teach program of the robot. The
maximum number of placing programs available in a teach program is limited to 16.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 321

If a picture has been associated with the selected teach program, can be used to
open the picture viewer.

can be used to email the Teach program as an email attachment (*.wip, *.htm
and *.txt file) using the manual email function of the robot.

Use to discard the entries and to close the window.

Use to confirm the entries and to close the window.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 322

3.6.3.6 Print
This function is used to print the teach program loaded in the Teachbox to either a
UNICODE-textfile *.TXT or an HTML-file *.HTM on the USB stick. Path and name of the
file are selectable. The default folder is D:\ROBOT\PRINT. The generated file can be
opened, displayed and printed with a PC.

Fig.: Window to print a teach program to a file

The button right next to the field for the filename is used to select the type of file for
printing:

activates printing to a textfile

activates printing to an HTML-file

The field Save in displays the path of the current folder.

The display of the contents of the current folder uses the following icons:

for a sub-folder

for a textfile *.TXT

for an HTML-file *.HTM

Only files of the same type as selected for the printout will be displayed.

The field Filename suggests the last filename used or the teach program name as
filename. After tapping the field you can use the dialogue for text input to change the
filename as desired. By tapping it in the display of the current folder, you can also use
the name of an existing file.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 323

is used to step up one folder.

opens the standard folder for this file operation.

could be used to create a new folder.

is used to delete the selected file or folder.

is used to rename the selected file or folder.

can be used to optimize the display of the contents of the folder for either long or
short file names.

is used to open the selected folder.

is used to save the printout to the current folder, applying the name from the
field Filename.

is used to abort the function and close the window.

Before storing is executed, a check is made to see whether a file of the same name is
already stored in the selected folder, and a checkback message may appear.

3.6.3.7 Exit to Main

Use the button or the option Exit to Main of the File menu to exit the Quick
Edit.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 324

3.6.4 Parameters for the Quick Edit

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

3.6.4.1 Create Parameters

You can create parameters in the Text Editor using the function Quick Edit Definition
in the Setup menu.

Fig.: Quick Edit Definition

Use the buttons on the left side of the screen to create parameters:

creates a percentage parameter for speed, acceleration and vacuum pressure.

creates a time parameter.

creates an absolute speed parameter.

creates a position parameter.

creates a counter value parameter.

creates a placing program parameter.

creates a distance parameter for commands with relative position values.

creates a parameter for predefined positions.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 325

Press to open the dialogue for changing the name of the parameter.

Press to open the dialogue for inputting an explanation text for the parameter.

Press to open the dialogue for managing axes values for axes related parameters.

Here, press to add an axis value to the parameter. You can remove axes values

marked with a from the parameter with .

Press to open the dialogue for determining the initial values, minimum and
maximum values for the parameter.

Press to open the dialogue for activating one or more display filters for the
parameter. The filter for the parameter type of the parameter is activated by default.

Press to open the dialogue for adding a picture or an animation to the parameter.
For pictures use PNG files. For animations MNG files are supported. The recommended

size is 150 x 175 pixels. Press to remove pictures and animations from the
parameter.

If several parameters are present, you can use the buttons and to
move the blue active one up and down in the sequence of parameters.

Press to exit Quick Edit Definitions.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 326

3.6.4.1.1 Create a Parameter-Counter Shortcut for the Quick Edit

This function enables the possibility to modify countervalues directly from the Quick
Edit. Creating a Parameter CounterShortcut is also done in the Text Editor by use of
the function Quick Edit Definitions in the menu Setup.

Push the button and hold it pressed.

Choose the second button in order to create a Parameter CounterShortcut.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 327

Press to open the dialogue for determining the initial values, minimum and
maximum values for the parameter.

Tap the field Counter to assign the Parameter Shortcut to the desired counter. Confirm

your entries then with .

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 328

Press to open the dialogue for changing the name of the parameter.

Press to open the dialogue for inputting an explanation text for the parameter.

Press to exit Quick Edit Definitions and return to the Text Editor.

The created Parameter CounterShortcut is shown in the Quick Edit after

transferring the changes.

The countervalue can be changed also during operating mode Automatic. The new
value is implemented into the teach program immediately. (see also 3.6.2 Operation of
the Quick Edit)

3.6.4.2 Apply Parameters

Previously created parameters can be applied to teach commands in the text editor. For
this display the parameter toolbar with Show Parameter Toolbar in the Edit menu first.

When you select a teach command now, for which a parameter is available, you can use

to open the dialogue for applying parameters.

Fig.: Applying a parameter

Tap the parameter you want to apply to the teach command.

You can use to remove the parameter from the selected teach command.

You can use to remove all parameters from the selected teach command.
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 329

4 How to Teach a Program

Before teaching the robot a program for the first time, read the safety instructions and
the operating manual completely.

Familiarity with the operating functions of the R8.3 control is essential for creating a teach
program.

4.1 Programming the Robot in the Text Editor

The robot is programmed simply by manually moving the robot through the motions and
functions that you want it to make in automatic mode. The instruction sequence created
in this way is stored in a teach program and is then processed step by step in automatic
operation. When the last instruction is reached, the program sequence is begun again at
the first instruction.

A program may be created completely new (as described below) or may be a revision of
an existing program. Once you are familiar with programming, revising an existing
program and saving it with a new name is a much quicker way to create programs.

4.1.1 Creating a New Program in the Text Editor

1) Enter the Text Editor by pressing .

2) To start with a blank program, the program stored in the editor must first be
deleted. This can be done by selecting the option New in the menu File. In the
dialogue Options for new teach program certain elements of the existing
program can be selected to be kept with the new program.
3) Set the threshold of the vacuum under-pressure for the utilized vacuum circuits.
4) Starting from the reference position, move the robot manually to trace the
movements that you want the robot to make. Manual movements are made by

selecting the desired axis (labeled on the robot) with the buttons

. After selecting the kind of motion, the axis can be moved to

the desired position using the drive keys. (+ direction is away from reference
position and - direction is toward reference position.)

When you reach the desired position, press and the instruction will be
stored as a line in the program. (Only the instruction active when you press the

key will become a line in the teach program – all other motions made will
be ignored.)
5) Repeat the process for the remainder of the motions and functions that you want
the robot to reproduce.
6) The program is complete once you have programmed all of the motions and
functions desired and the robot is in a suitable position to restart from the
beginning of the program.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 330

Caution!
After placing the parts the Y and X axes must be positioned suitable for traveling
over the IMM, since the first motion in the program is typically a Z-axis (traverse)
motion towards the molding machine.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 331

4.1.2 Verifying Your Program Using STEP Mode

1) Bring the cursor back up to the beginning of the program using the button .

2) Move the robot to reference position with the key.

3) Test the program one line at a time in the STEP mode.

Each time the key is held down, the next instruction will be executed.

4) Releasing the key will cause the robot to be halted immediately, in order to
avoid collisions or other program errors. A flag will appear.
Correct the program line if necessary and then continue to step through the
program.

5) When the end of the program is reached, press the key and the cursor will
jump back up to the beginning of the program.
It is important to continue stepping through the program a second time to
verify that there is no problem with the robot’s position at the end of the
program.

4.1.3 Storing Your Program on a storage medium

1) Connect a USB stick to the Teachbox, if required.

2) Press the button to enter the text editor again.

3) Use the option Save as in the menu File to callup the function for saving programs.
After tapping the field Save in select either the internal storage medium of the
Teachbox or the USB stick as the target medium. The teach programs *.WIP
already stored on the selected medium will be displayed.
4) Enter the desired name for the program using the dialogue for text input and

confirm with .

5) Press to store the program and to exit the function.

6) Use to exit the editor, press to transfer your new program into
the robot. Decide to reset all counters and placing programs or not.
7) You are now ready to run the program in full AUTOMATIC mode.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 332

4.2 Program Example

The following example will help you to further understand and practice the teach
programming of the system.

Note that this is only an example. At a minimum, axis positions, IMM interface signals
and program functions must be adjusted to your specific application!

The program example is based on a robot with 2 vacuum circuits and 2 gripper circuits.

4.2.1 Function of Program

Plastic housings are to be injection molded.

The robot’s job is first to move into waiting position above the injection molding machine.
When the mold opens, the robot removes the molded part. The molded part is stacked
on a conveyor by means of a placing program. When the stack is finished, it is carried
away by the conveyor.

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 333

4.2.3 Sketch of Sequence

The ejector presses the parts on the vacuum cup.

Fig.: Sequence

1 ... Reference position

2 ... Waiting position over the mold
3 ... Part removal position inside the mold
4 ... Placing positions in the box on the conveyor

4.2.4 Sketch of Depositing Program

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

4.2.5 Reference Travel of Robot

The robot reference program must include axis motions in the mold, in order to allow
reference travel out from the mold area. If a part is on the gripper, it shall be placed on a
safe position. In reference position, all vacuum circuits are switched off and all grippers
are opened.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 334

4.2.6 Robot Teach Program (Robot Prg.)

0001 ECOMODE ON Turn on automatic speed settings.

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 335

4.2.6.1 Placing Program Placingp-001

Name of placing program: Placingp-001

Drive: 1D
Sequence of axes movement: ZXY
Sequence of placing: ZXY
Stacking sensor: No
Axis: X Y Z
Start position: 100.0 1000.0 600.0
relative endposition: 100.0 -300.0 -400.0
Number of Parts: 2 3 4
Displacement: 0.0 0.0 0.0

4.2.7 Reference Program for the Robot (Robot Ref.)

0001 IF MOLD AREA Reference travel from in and over the mold.
0002 IF I(ROLLER SWITCH S5) = OFF If inside the mold,
0003 WAIT IMM: EJECTORS BACK = ON check for the ejectors,
0004 X: 114.9 and position the X axis first.
0005 ENDIF
0006 Y: 0.0 Move out from the machine.
0007 X: 0.0
0008 C: 0.0
0009 ELSE Reference travel in the placing area.
0010 Y: 0.0 Move up from the placing area.
0011 X: 0.0
0012 ENDIF
0013 –
0014 IF Vacuum-01 = ON If a product is on,
0015 Z: 1267.8
0016 C: 90.0
0017 X: 173.8
0018 Y: 804.7
0019 Vacuum-01 = OFF place it on a safe position.
0020 TIME = 1.00s
0021 Y: 0.0
0022 X: 0.0
0023 ENDIF
0024 –
0025 C: 0.0 Move to the reference position.
0026 Z: 0.0
0027 Vacuum-01 = OFF Switch all vacuum and
0028 Vacuum-02 = OFF
0029 Gripper-01 = OPEN gripper circuits to their reference state.
0030 Gripper-02 = OPEN
0031 -

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 336

5 Troubleshooting
5.1 Operating Errors
These errors are the result of operational causes. If such an error occurs, the relevant
text error message will be displayed on the teachbox. Multiple errors are listed according
to their priority:

Every error message is preceeded by an error code with the following meaning:

Error group – Error number – Supplementary number

In addition, the error icon is displayed on the right in the status line.

The majority of these errors cause an immediate stop of the robot and a switch to
MANUAL mode. In order to continue automatic operation, first clear the errors by

pressing the key, after their causes have been eliminated. The robot must be
moved to reference position before restarting automatic operation.

Errors whose cause is still present are displayed in red. If the cause of error is eliminated
or is no longer active, the display color changes to gray.

Errors whose cause is still present cannot be acknowledged.

Pressing closes the window, but cannot acknowledge or delete errors.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 337

5.1.1 Operating Errors in Plain Text Messages

5.1.1.1 Axis Error messages

Group No. Supplement Message Cause/Remedy
004 000 0-11 xx: CONTOURING ERROR The actual speed of the axis lags
behind internal calculations. This can
be caused by mechanical friction in
guides/bearings or by a too high
payload. May also indicate a
defective converter or servo module.
004 001 0-11 xx :ENDSWITCH 0-POSITION While the axis was moved, the end
switch in - direction had been hit.
004 002 0-11 xx :ENDSWITCH END-POSITION While the axis was moved, the end
switch in + direction had been hit.
004 003 0-11 xx :MOTOR TEMPERATURE Motor temperature too high.
004 004 0-11 xx :FREQ. INVERTER FAULT There may be many causes for an
inverter fault. Read the display on the
Inverter and contact our nearest
service facility.
The error messages of the controller
can be confirmed be sending a drive
command (selecting the axis emits
the release signal). If for example 3
errors are active at the controller, the
axis has to be selected 3 times.
However, this error may also indicate
a mechanical defect or sluggishness
of guides/bearings.
004 005 0-11 xx: ENDSWITCH MONITORING Reserved for future use
When both end switches are active at
the same time, e.g. when end
switches on a pneumatic
axis/cylinder are adjusted too close or
in case of electrical fault.
004 006 0-11 xx :ENCODER FAULT This error indicates, that the
incremental encoders do not count as
provided. The reason for this could be
a cable failure in the incremental
transmitter line or a defect in the
scoring logic. Another cause might be
increased mechanical friction
between guide shaft and bearing. In
this case this error occurs mainly at
very low speeds, especially in the first
acceleration or last braking phase.
004 007 0-11 xx :STROKE LIMIT The axis reported an actual position
outside its stroke limits.
004 008 0-11 xx :SPEED LIMIT FAILED During operation with dead-man-
keys the axis moved faster than 250
mm/s
004 009 0-11 xx : SAFETY CONTACT FAILED !!Unused!!
004 010 0-11 xx : AXIS POSITION NOT ALLOWED The pneumatic axis has stopped
between its valid positions; none of
the position limit switches is actuated.
004 011 0-11 xx: BRAKE OVERLOAD !!Unused!!
004 012 0-11 xx :ILLEGAL SET POSITION There is an invalid set position in the
teach program for the robot or the
stroke limit was set too low. With
activated safety areas this message
appears as soon as the robot would
leave the safety areas.
004 013 0-11 xx :UNCONTROLLED SPEED The numerical axis has left its set
position during standstill. Brake or
axes contactors might be defective.
004 014 0-11 xx: UNCONTROLLED !!Unused!!
ACCELERATION

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 338

Group No. Supplement Message Cause/Remedy

004 015 0-11 xx: ROLLER SWITCH UNEXPECTED The axis moves and the roller switch
changes its state, but no memorized
switching point is near the actual
position. Either the roller switch is
defective or the position of the roller
switch bar had been changed.
004 016 0-11 xx :OUT OF SAFETY AREA !!Unused!!
At least one axis is outside the defined
safety area. To travel back into the
safety area, deactivate Monitoring in
the Menu INIT.
004 017 0-11 xx :AXIS NOT IN 0-POSITION Before the start of the standard
reference travel the B axis is checked
for being in 0-position. If it is not, the
reference travel is aborted by sending
this error message.
004 018 0-11 xx : ROLLER SWITCH EXPECTED The axis moved past a memorized
switching point, but the roller switch
input has not changed its state.
The related mold safety switch (or its
circuitry) is defective, or the position of
the roller switch bar has changed.
004 019 0-11 xx :POSITION MONITORING Position monitoring compares
internally the listed end position with
the actual position. If they do not
correspond, this error message
appears.
004 020 0-11 xx :LATCH NOT OPEN This error occurs, when the latch of a
digital axis cannot be released at the
beginning of a movement. It will be in
most cases a mechanical problem.
004 021 0-11 xx :EJECTOR TOO FAST / Occurs at the Push function. The
BREAKING DISTANCE REACHED movement of the ejector was too fast,
or the distance between intermediate
position and target position is too short.
004 022 0-11 xx :TIME MONITORING Pneumatic axis: the axis did not reach
its target position within the time limit of
10s.
Digital axis: the axis should receive a
new counting edge every 750ms and
reach its target position within the time
limit of 10s.
Numeric axis: the robot starts an axis
movement, but the inverter is not ready
after 2s. Possibly main power supply is
not available.
004 023 0-11 deprecated xx: INTERMEDIATE !!Unused!!
POSITION NOT POSSIBLE
004 024 0-11 xx :COLLISION MONITORING One of the (partly optional) collision
monitorings has been triggered: Mold
Monitoring, Roller Switch Monitoring,
Safety Areas, Collision Monitoring
AND/OR, Carrier Monitoring.
According to the configuration of the
robot.
004 025 0-11 xx :MANUAL MOVEMENT DENIED Either the dead-man-key has not been
released and pressed again, when
switching between axes in manual
mode of the safety package;

or somebody tried to move further

towards the obstacle, with the axis
already positioned in violation of a
safety area.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 339

Group No. Supplement Message Cause/Remedy

004 026 0-11 xx : ROLLER SWITCH REPEATEDLY The roller switch input changed its
state without an axis movement.
The axis moved in negative direction
and has travelled over the first
memorized switching point already,
but the roller switch input changed its
state again.
The axis moved in positive direction
and has travelled over the last
memorized switching point already,
but the roller switch input changed its
state again.
The related mold safety switch (or its
circuitry) is defective, or the position
of the roller switch bar has changed.
004 027 0-11 xx : LATCH NOT CLOSED The latch of a digital axis could not be
closed at the end of the movement.
Either a mechanical problem or an
edge counting failure.
004 028 0-11 xx : CRANE IN ROBOT AREA With the optional crane interlock
active, the robot may not be moved,
while the crane is in the robot area.
004 029 0-11 xx : CABLE BREAK Digital axis: The error occurs, if the
inputs for 0-Position Check and
Encoder Check are LOW, and neither
input Line A nor Line B is HIGH.
Numeric axis: see error message “41”
004 030 0-11 xx : TORQUE MONITORING The actual torque was bigger than the
calculated maximum torque. Possible
causes include collision, overload
and sluggishness.
004 031 0-11 xx : CARRIER MONITORING The collision monitoring "carrier
monitoring" has been triggered.
004 032 0-11 xx : POSITION MONITORING The robot left its set position while
(WAIT IMM) being in the operation mode Wait
IMM.
004 033 0-11 xx : BELT INSPECTION INTERVAL As soon as the belt inspection interval
REACHED is reached the error message will
show up once. Additionally, it will
appear again, whenever the robot is
being powered up and the interval
has already been reached prior to
powering off. The belt should be
checked and checking must be
confirmed.
004 034 0-11 xx : BELT REPLACEMENT When the belt replacement interval is
INTERVAL REACHED reached, the error message will
display one time. Additionally, it will
appear whenever the robot is being
powered up and the interval has
already been reached prior to
powering off. The belt must be
replaced and the replacement must
be confirmed.
004 035 0-11 xx : CARRIER MONITORING VABS The collision monitoring "carrier
monitoring" has been triggered
during automatic mode while
performing a VABS movement.
004 036 0-11 xx : OVERLOAD DETECTION Overload was detected. Reduce
DYNAMIC DRIVE DISABLED payload or acceleration or enable
Dynamic Drive.
004 037 0-11 xx : ROLLERSWITCH OUT OF A switching point of an emulated
STROKE LIMIT roller switch is located outside of the
stroke limits of the axis.
004 038 0-11 xx : BRAKE HOLDING FORCE TOO The automated brake test returned
LOW not enough holding force for the
brake. This may lead to unexpected,
uncontrolled movements of the axis
at an idle robot. Have the brake
(motor) of the respective axis be
repaired/replaced immediately.
004 039 0-11 xx : REFERENCE DRIVE Start of the reference missing drive
WITHOUT REFERENCE SWITCH for axis without 0 position or direction
switch not possible.
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 340

004 040 0-11 xx : WITH ABSOLUTE ENCODER The error occurs if the inverter
RETURNS INVALID POSITION returns an invalid position (control
word flag) after power on.
Possible reasons:
Battery power supply lost during
power off
Motor - Inverter cable connection lost.
004 041 0-11 xx : A24V MISSING (STO) The error occurs when the robot
starts an axis movement, but the
inverter switched 24 Volts are not
available.
Reasons:
cable break, connectors, …
004 042 0-11 xx : INVERTER NOT READY The error occurs when the robot
starts an axis movement, but the
output stage is not supplied with
power.
Reason: main power supply is not
available

The supplementary number indicates the axis, xx stands for the axis designation.
000 ... X, 001 ... Y, 002 ... Z, 003 ... A, 004 ... B, 005 ... C, 6 ... X2, 7 ... Y2, etc.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 341

5.1.1.2 Vacuum Error messages

Group No. Supplement Message Cause/Remedy
006 000 0..n VACUUM xx PART LOST This error message appears when
the vacuum monitoring for the
indicated circuit is activated,
because the vacuum pressure of
the respective circuit falls below the
preset threshold.
006 001 0..n VACUUM xx NOT OFF The vacuum reference position was
chosen to be OFF, but at the end of
the reference travel the respective
vacuum circuit was not OFF.
006 002 0..n VACUUM xx NOT ON The vacuum reference position was
chosen to be ON, but at the end of
the reference travel this vacuum
circuit was not ON.
006 003 0..n VACUUM PUMP THERMO- Thermal contact of the vacuum
MONITORING pump responded to increased
motor temperature.
006 004 0...n VACUUM xx DEAD-MAN-KEY NOT With safety not met, the key switch
PRESSED has to be set to manual mode, and
a dead-man-key must be pressed
to make the switching of a vacuum
possible.
006 005 0...n VACUUM xx BLOW OUT NOT OFF Vacuum blowout was switched on
at the end of the reference travel.
006 006 0…n VACUUM xx SUCTION CUP LEAKY The vacuum suction cup monitoring
level is not reached within 10 runs.
Change the suction cup and check
the vacuum hoses for leakiness.

xx indicates the vacuum number, e.g., 01

Supplementary numbers: 000 = VACUUM 01

001 = VACUUM 02, etc.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 342

5.1.1.3 Gripper Error messages

Group No. Supplement Message Cause/Remedy
007 000 0..n GRIPPER xx PART LOST This error message appears when
the gripper monitoring for the
indicated circuit has been activated
and the part monitoring input of that
gripper signals part loss.
007 001 0..n GRIPPER xx NOT OPEN The gripper reference position was
chosen to be OPEN, but at the end
of the reference travel this gripper
was not OPEN.
007 002 0..n GRIPPER xx NOT CLOSED The gripper reference position was
chosen to be CLOSED, but at the
end of the reference travel this
gripper was not CLOSED.
007 003 0..n GRIPPER xx TIME MONITORING The gripper has not reached its set
position within the time limit.
007 004 0...n GRIPPER xx DEAD-MAN-KEY NOT With safety not met, the key switch
PRESSED has to be set to manual mode and
a dead-man-key must be pressed
to make the switching of a gripper
possible.
007 005 0...n GRIPPER xx NOT RELEASED The reference state of the gripper is
RELEASED, but the gripper was
actually OPENED or CLOSED at
the end of the reference travel.

xx indicates the gripper number, e.g., 01

Supplementary numbers: 000 = GRIPPER 01

001 = GRIPPER 02, etc.

5.1.1.4 Peripheral Equipment Output Error Messages

Group No. Supplement Message Cause/Remedy
009 000 0..n xx MONITORING This error message is displayed as soon as part
monitoring for the indicated peripheral output is
activated, and the peripheral input with the same
number is OFF.

xx shows the PO names: e.g., PO-001

Supplementary numbers: 000 = PO-001

001 = PO-002, etc.

5.1.1.5 Cylinder Error Messages

Group No. Supplement Message Cause/Remedy
010 000 0...n CYLINDER xx NOT ON The cylinder has moved away from its on-position
during standstill. Possible causes are loss of air
pressure or mechanical problems. Check
periodically if the cylinder left its position during
standstill.
010 001 0...n CYLINDER xx NOT OFF The cylinder has moved away from its off-position
during standstill. Possible causes are loss of air
pressure or mechanical problems. Check
periodically if the cylinder left its position during
standstill.
010 002 0…n CYLINDER NOT !!Unused!!
RELEASED
010 003 0...n CYLINDER xx TIME The cylinder has not reached its desired target
MONITORING position within the set timeout.
010 004 0...n CYLINDER xx DEAD- With safety not met, the selection switch has to be
MAN-KEY NOT PRESSED on manual and a dead-man-key must be pressed
to enable moving a cylinder.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 343

5.1.1.6 Conveyor Belt Error Messages

Group No. Supplement Message Cause/Remedy
019 000 0..n CONV. xx The thermal contact of the conveyor belt
TEMPERATURE responded to increased motor temperature. Any
MONITORING active conveyor command will be aborted, which
means the conveyor will not move on even if the
input falls back to its normal state.
019 001 0..n CONV. xx FOLLOWING The follow conveyor command has reached the
Primus TARGET POSITON target position P2. The error message has been
Robot: REACHED triggered, and the teach program will continue at
the label for the alternative routine.
not
available

xx shows the belt number: e.g., 01

Supplementary numbers: 000 = CONVEYOR BELT 01

001 = CONVEYOR BELT 02, etc.

5.1.1.7 Load Cell Error Messages

Group No. Supplement Message Cause/Remedy
020 000 0..n LOAD CELL xx LATCH The load cell latch is actually open (active
Primus NOT CLOSED measuring) at the beginning of the reference
Robot: travel.
not
available

5.1.1.8 Camera Error Messages

Group No. Supplement Message Cause/Remedy
021 000 0..n CAMERA xx COMMUNICATION TCP/IP connection to the camera is not
Primus ERROR possible. Check:
Robot:  The configured IP address and
not port
 The Ethernet cables/switches
available
/routers
 The loaded camera job
(TCP/IP settings)
 The-camera state (offline
/online)
021 001 0..n CAMERA xx USER DLL New position from camera received, but
Primus FUNCTION NOT AVAILABLE user dll is not loaded or access to the
Robot: camera function is not possible.
Check:
not
 User dll is loaded
available
 User dll contains the camera
function (rebuild the user dll
project)
021 002 0..n CAMERA xx INVALID POSITION New position string from camera
Primus STRING received, but the string contains parsing
Robot: errors.
not
available

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 344

5.1.1.9 General Hardware Error Messages

Group No. Supplement Message Cause/Remedy
124 000 000 EMERGENCY STOP An emergency stop button was pressed
either at the IMM, a peripheral station or
at the robot.
After resetting the emergency stop
button, the power on key at the
subpendant must be pressed to switch
on the control-voltage again.
124 001 000 AIR PRESSURE TOO LOW The operating pressure of compressed
air dropped below 3.5 to 4 bars.
124 002 000 PHASE MONITORING Phase monitoring in the control cabinet
reports voltage fluctuations and
asymmetries in supply exceeding or
deceeding a given adjustable range.
124 005 000 OPERATION WITHOUT ROBOT In order to change to automatic
operation, "Operation With Robot" must
be on. Use the button on the Subpendant
to switch on "Operation With Robot".
124 006 000 IMM IN MANUAL MODE The injection molding machine was in
Manual Mode when the AUTOMATIC
key was pressed.
124 007 000 MOLD MONITORING Mold safety ensures that the robot does
not travel into a closed mold or that the
mold does not close while the robot is in
the mold area. Mold safety is realized
with the roller switches S5 (Y axis) and
S6 (Z axis).
124 008 000 IMM SAFETY DOOR OPEN The safety door of the injection molding
machine was opened during automatic
operation.
124 009 000 DOOR NOT LATCHED The door of the safety package could not
be locked mechanically. The door
contact may have become bent, not
allowing the bolt to lock.
124 010 000 KEY SWITCH IN SETTING The safety system of the robot reports
MANUAL that the safety requirements for operation
have not been met.
124 011 000 DEAD-MAN-KEY TIME The permit key on the Teachbox must be
MONITORING pressed and released at regular
intervals.
124 012 000 REFERENCE IN MOLD NOT For safety reasons, the standard
ALLOWED reference travel may not be carried out in
the mold area. The error message
appears when the robot is in the mold
area and the operator did not program a
reference travel. Note that in the NO
REFERENCE mode the reference travel
cannot be carried out in the mold area.
124 015 000 RELEASE PERMIT KEY The permit key on the teachbox must be
pressed and released at regular
intervals.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 345

Group No. Supplement Message Cause/Remedy

124 016 000 COMMUNICATION FAILED Device-ID holds field bus-type which
leaded to COMMUNICATION FAILED
error:

0: CanBus

1: Profibus

2: Ethernet

3: RS232

4: RS485

5: Hardware Handshake

6: emergency block (teachbox cable?!)

Some further information about e.g. the

CanLine (Plug 1 to 3 on the R8 IPC) or
the device's station-nr may be available
and be displayed within the error text

e.g. "124 016 000: 18 3 Communication

failed" references the Canbus Line 3
and Station 18
124 017 000 TIME MONITORING PROCESS Time out at communication with an
COMMUNICATION emergency stop block or with a
Teachbox. In most cases normal
operation is possible after confirming the
error message.
124 018 000 SAFETY SYSTEM NOT ENABLED The safety system of the robot reports
that the safety requirements for operation
have not been met. Also check
EMERGENCY STOP of robot and IMM
as well as CONTROL VOLTAGE ON.
124 019 000 BMM IN MANUAL MODE BMM number is given in device-ID
124 020 000 SAFETY AREA: x VIOLATED A robot axis tried to enter an exclusionary
safety area. Move the axis back out of the
safety area.
0 … 99: error from an area defined in the
teach program
100 … 199: error from an area defined by
the global teach program
200 … 299: error from an area defined by
the configuration
124 028 000 CHECK CENTRAL LUBRICATION Stop the robot as soon as possible and
check the central lubrication system.
(Run out of grease?)
124 029 000 CENTRAL LUBRICATION FAILED Check and repair the central lubrication
system (Run out of grease?)
124 030 000 AUTOMATIC-MODE NOT The robot was not in Reference- or
POSSIBLE (“operating Mode“) Block-stop Mode, when the Automatic-
Mode button was pressed. 00x shows
the current Operation Mode:
0...Reference Missing, 1…Reference
Travel, 2...Reference, 3...Manual,
4...Block Stop, 5...Block Stop Travel,
6...Automatic
124 031 000 CENTRAL LUB. PRESSURE Check and repair the central lubrication
DROP NOT OCCURED system (blocked?)
124 032 mmm IMM “mmm“ MOLD IS OPEN The "Easy Automatic Start Sequence"
cannot be started.
124 033 mmm IMM “mmm“ MOLD POSITION The "Easy Automatic Start Sequence"
UNDEFINED cannot be started.
124 034 mmm IMM “mmm“ MOLD MONITORING An attempt was made to enter the
BREAKING DISTANCE respective IMM while its mold was not
completely open.
124 035 000 LUBRICATION INTERVAL Is triggered once, when the lubrication
REACHED interval is being exceeded. Additionally
the message will appear each time the
robot is being powered up with the
lubrication interval exceeded.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 346

Group No. Supplement Message Cause/Remedy

124 036 000 CONTROL VOLTAGE NOT ON Indicates that the control voltage is not
on. In order to be able to meet safety, the
control voltage must be switched on,
using the button "Control Voltage On" at
the Subpendant (emergency stop block).
124 037 000 CONTROL VOLTAGE CIRCUIT Hardware defect in connection with the
PROBLEM control voltage relay.
124 038 000 CENTRAL LUBRICATION TANK The central lubrication system signals
EMPTY that its tank is empty.
124 039 000 IMM-INPUT DIFFERENCE When restarting the robot after a stop,
DURING BLOCKSTOP one or more IMM signals states are
different than at the moment of stopping.
124 040 mmm IMM “mmm” ROBOT OUTSIDE A problem with the generation of the
MOLD CIRCUIT PROBLEM “robot mold area free” signal was
detected. Check related electrical
circuitry and relay.
124 041 mmm IMM “mmm” MOLD STATE NOT The states of the inputs from the iMM are
SAFE FOR ENTRY different from their reference (stored at
the falling edge of the IMM signal Mold Is
Closed) and they do not match the states
of the outputs to the IMM.
124 042 Mmm IMM “mmm” MOLD CLOSE/OPEN The configurable functionality "Prevent
INPUTS MISMATCH the reference drive" is activated.
The reference drive (reference missing
and standard reference) is not possible,
because the input S5 and/or S52 is not
active.
Create a reference teach program to
avoid the error message or you drive
manually to the S5/S52 switching point.
124 043 000 REFERENCE DRIVE BLOCKED The function "Prevent the reference
BY INPUT drive" is configured. The standard
reference drive is inhibited because the
input S5 and/or S5.2 is not ON. Use a
reference teach program to avoid the
error message or use manual functions
to drive onto the S5/S5.2 switch.
124 044 000 SAFETY RELAY MONITORING The safety relay monitoring hardware
24 V CIRCUIT PROBLEM signals a 24 volts circuit problem.
124 045 000 SAFETY RELAY MONITORING The safety relay monitoring hardware
0 V CIRCUIT PROBLEM signals a 0 volts circuit problem.
124 046 mmm “mmm” MOLD OPEN SYNC IMM The mold movement changed its
DIRECTION CHANGE direction while the Mold opening
synchronization command was being
executed.
124 047 mmm “mmm“ ROBOT MOVES INTO An attempt was made to move in to the
MOLD WITH ACTIVE MOLD mold while the permit Mold Close was
CLOSE SIGNAL on.
124 048 mmm “mmm“ MOLD POSITION Nothing is connected to the analog input
MEASUREMENT INPUT OPEN for the mold position measurement.
124 049 000 OUTSIDE WORKING AREA SR: x Axes are outside the defined working
areas (if working areas are defined).
0 ... 99: error from an area defined by
teach program
100 ... 199: error from an area defined by
the global teach program
200 ... 299: error from an area defined by
configuration.
124 050 mmm BRAKE RESISTOR FAN “mmm” Fan for brake resistor is not working
FAULT
124 051 mmm IMM “mmm” IN AUTOMATIC Robot stays in the dry cycle mode and
MODE the IMM stays in automatic mode
124 052 mmm “mmm” EJECTOR FORWARD The ejector changes its direction during
DIRECTION CHANGED the respective teach command (permit).

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 347

Group No. Supplement Message Cause/Remedy

124 053 mmm “mmm” NUMBER OF Error occurs if the emergency stop is
EMERGENCY STOPS REACHED triggered by the emergency stop button
or by opening the IMM door
AND
the velocity of the axes is above a
percentage set by a parameter
AND
the number of times the emergency
stops reach a certain number set by a
parameter.
124 054 0…n CABINET FAN NUMBER FAULT The cabinet fan signals an error. Input
1000 (fan 1) or 1001 (fan 2) is low during
automatic mode.
124 055 0…n AXIS FAN FAULT The axis fan signals an error. Input fan
monitoring or fan booster monitoring
inside the axis IO field.

5.1.1.10 General System Error Messages

Group No. Supplement Message Cause/Remedy
127 003 ggg EXTERNAL TEACH PROGRAM A Teachprogram from an external source
CHANGE was received. The supplemental error
number indicates the source like this:
0...Teachbox 1, 1...Teachbox 2, 10...IMM,
23...Remote Access
127 010 ttt REAL-TIME VIOLATION Internal software fault. Processing of the
axes calculations was started too late. The
supplemental error number shows the
delay in milliseconds.
127 011 ttt SEVERE CLOCK OVERFLOW Internal software fault. Processing of the
axes calculations was started too late. The
supplemental error number shows the
delay in milliseconds.
127 012 000 QUIT QUEUE FULL Internal software fault while processing
axes drive commands.
127 013 000 SET STROKE LIMITS NOT In case of axes being assigned to the All
POSSIBLE ALLMODE PRG. Modes Program, the Stroke Limits cannot
be changed while the All Modes Program is
running.
127 014 000 USER REALTIME-FUNCTION: Executing the user function "RTFunc" has
EXECUTION TIME TOO LONG taken too much time. The execution is
stopped. Check the user dll functions and
restart the CPU.
127 015 000 SYSTEM ERROR Contact manufacturer

5.1.1.11 CAN Device Error Messages

Group No. Supplement Message Cause/Remedy
141 000 aaa xx :FREQ. INVERTER FAULT ff Only on robots equipped with CAN-BUS
controlled inverters. Contact our service
department for further information.

The error messages of the controller can be

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

However, this error may also indicate a

mechanical defect or sluggishness of
guides/bearings.
141 001 mmm mm : CAN-MODULE An error occurred while trying to
COMMUNICATION ERROR communicate with the CAN module with the
indicated number.
141 002 bbb CAN Bus “bbb” WARNING This indicates communication problems on
or the indicated CAN bus line.
CAN Bus “bbb”|”BUS OFF” WARNING indicates bad communication.
BUS OFF indicates no communication.
141 003 bbb “bbb” ROBOT INTEGRATION The communication between two robots is
COMMUNICATION ERROR interrupted because of an unpowered
second robot or a cable break.
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 348

Group No. Supplement Message Cause/Remedy

141 004 bbb CAN Bus “bbb” AXIS An error during axis specific parameter
PARAMETER TRANSFER download occured. (for more details take a
look into the bootup infos)
ERROR
141 005 bbb CAN Bus “bbb” BASE An error during base parameter download
PARAMETER TRANSFER occured. (for more details take a look into
the bootup infos)
ERROR
141 006 0-11 xx : INVERTER “CANopen Device-ID describes: contains axis number
code”: MANUFACTURERS 0 -11 ~ X, Y, Z , A, B, C, X2, Y2, Z2, A2, B2,
C2
SPECIFIC CODE “ttt” Additional info byte 1 = CAN line
Additional info byte 2 = node ID
Additional info byte 3 = Inverter type
(generic = 0; Sanyo = 1, W-Drive = 2, PRO-
Drive = 3)
Additional info byte 4-5 = CANopen code
(shown as hex 0x0000)
Additional info byte 6-7 = manufacturer
specific code (shown as hex 0x0000)
Additional info byte 8-38 = Text (0
terminated)

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 349

5.1.1.12 Teach program Compiler Error Messages

Group No. Supplement Message Cause/Remedy
160 000 000 TEACH PROGRAM TOO The program exceeds the memory size.
LARGE
160 001 lll LABEL NOT FOUND The label used by a JMP command could
not be found. The supplemental error
number indicates the label number.
160 002 sss SUBROUTINE NOT FOUND The subroutine used by a CALL command
could not be found. The supplemental error
number indicates the subroutine number.
160 003 000 COMMAND UNSUPPORTED The command is not supported by the
software version used in this robot.
160 004 NOT CONFIGURED DEVICE The Teach program uses a device that is
not present on this robot.
160 005 aaa aa: TARGET OUT OF STROKE The target for the respective axis is outside
LIMITS its stroke limits.
160 006 000 TEACH PROGRAM INVALID The Teach program is broken. Try to use a
safety copy of the Teach program, if
available.
160 007 000 CHECKSUM ERROR IN TEACH The Teach program is broken. Try to use a
PROGRAM safety copy of the Teach program, if
available.
160 008 ppp PLACING PROGRAM The Teach program contains the undefined
UNDEFINED placing program with the number indicated
by the supplemental error number.
160 009 nnn “part program name“ AXIS The axis definition of the respective part
Primus DEFINITION INCORRECT program contains an axis that is not present
Robot: on this robot.
not
available
160 010 CYLINDER DEFINITIONS DO An attempt was made to transfer a Teach
Primus NOT MATCH THE RUNNING program, while the All Modes Program was
Robot: ALLMODE PROGRAM running, with cylinder definitions not
matching the running program.
not
available
160 011 VACUUM DEFINITIONS DO An attempt was made to transfer a Teach
Primus NOT MATCH THE RUNNING program, while the All Modes Program was
Robot: ALLMODE PROGRAM running, with analog vacuum settings not
matching the running program.
not
available
160 012 CAN NOT REPLACE “part An attempt was made to transfer a Teach
Primus program name “WITH NEW program, while the All Modes Program was
Robot: ALLMODE PROGRAM running.
not
available
160 013 TEACH PROGRAM NOT In the current mode of operation it is not
ACCEPTED IN „operating mode“ possible to transfer the Teachprogram. The
supplemental error number indicates the
current mode of operation like this:
0...Reference Missing, 1...Reference
Travel, 2...Reference, 3...Manual, 4...Block
Stop, 5...Block Stop Travel, 6...Automatic
160 014 TEACH PROGRAM HEADER The Teach program is broken. Use a valid
INVALID Teach program.
160 015 TEACH PROGRAM VERSION The version of the Teachprogram loaded to
NOT SUPPORTED the robot is not supported. Eventually the
program can be converted to a compatible
version by loading it to the Teachbox and
transferring it back to the robot.
160 016 ERROR ON READING TEACH When a broken Teach program was
PROGRAM FROM FILE transferred as a file, e.g. at integration.
160 017 TEACH PROGRAM FROM The control number stored in the Teach
ANOTHER ROBOT program does not match the control
number of the robot. The Teach program
can be loaded to the Teachbox, and after
thorough checking be stored back into the
robot.
CAREFUL: The sequence and the
positions of the program probably do not
suit the current application!!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 350

Group No. Supplement Message Cause/Remedy

160 018 LOGICAL AND/OR SEQUENCE AND/ OR commands were found without a
ERROR preceding IF, JMP, WAIT, CALL command
with a condition in the lines directly before
the AND/OR commands
160 019 TEACH PROGRAM WAS NOT The new Teach program could not be
TRANSFERRED transferred; the existing Teach program in
the robot has been retained.
160 020 ppp “ppp“ PLACING PROGRAM The axes used in the indicated placing
COUNTER MISMATCH program do not match the axes definition of
the part program.
160 021 COMMAND INVALID The execution of the command is either not
possible or not allowed.
Examples:
Release axis teach command but release
function not configured.
Numeric axis teach command but the axis
is a digital axis.
160 022 MANUAL CONVERSION OF The All Modes program has the wrong part
Primus TEACH PROGRAM program number. The program must be
Robot: NECESSARY converted manually.
not
available
160 023 INVALID PARAMETER A Teachcommand has a parameter applied
that doesn't exist.
160 024 POSITION NAME NOT An axis movement command or placing
DEFINED program uses an undefined position name.
160 025 “ppp“ INVALID DIRECTION OF The stacking sensor movement of the
STACKINGSENSORDRIVE indicated placing program is pointing into
the opposite direction of the approaching
movement.
160 026 GLOBAL TEACHPROGRAM The global teach program has been loaded,
Primus COMPILE ERROR but it can’t be executed. In a global teach
Robot: program only All Modes programs may
contain commands; axes may not be used.
not
available
160 027 TEACH PROGRAM IS NOT The teach program has not been created
SUPPORTED BY THE LITE with a lite robot.
VERSION
160 028 PRIMUS: ONLY 1000 LINES A Primus robot supports only 1000 lines per
ALLOWED IN TEACH part program.
PROGRAM
160 029 PRIMUS: KIND OF PART A Primus robot supports only the Robot
PROGRAM NOT SUPPORTED program and Robot reference program, but
the transferred program contains an
Allmode program, a Peripheral program,
a Peripheral reference program a.s.o.
160 030 PRIMUS: MAX. NUMBER OF A Primus Robot supports only 2 Placing
PLACING PROGRAMS Programs.
EXCEEDED
160 031 PRIMUS: DOUBLE SERVO A Primus Robot supports only standard
PLACINGPROGRAM NOT placing programs.
SUPPORTED
160 032 IF WITHOUT ENDIF An if teach command without an endif
should be a treated as a logical error =>
compilation error and execution shouldn't
be possible
160 033 ILLEGAL TAUGHT AXIS A teach command (vabs, aabs, stacking
VELOCITY DETECTED sensor drive command, ...) contains a value
higher than the configured axis limits.
160 034 PARAMETER ASSIGNMENT An illegal parameter assignment was
NOT ALLOWED detected (parameter link to a all mode part
program teach command , ...).

The supplementary number indicates the axis, aa stands for the axis designation.
000 ... X, 001 ... Y, 002 ... Z, 003 ... A, 004 ... B, 005 ... C, 6 ... X2, 7 ... Y2, etc.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 351

5.1.1.13 Teach program Interpreter Error Messages

Group No. Supplement Message Cause/Remedy
170 000 000 DIVISION BY ZERO The Teach program attempted to do a
division by zero.
170 001 000 TOO MANY CALL-COMMANDS This error appears when the nesting depth
of subprogram calls becomes too big. The
cause could be a teach program error or too
frequent calling of CALL instructions
without previous encounter of RET
instructions.
170 002 000 RET WITHOUT CALL- Execution of the teach program has
COMMAND encountered a RET instruction before
having executed a CALL command.
170 003 000 “part program name“ ALREADY The Teach program attempted to start a
Primus ACTIVE part program that was already running.
Robot:
not
available
170 004 000 RESULT OUT OF RANGE The result of a counter / placing counter
calculation is out of the range of possible
values.
170 005 000 RUN ON SUBROUTINE The program ran on a Subroutine
WITHOUT CALL COMMAND command, without calling it with a CALL
command.
170 006 sss “stacking sensor name“ The stacking sensor was actuated while
UNEXPECTED processing a stacking sensor command or
a placing program with stacking sensor,
before the intermediate position was
reached.
170 007 ppp „ppp“ BOX CRASH An attempt was made to use the placing
MONITORING program to travel over the box below the
box height.
Check the position of the robot before
execution of the placing program.
170 008 ppp “ppp“ STACK CRASH An attempt was made to use the placing
MONITORING program to travel over the box below the
height of the stack.
Check the position of the robot before
execution of the placing program.
170 009 ppp “ppp“ MOVEMENT CONTRARY The traveling direction of the placing axis
TO STACKING DIRECTION does not match the calculated placing
direction.
Check the position of the robot before
execution of the placing program.
170 010 aaa “aaa“ ABSOLUTE MOVEMENT During the execution of the conveyor
Primus DURING CONVEYOR following command only relative
Robot: FOLLOWING movements are allowed.
not
available
170 011 000 SMART REMOVAL STRAIGHT The distance for straight travel in the Smart
FORWARD DISTANCE TOO Removal command is bigger than the
LONG overall distance programmed for the
respective axis.
170 012 aaa “aaa“ IS RELEASED An attempt was made to drive the released
axis using an axis drive command.
170 013 000 „part program name“ POSITION A Teach program command uses an
Primus UNDEFINED undefined or not completely defined
Robot: position.
not
available
170 014 000 AXIS PUSH INVALID MOTION Axis Push command:
DIRECTION The direction from current actual axis
position to intermediate position is different
than the direction from intermediate
position to target position.
A correct motion is not possible.
170 015 000 IMM PERMISSION TEACHCMD Occurs on execution of a IMM permission
BUT NO OPERATION WITH teachcommand when the operation with
ROBOT robot for that IMM is inactive.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 352

Group No. Supplement Message Cause/Remedy

170 016 000 WAIT IMM INPUT SIGNAL, BUT Occurs on execution of a Wait IMM
IMM IN MANUAL MODE teachcommand when that IMM is in manual
mode.
170 017 000 MONITORING ALREADY USED A Teachcommand tried to activate a device
monitoring that is already active.
170 018 000 PERMIT MOLD CLOSE The Teach program attempted to switch on
ALREADY ACTIVE the permit Mold Close although it was
already on.
170 019 000 MOLD CLOSE TAUGHT INSIDE The Teach program attempted to switch on
MOLD the permit Mold Close while the robot was
situated inside the mold of the IMM.
170 020 000 CAMERA POSITION IS Occurs if the camera position of the
UNDEFINED processed 1D/3D camera command is
undefined. (camera delivers a quality value
< 1, camera delivers no value for this axis,
camera delivers no values for this position)
170 021 000 EJECTOR FORWARD INVALID Direction actual axis position / intermediate
MOTION DIRECTION position is different to direction intermediate
position / target position => correct motion
not possible.

5.1.1.14 Configuration Error Messages

Group No. Supplement Message Cause/Remedy
180 000 000 CONTROL VOLTAGE The output 511 - Control Voltage On is configured
CONFIGURATION but not all other required IOs are configured.

Required IOs:
Input 511 - Control Voltage On,
Input 510 - Control Voltage On Monitoring,
Input 164 - Key Control Voltage On,
Output 511 - Control Voltage On
180 001 000 ANALOG VACUUM An analog vacuum monitoring is not correctly
CONFIGURATION assigned to a vacuum device or a hardware device.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 353

6 Maintenance
Following the recommended maintenance schedule is required to ensure trouble-free
operation of the robot. The robot warranty does not cover neglected or poorly maintained
equipment.

Maintenance must be performed by qualified personnel only.

6.1 General

The user of the robot is responsible for maintenance and monitoring of the safety devices
and systems.

In particular, the safety systems marked must be checked according to the

instructions to ensure a safe and fully functioning robot system.

Before entering the work envelope of the robot to perform maintenance work, lock out
the main power disconnect switch and turn off the compressed air supply to the robot.

IMPORTANT! Robots with pneumatic linear axes often use 5-way or 3-way valves,
which can leave trapped high-pressure air in a cylinder even with air pressure
removed. This can result in uncontrolled axis motions if one side of the cylinder is
exhausted during a maintenance procedure. For this reason, it is recommended that all
pneumatic axes be blocked to prevent unintended hazardous motions.

For workings that cannot be executed standing on the floor use standardized and
certified ascent devices only.

For safe operation of the robot use original spare parts only

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 354

6.2 Lubrication Instructions for Linear Guides and Gear Racks

6.2.1 Lubrication Intervals for Linear Guides at Standard Robots

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

Fig.: Window for lubrication interval of linear guides

When lubrication is done, reset the distance counter by pushing and close then

the window with .

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 355

6.2.2 Lubrication Intervals for Gear Racks and pinions at Standard Robots
The lubrication intervals are calculated automatically by the control system and are
displayed with a message “lube interval reached“ and the lubrication flag on the
upper right-hand corner of your screen. Generally, it is necessary to lubricate the gear
racks and the pinion after a distance of 500 km; the axis that completes this distance
first is the one that determines the beginning of the lubrication interval.

Fig. Window for lubrication interval of gear racks and pinions

When lubrication is done, reset the distance counter by pushing and close then

the window with .

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 356

6.2.3 Lubrication Procedures

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

6.2.4 Grease Recommendation

Wittmann Robots without automatic lubrication systems are lubricated by standard with
Dynalub 510 by Bosch Rexroth prior delivery to the customer. This grease is according
to US Fed Std.209 / ISO 14644-1 class 6 suitable for all standard- and clean room
applications at clean room classes > 1000.
The other greases mentioned in the list below can be used as alternative.

GREASE: MANUFACTURER TYPE

Bosch Rexroth AG Dynalub 510 Standard grease at
delivery
Castrol Longtime PD2
Chemie-Technik Ekalub GLS 135/N2 alternatively useable
Klüber Klüberplex BEM 34-132

Dynalub 510 can be ordered at Wittmann Company under the following item number:

 As 400g cartridge for the standard grease gun:

Wittmann item number: HA00001292

6.2.4.1 Lubricant suitable for food-stuff

For applications in the food industry use only Cassida Grease EPS2. Wittmann
Company provides this lubricant under the following item nuber:

 As 500g cartridge for the grease gun System-Reiner:

Wittmann item number: HA00001293

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 357

6.3 Drive Belts

Drive belts have to be visually checked for wear and tear or cracks every 6 month. If any
such are found, the affected drive belt has to be replaced immediately, in order to prevent
damages and idle times.

For safety reasons we recommend to replace the drive belts every 24 months during a
general maintenance session. Drive belts of high speed robots should be replaced every
12 months.

The refit of a drive belt may only be carried out by trained personal equipped with the
proper tools, because also the tension of the belt has to be set correctly.

Our skilled technicians are available to perform the refit.

6.4 Motor Brakes

When entering the protective gate (operating mode BlockStop or Manual), check if any
sagging is visible at the axes.

If this should be the case, the brake of the respective motor must be renewed
immediately.

A brake refit may only be carried out by trained personal. Before starting to work on a
vertical axis ensure that the axis is inhibited from falling down by suitable precautions.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 358

6.5 Battery Replacement

6.5.1 IPC
The battery of the IPC inside the cabinet serves to buffer the data in a part of the memory
(SRAM) in case of loss of supply voltage. At average operation of the robot, the lifetime
of the battery should be approximately 3 years.

In order to replace the battery, remove the

cover plate of the IPC.

The two screws securing the cover plate

are marked with arrows in the adjacent
illustration.

Now you can remove the old battery and

install the new one.

When inserting the new battery, take care

about the correct polarity according to the
adjacent illustration.

Finally, re-attach the cover plate of the IPC.

The battery should only be replaced while the robot is powered down! After switching off
the 24V supply, the battery of the IPC will be buffered for 5 minutes. The battery must be
replaced within this time, else data loss will occur!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 359

6.5.2 Sanyo R Inverters at Axes with Absolute Encoders

The batteries inside the Sanyo R inverters serve to secure the zero points of the axes in
case of loss of supply voltage. At average operation of the robot, the lifetime of the battery
should be approximately 5 years.

Fig.: Battery in a Sanyo R inverter

The procedure for replacing the batteries is as follows:

1. Move all affected axes to their zero points (with a reference travel).
2. Power down the robot.
3. Open or dismantle all covers as needed for accessing the inverters.
4. Flip open the front lid of the inverter.
5. Pull out the old battery and unplug it.
6. Push the new battery into the holder and plug it on. Make sure you feel the plug
locking in correctly.
7. Close the lid of the inverter.
8. Repeat steps 4 to 7 for all affected inverters.
9. Close and re-attach all covers.
10. Power up the robot.
11. Login as Admin.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 360

12. Open the menu Init – Absolute Encoders.

13. Select all affected axes.

14. Press in order to use the current positions of the axes as the zero point. Wait
until the positions of all selected axes show 0.0.

15. Exit the menu with .

Do not move the robot while you carry out steps 3 to 15. Else the zero point settings of
the robot will be lost!

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 361

6.6 Mold Safety Relays

The signals of the mold safety switches (“Roller Switches”) are processed and forwarded
using safety relays. These have a limited number of switching cycles as their life
expectancy.

We recommend having the mold safety relays replaced before the end of their life
expectancy.

The life expectancy of the mold safety relays is determined by the cycle time of the robot
and the number of switching cycles of the relays per robot cycle.
Relay life expectancy in years

Robot cycle time in seconds

shows the life expectancy of relays with 1 switching cycle per robot cycle:
Z-axes mold safety relays of standard robots with 1 placing area,
Mold safety relays of standard robots with absolute encoders,
Mold safety relays of IML units.

shows the life expectancy of relays with 2 switching cycles per robot cycle:
Y- axes mold safety relays of standard robots.

Example:
A robot runs an application with a cycle time of 10 seconds.
The life expectancy of the Y-axis mold safety relay is 8 years.
The life expectancy of the Z-axis mold safety relay is 16 years.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 362

6.7 Maintenance Schedule

INTERVAL IN
Description of Service OPERATING HOURS
PER CYCLE TIME
<10 s 10-30 s >30 s

1) Safety Systems and Devices

Emergency Stop Buttons: 150 150 150
When the device is at a standstill, activate the Emergency Stop switch
and check to see if „EMERGENCY STOP“ is indicated on the hand set.
The injection-molding machine must also indicate Emergency Stop.
Function of Permit Keys on the Teachbox: 150 150 150
Switch robot to manual operation, set the key switch at the safety door to
Set-up Mode. When the permit key is pressed, the “robot enabled“ light
must go on. This function must be tested with both permit keys.
Safety Roller Switches S5+S6: 150 300 500
Switch to operation without robot (robot LED key does not light).
Close mold slightly (Mold Open signal must be out). Now try to ride
into the mold area with the Y axis. The Y axis should ride only until
leaving S5. The error message “mold monitoring“ must be displayed
on the robot. Acknowledge message with ESC. Now try to close and
open the mold. This should not be possible, and an error message
should appear on the IMM. Now raise the Y axis.
See 6.2 See 6.2 See 6.2
2) Guides and Gear Racks
3) Other Components
Function of Vacuum Switches: 150 150 150
The vacuum switch inputs should be checked using the Input Display
screen on the teachbox. The input must only be on when a complete
set of parts is on the vacuum cups. Be sure that the input switches
back off when just one part is removed.
Air Filter: 150 300 500
Drain the filter bowl and check and fill the oiler as required.
IMPORTANT: Use only oil in accordance with ISO VG 32 KL1.
Control Cabinet Cooling Fans: 150 150 150
Visually check if all fans are operating. Clean the filters of the fans or
replace them when dirty (In high dust environments reduce the
interval for checking).
Drive Belts: 300 600 800
Visually check belt alignment and tension while the axis is moved
through first full stroke. Inspect the belt for damage and “necked-
down“ areas which indicate approaching belt failure.
Rack and Pinion Clearance: 300 600 800
Check for minimum rack to pinion clearance of 0.1 mm (0.004“).
Gearbox Gaskets and Drain Plugs: 500 800 1000
Check for leaks.
Cable Chains:
Inspect for proper alignment of cables in cable chain (IMPORTANT: 500 800 1000
Loose cable clamps can cause cable binding and chafing)
Motor Brakes: 800 1200 2000
Visually check, if vertical axes sag during standstill.
Screws: 800 1200 2000
Check robot screws and bolts for tightness.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 363

6.8 Automatic Lubrication

6.8.1 Description for the type VOGEL

The optional, automatic system lubricates all linear bearings and the respective
sprockets and racks of the robot. The system measures the X, Y, and Z-axis travel
distances to determine when grease should be applied. When the lubrication interval
(100 km) is reached, a fixed quantity of grease is injected into each bearing through the
grease distributors.

The grease-pump is equipped with a pressure sensor. If the given pressure is not
reached within 15 seconds after switching on the pump, or if the pressure doesn’t drop
below the given value within 15 seconds after switching off the pump, the error message
„CHECK CENTRAL LUBRICATION“ will be displayed on the Teachbox. This will not
interrupt the automatic execution of the robot teach program, but can be confirmed with

. The lubrication system should be checked as soon as possible, and the cause
of the error should be fixed. Possible causes for the error are:

Lack of grease in the container

Leaking, unplugged or burst hoses
Functional breakdown of the pump

If the cause of the error is not fixed before the next lubrication interval, the error message
“CHECK CENTRAL LUBRICATION” will be displayed again, and can be confirmed with

again.

Should the cause of the error again not be fixed until the 3rd lubrication interval, the error
message “CENTRAL LUBRICATION FAILED” will be displayed, and the robot will switch
to block stop. Now the cause of the error must be fixed. After the cause of the error was

fixed, the grease pump can be started by pressing inside the menu
INIT/LUBRICATION INTERVAL a number of times until lubrication was executed
correctly without error message. This enables the start of automatic mode again.

During filling of the grease pump container, extra precaution must be taken to avoid air bubbles
in the grease and to use only the specified greases.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 364

6.8.1.1 Suitable greases

Wittmann Robots equipped with automatic lubrication system VOGEL are lubricated by
standard with Dynalub 520 by Bosch Rexroth prior delivery to the customer. This
grease is according to US Fed Std.209 / ISO 14644-1 class 6 suitable for all standard-
and clean room applications at clean room classes > 1000.
The other greases mentioned in the list below can be used as alternative.

MANUFACTURER TYPE
Bosch Rexroth AG Dynalub 520 Standard at delivery
Castrol Longtime PD00
alternatively useable
Chemie-Technik Ekalub GLS 135/N00

Dynalub 520 can be ordered at Wittmann Company under the following item number:

 As 5kg container:
Wittmann item number: BA0000624

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 365

6.8.2 Description for the type HERION

The optional, automatic system lubricates all linear bearings and the respective
sprockets and racks of the robot. The system measures the X, Y, and Z-axis travel
distances to determine when grease should be applied. When the lubrication interval
(100 km) is reached, a fixed quantity of grease is injected into each bearing through the
grease distributors.

6.8.2.1 Suitable greases

Wittmann Robots with the optional automatic lubrication system HERION are equipped
by standard with a cartridge of Dynalub 510 by Bosch Rexroth prior delivery to the
customer. This grease is according to US Fed Std.209 / ISO 14644-1 class 6 suitable
for all standard- and clean room applications at clean room classes > 1000.
The other greases mentioned in the list below can be used as alternative.

MANUFACTURER TYPE
Bosch Rexroth AG Dynalub 510 Standard at delivery
CASSIDA EPS2 for use in food industry

The cartridge with Dynalub 510 can be ordered at Wittmann Company under the
following item number:

 Wittmann item number: HA00001013

The cartridge with CASSIDA EPS2 can be ordered at Wittmann Company under the
following item number:

 Wittmann item number: HA00001286

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 366

6.8.2.2 Cartridge change

 Because of safety turn off the robot

 Turn the exhaust locking from CLOSE to OPEN and remove it

 Open the cover with a left turning motion and remove it

 Pull off straight the empty cartridge

 Remove the protective cover from the new

 Grease the O-ring seal carefully

 Insert the new cartridge with a twisting motion

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 367

 Apply cover with light pressure. Screw on the cover hand tight by a right turning
motion

 Set the exhaust locking and turn it from OPEN to Close

 Turn on the robot

6.8.3 System Maintenance

It is important to remember that the automatic lubrication system does not
eliminate maintenance requirements for the robot! It just reduces the frequency of
the maintenance intervals. Lubrication system maintenance is crucial in detecting system
faults, such as:

 Burst Hoses
 Plugged Tubes
 Air Pockets
 Faulty Lubrication Pump or Solenoid Valve
 Faulty Injectors

6.8.3.1 Lubrication System Maintenance Procedure:

1. Inspect the system for burst, leaking, or disconnected tubes and hoses.
2. Check that some grease build-up is present on all linear bearings wipers to verify
that grease is reaching all bearings. Clean the grease off of the wipers to "reset" this
test for next time.

Use only original grease cartridges, which contain grease with the correct specifications.
Cartridges can be ordered at your local Wittmann Service Center.

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 368

7 Key Terms
For better understanding of these operating instructions, some key terms are explained
below:

Term Explanation
EJ Ejector
BM Blow machine
DIAS BUS DIAS – Decentralized Intelligent Automation System

CNC CNC - Computer Numerically Controlled – microprocessor

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

R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 369

8 Service Centers group.com.br

www.wittmann-group.com.br
India pvt Ltd.
1 & 2 Arumugam Nagar
HEADQUARTERS Chinna Porur, Chennai 600
Bulgaria 116
WITTMANN WITTMANN BATTENFELD INDIA
Kunststoffgeräte GmbH Bulgaria EOOD Tel. +91 44 42077009
Lichtblaustraße 10 Hr. Smirnenski Str. 24 Fax +91 44 23719602
A-1220 Vienna 4147 Kalekovets [email protected]
AUSTRIA BULGARIA www.wittmann-group.in
Tel. +43/1/250 39-0 Tel. +359 3124 2284
Fax +43/1/250 71-70 Fax +359 3124 2279 Indonesia
[email protected] jassen.sterev@wittmann- WITTMANN BATTENFELD
www.wittmann-group.com group.com (Singapore) Pte. Ltd.
www.wb-bg.com Indonesia Representative
WITTMANN BATTENFELD Office
GmbH China Ruko Easton Jl. Gunung
Wiener Neustädter Straße 81 WITTMANN Robot Panderman, Blok A-09
A-2542 Kottingbrunn (Kunshan) Co., Ltd. ID 17550 Lippo Cikarang
AUSTRIA No. 1 Wittmann Rd. INDONESIA
Tel. +43 2252 404-0 Dianshanhu, Kunshan Tel. +62 21 2909 3145
Fax +43 252 404-1062 Jiangsu Province Fax +62 21 2909 3146
[email protected] CHINA 215345 [email protected]
www.wittmann-group.com Tel. +86 512 5748 3388
Fax +86 512 5748 3399 Italy
WITTMANN ------------------------------- WITTMANN BATTENFELD
Kunststoffgeräte GmbH WITTMANN BATTENFELD Italia
Percostraße 20 (Shanghai) Co., Ltd. S.r.l.
A-1220 Vienna No. 1 Wittmann Rd. Via G. Mazzini n. 180/A
AUSTRIA Dianshanhu, Kunshan 20816 Ceriano Laghetto (MB)
Tel. +43 1 25039-0 Jiangsu Province ITALY
Fax +43 1 25971-70 CHINA 215345 Tel. +39 (02) 96 98 10-1
Tel. +86 512 5748 3088 Fax +39 (02) 96 98 10-49
WITTMANN Fax +86 512 5748 3399 [email protected]
Kunststoffgeräte GmbH [email protected] www.wittmann-group.it
Kaplanstraße 7 www.wittmann-group.cn Canada
A-2120 Wolkersdorf WITTMANN Canada Inc.
AUSTRIA WITTMANN BATTENFELD
Germany GmbH 35 Leek Crescent
Tel. +43 1 25039-0 Richmond Hill, ON L4B 4C2
Fax +43 1 25971-70 Am Tower 2, 90475 Nürnberg
GERMANY CANADA
Tel. +49 9128 7099-0 Tel. +1 905 887-5355
BRANCHES WORLDWIDE Fax +1 905 887-1162
Fax +49 9128 7099-500
Australia / New Zealand [email protected] toll free: 1 888 466 8266
WITTMANN BATTENFELD ------------------------------ [email protected]
Australia Pty Ltd Facility Meinerzhagen www.wittmann-group.ca
Unit 9, 42 Garden Boulevard Werner-Battenfeld-Straße 1 Malaysia
Dingley Village Victoria 3172 58540 Meinerzhagen WITTMANN BATTENFELD
PO Box 614 Braeside 3195 Tel. +49 0 2354 72-0 (Malaysia) Sdn Bhd
AUSTRALIA Fax +49 0 2354 72-485 No. 16, Jalan Bandar
Tel. +61 3 9551 4200 empfang@wittmann- Limabelas
Fax +61 3 9551 4300 group.com Pusat Bandar Puchong
peter.lucas@wittmann- 47100 Selangor
group.com.au France
WITTMANN BATTENFELD D.E. MALAYSIA
www.wittmann-group.com.au Tel. +60 3 5882 6028
France SAS
Belgium/Netherlands/Luxem Centr'Alp 2, 325 Rue Louis Fax +60 3 5882 6036
burg Barran [email protected]
WITTMANN BATTENFELD 38500 La Buisse Mexico
Benelux NV FRANCE WITTMANN BATTENFELD
De Vunt 9 Tél.: +33 (0)476 310 880 México S.A. de C.V.
B-3220 Holsbeek Fax: +33 (0)476 310 881 Av. Rafael Sesma Huerta No.
BELGIUM [email protected] 21
Tel. +32 (0) 16 551180 www.wittmann-group.fr Parque Industrial FINSA
Fax +32 (0) 16 562659 C.P. 76246
[email protected] Great Britain / Ireland
WITTMANN BATTENFELD El Marqués Querétaro
www.wittmann-group.be MEXICO
UK Ltd
Sanders Road, Finedon Road Tel. +52 442 10 17 100
Brasil Fax +52 442 10 17 101
WITTMANN BATENFELD do Industrial Estate
Wellingborough -----------------------------
Brasil Ltda. WITTMANN BATTENFELD
Av. Francisco de Angelis 166 GB-NN8 4NL Northants
GREAT BRITAIN Maquilas, Inc.
Jardim Okita - Campinas SP 11601 Pellicano Drive C7
CEP 13043-030 Tel. +44-1933275777
Fax +44-1933270590 El Paso, TX 79936
BRASIL USA
Tel. +55-19 2511-8150 [email protected]
www.wittmann-group.co.uk Tel. +1 915 594 7400
Fax +55-19 2511-8157 Fax +1 915 594 7548
wittmann@wittmann- India [email protected]
WITTMANN BATTENFELD www.wittmann-group.mx
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 370

Poland Tel. +34-93 808 7860 Tel. +36 23 880 828

WITTMANN BATTENFELD Fax +34-93 808 7197-7199 Fax +36 23 880 829
Polska Spol. z o.o. ------------------------------ [email protected]
Adamowizna, ul. WITTMANN BATTENFELD www.wittmann-group.com
Radziejowicka 108 Norte
05-825 Grodzisk Mazowiecki Errekaondo, 6. (Polígono) USA
POLAND 48450 Etxebarri (Bizkaia) WITTMANN BATTENFELD,
Tel. +48 (0) 22 7243-807 SPAIN INC.
Fax +48 (0) 22 7243-799 Tel. +34 944 408 646 1 Technology Park Drive
[email protected] Fax +34 629 758 949 Torrington, CT 06790
www.wittmann-group.pl [email protected] USA
www.wittmann-group.es Tel. +1 860 496 9603
Romania Fax +1 860 482 2069
WITTMANN BATTENFELD Taiwan ------------------------------
S.R.L WITTMANN BATTENFELD West Coast Tech Center
Cotroceni Business Center (Taiwan) Co. Ltd. 1000 S. Melrose St.
B-dul luliu Maniu Nr. 7, Corp No. 16, Gongyequ 36th Rd., Placentia, California 92870
T, Et. 2, Sector 6, Xitun Tel. +1 860 496 9603
Bukarest RO 061072 Dist. Fax +1 860 496 2037
ROMANIA Taichung City 40768 ------------------------------
Tel. +40 720 227 255 TAIWAN (R.O.C.) Midwest Tech Center
Fax +40 213 172 718 Tel. +886 4 2359-5158 1620 Shanahan Drive
bogdan.nestor@wittmann- Fax +886 4 2359-2878 South Elgin, IL 60177-2277
group.ro [email protected] Tel. +1 860 496 9603
www.wittmann-group.ro www.wittmann-group.tw Fax +1 847 531 0029
[email protected]
Russia/Belarus Thailand www.wittmann-ct.com
OOO WITTMANN WITTMANN BATTENFELD
BATTENFELD (Thailand) Co. Ltd. AGENTS WORLDWIDE
Altufievskoe shosse 294/2 Soi RK Office Park
house 48, block 1, office 1 Romklao Rd., Klong Sam Egypt
127566 Moscow Prawet MEISCA (Middle East
RUSSIA Lad Krabang, Industrial Services &
Tel. +7 495 983-02-45 Bangkok 10520 Commercial Agencies)
Fax +7 495 983-02-45 THAILAND 27 Ahmend Fakhry Str.,
[email protected] Tel. +66 2 184 9653 Apt. 2-Zone 6 Nasr City
www.battenfeld.ru Fax +66 2 184 9654 Kairo 11391, EGYPT
info@wittmann- Tel. +20 (2) 2270 0919
Switzerland/Liechtenstein battenfeld.co.th Fax +20 (2) 2271 7032
WITTMANN [email protected]
WITTMANN Kunststofftechnik Czech Republic
AG WITTMANN BATTENFELD Algeria
Uznacherstrasse 18 CZ EAGCO (Egypto-Algérienne
CH-8722 Kaltbrunn spol. S.r.o. de Services Industriels)
SWITZERLAND Male Nepodrice 67 Cap Beddad, B2 No. 1-4 Cité
Tel. +41 55293 40 93 CZ-397 01 Pisek el
Fax +41 55293 40 94 CZECH REPUBLIC Hidhab
[email protected] Tel. 00420 382-272-995 Setif
www.wittmann-group.ch Fax 00420 382-272-996 ALGERIA
[email protected] Tel./Fax 00213 36 63 74 12
Singapore www.wittmann-group.cz [email protected]
WITTMANN BATTENFELD www.mergawi.com
(Singapore) Pte. Ltd. Turkey
No. 48 Toh Guan Road East, WITTMANN BATTENFELD Argentinia
#03- Plastik Makineleri Ltd. Sti, BeMaq S.A.
123 Küçükyali is merkezi Colectora Panamericana
Enterprise Hub Girne Mahallesi, Irmak Sokak Este 2011 – Of. 104
SINGAPORE 608586 F Blok No: 20 B1609 JVB Boulogne
Tel. +65 6795 8829 TK-34852 Maltepe Istanbul Prov. de Buenos Aires
Fax +65 6795 8786 TÜRKEI ARGENTINIA
[email protected] Tel. +90 216 550 93 14 Tel. +54 11 4139 8877
mobile +90 533 583 44 06 Fax +54 11 4139 8876
Slovakia Fax +90 216 550 93 17 [email protected]
WITTMANN BATTENFELD [email protected] www.bemaq.biz
SK www.wittmann.com.tr
Spol. s.r.o. Chile
L‘. Stárka 2722/16 Hungary Intermaq LTDA
91105 Trenčin WITTMANN Robottechnikai Manuel Fischmann
SLOVAKIA Kft. 0568 La Cisterna, Santiago
Tel.: +421 32 642 08 52 Központ és gyártó üzem CHILE
[email protected] H-9200 Mosonmagyaróvár Tel. +56-2-3109108
Eke u. 6, HUNGARY [email protected]
Spain Tel. +36 96 577470 www.intermaq.cl
WITTMANN BATTENFELD Fax +36 96 577471
SPAIN S.L. Costa Rica
------------------------------ Jonathan José Barth Solis
Pol. Ind. Plans d’arau WITTMANN BATTENFELD
C/Thomas Alva Edison Nr. 1 Asesor Externo
Kft. WITTMANN BATTENFELD
08787 La Pobla de Claramunt Gyár utca 2
Barcelona, SPANIEN Costa Rica
H-2040 Budaörs, UNGARN Villa Barsa de la Escuela
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 371

San Diego 200 Mts. Sur 3rd floor – Nr. 10 – Fathi Saudi-
Calle la Claudia Shaghaghi Arabia/Emirates/Kuwait
Desamparados Alajuela St. – Asad Abadi St. /Oman/Qatar
COSTA RICA, C.P. 20110 Teheran, IRAN Plasteq Trading LLC
Tel. +506 24 41 53 24 Postal Code: 1433633456 Your Plastic Equipment
jonathan.barth- Tel. +98 21 8872 3148 Partner
[email protected] Fax +98 21 8872 2838 401 Al Zarouni Business
Centre
Denmark Israel Sheikh Zayed Road, Barsha
WiBa Tech ApS A.ZOHAR Ltd. First
Kratbjerg 202 Systems & Technology P.O.Box 116171
DK-3480 Fredensborg Trade Center Hashmura str. 2 Dubai
DENMARK IL-30900 Zichron Ya´Akov UNITED ARABIC EMIRATES
Tel. +45-4846 6500 ISRAEL Mr. Velemir Sarcevic
Fax +45-4846 6519 Mr. Arieh Zohar Mobil +971 (52) 955 55 26
[email protected] Tel. +972 54 4270 582 [email protected]
www.wibatech.dk Fax +972 54 6392 113 Mr. Velemir Sarcevic
Hdy. +972 64 4270 582 Mobil +971 (52) 955 55 27
Finland Fax +972 64 4270 583
WiBa Finland Oy [email protected]
[email protected]
Pailinnantie 6 Sweden/Norway
FI-24910 Halikko asema Kolumbien BATTENFELD Sverige AB
FINLAND WIBA Colombia Skallebackavägen 29
Tel. +358 44 72 73 810 OXUS Centro Empresarial 30241 Halmstad
[email protected] Oficina 320 SWEDEN
www.wiba.fi Km. 1.5 vía Chía – Cajicá Tel. +46 35 15 59 50
Chía - KOLUMBIEN Fax +46 35 15 59 59
Greece Tel. +57 (1) 862 28 50 – 638
Fortunas Georgios [email protected]
63 43 www.battenfeld.se
Sole Limited Liability Cel. +57 (1) 317 51300 356
Company [email protected] Switzerland
31 Sevdikiou & 8 Eptanisou BATTENFELD Schweiz AG
146 71 – Nea Erithrea Kosovo/Albania Vogelsangstraße 15
GREECE Eco Power Energy Efficiency 8307 Effretikon,
Tel. +30 210 6810037 doo SWITZERLAND
+30 210 6202872 Jovana Brankovica 164c Tel. +41 (44) 908 65 65
Fax +30 210 6893238 11273 Belgrad, SERBIEN Fax +41 (44) 908 65 50
[email protected] Tel +381 114 050 446 [email protected]
www.fortuna.gr [email protected] www.battenfeld.ch
Guatemala/Honduras/El Estonia/Latvia/Lituania Serbia/Bosnia-
Salvador WIBA Baltic SIA Herzegovina/North-
maprimaq Ventas 16, Sigulda Macedonia/Montenegro
Calzada Roosevelt 22-43 LV-2150, LATVIA Marka Oreškovića 13
zona 11 Hr. Edgars Krasovskis Ruma 22400
TIKAL FUTURA Mobil: +371 298 002 67 SERBIA
Business & Convention Center [email protected] Tel. +386 (0) 1 788 85 35
Torre Sol – Oficinas 9C & 9D www.wiba.lv Fax +386 (0) 1 788 85 31
Guatemala Ciudad [email protected]
GUATEMALA, C.A. (01011) Morocco
SMARTINDUS sarl www.robos.si
Tel. +(502) 2440 1840
Fax +(502) 2440 1830 Lot N°37 Z.I. Slovenia/Kroatia
Mobile +(502) 5781 2777 Gzenaya 90000 Tanger ROBOS d.o.o.
SKYPE: fritz.schloesser MOROCCO Brnčičeva Ulica 31
[email protected] Tel: +212 5 39 94 98 83 1231 Ljubljana – Črnuče
www.maprimaq.com Fax: +212 5 39 94 98 83 SLOVENIA
[email protected] Tel. +386 (0)1 7888 535
India www.smartindus.ma Fax +386 (0)1 7888 531
Kromes Marketing India [email protected]
13-C Gr. Fl. Parmanand Co- Peru
SAPRI S.A.C. www.robos.si
op
Hsg. Soc., 5th Rd, Khar West Silvana 134, Lima 33 South Africa
400052 Mumbai, INDIEN PERU Ipex Holdings (Pty) Ltd
Tel. +91 (22) 2600-8463 Tel. +51 (1) 372 61 72 55 Trump Street West
Fax +91 (22) 2600-8462 Mobil +51 999 031 488 Selby Ext. 4
[email protected] Mr. Sebastián Allue Johannesburg, 2001
[email protected]
SOUTH AFRICA
Iran - WITTMANN www.sapri.pe
Tel. +27 (0) 114 937 816
DANA CONTROL
Portugal Fax +27 (0) 114 932389
No. 304 – 3rd floor –
TECNOFRIAS, Lda [email protected]
Sarve Saee Tower – Valiasr
Mr. Rui Fonseca www.ipex.co.za
Ave
Teheran, IRAN Rua Principal N 35
South Korea
Tel. +98 21 8855 2020 2425-279 Careira Lra
Petra Corp. Ltd.
Fax +98 21 8855 2010 Leiria, PORTUGAL
#204, Iandvill 4, 5 Hanbora
[email protected] Tel. +35 (1) 917 581 749
2ro,
www.danacontrol.com rui.fonseca@wittmann-
Giheung gu
group.es
Yong in si, Gyung Gi do
Iran – BATTENFELD
SOUTH KOREA
HOMA PAKHSH SAHAR Co.
R83_V8_32_00_WIT_EN / 01.10.2020
 R8.3 USER MANUAL Page 372

Tel. +82 312 744 812

Fax +82 318 039 48 12
[email protected]
Tunesia- WITTMANN
IDS – Industrial Development
Services
23 rue Sallem Harzallah
Imm. Echefii, 2e étage
3000 SFAX
[email protected]
www.ids.com.tn
Ukraine
WIBA TOV
Office 24
Saksahanskoho Street 120
02000 Kiev
UKRAINE
[email protected]
www.wiba-ua.com
Venezuela
Process Consult C.A.
Urbanización Andrés Bello
Avenidas Las Delicias
Residencias Nivaldo, Piso 7°,
Apto. 73
Maracay, Edo. Aragua CP
2102
VENEZUELA
Tel. +58 243 2186 333
Fax +58 243 2413 197
Ing. Osvaldo Suárez
[email protected]
www.osprocessconsult.com
Vietnam
T.A.O. BANGKOK
CORPORATION LTD.
Sinsakhon Industrial Estate
30/11 Moo 1, Chetsadawithi
Road
Khokkam, Muang,
Samutsakhon
74000 THAILAND
Tel. +66 (0)34 452 077-83 ext.
51
Fax: +66 (0)34 452 075-6
Mobile: +66 (0)89 780 4513
Skype: chawalan-taobangkok
------------------------------
TAO BANGKOK (VIETNAM)
CO. LTD
Ho Chi Minh City
Unit 18–01, Tower 2,
The Vista building, Thao Dien-
An Phu, 628C Hanoi Highway,
Dist. 2
Tel. +84 8 628 10 712
Fax: +84 8 628 10 721
VIETNAM
www.taobangkok.co.th

R83_V8_32_00_WIT_EN / 01.10.2020