www.conairnet.com USERGUIDE S900-II Version 2.1 WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death! This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
S900–II USER MANUAL Version 2.1 |–> – CONTENTS – &.&1", *.'/1-"3*/. 823&- "1$)*3&$341& /4.3*.
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S900–II USER MANUAL Version 2.
S900–II USER MANUAL Version 2.1 |–> I – Presentation I – PRESENTATION I – 1. General information S900–II is an electronic control system for Cartesian robots equipped with 3 to 5 simultaneous numeric axes. These robots are designed to unload Injection Moulding Machines (IMM) from above. It is simple to use thanks to its ideographic keyboard and its large screen showing clear messages, and new cycles can be easily created with a System for Assisted Programming (SAP).
S900–II USER MANUAL Version 2.1 |–> I – Presentation I – 2. Safety devices I – 2. 1. Use The robot must only be used on an injection machine in a safe environment. Safeguards must be installed for a part to be removed from the inside of the IMM : these safeguards limit access to the work area. Access for operations such as maintenance or part manipulation by operators must only be carried out after a shut–down procedure or following a special safeguard conception.
S900–II USER MANUAL Version 2.1 |–> I – Presentation Certain robots have two other safety areas. This is the case when the arm cannot move up completely (Z axis) in a certain part grip position (risk of collision with another part of the robot). X Y AREA A Z AREA B Area A : or Gripper base plate must be vertical, Gripper base plate must not be horizontal. Area B : No restrictions on the gripper base plate position.
S900–II USER MANUAL Version 2.1 |–> I – Presentation I – 3. Options The following options are possible on the robot : IMM restart box (BRP) This small box is a simplified version of the pendant and enables IMM cycles to be restarted without having to use the pendant. Figure 6 : IMM restart box (BRP) Customized keys keys can be programmed for particular actions (specific to each robot).
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 1. 1. Display The display contents depends on the operating mode or the selected menu. Expected action or current comand Robot area Arm in free Area |Press START PRG 10 – [ PLC – [ SP – [ SPP 81 – [ X = 178.9 mm Y = not ini mm Z = 196.
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 1. 2. Cursor movement To move the cursor up To cancel data / escape Preceding step or window To delete a step To move the cursor to the left To change data or move the cursor to the right To insert a step Following step or window To move the cursor down Figure 9 : Cursor movement Machine axis active window cursor | Continuous X = 749.5 mm Y = 133.4 mm Z = 105.
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 1. 3. Entering values and text Text is entered using the following alphanumeric keys : Space Figure 11 : Alphanumeric keys Numeric or alphanumeric data is validated by one of the keys. II – 1. 4.
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 1. 5. Example of the allocation of customized keys For a second pneumatic arm : vertical movement demoulding movement mechanical gripper II – 1. 6. Locking modes It is possible to lock mode changing (using parameters) so that passwords must be used. Mode access request [PROG] No password to be entered Enter password then press Selected mode Figure 13 : Password for mode access 10 01T01518_1 25.11.
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 2. Control cabinet Luminous column : White light => cabinet powered up Orange light => . continuous = fault . quick flashing = part grip fault . slow flashing = robot ready Emergency stop (Key No. 455) Power isolator which can be shut–down (see file I of the Instructions Manual).
S900–II USER MANUAL Version 2.1 |–> II – Command and visualisation devices II – 3. IMM restart box (BRP) This small box is a simplified version of the pendant which enables IMM cycles to be restarted without having to use the pendant. Figure 15 : IMM restart box (BRP) The keys on the BRP have the same functions as the corresponding keys on the pendant, except for the key. This key cannot be used to cancel faults apart from the “Part grip” fault.
S900–II USER MANUAL Version 2.1 |–> III – Setting–up III – SETTING–UP III – 1. Powering–up 1 General power isolator in position 1 Î Î Does the message on the screen disappear ? YES YES but ... NO ... the message “Axi(e)s in overtravel. ” appears as soon as is released ROBOT STATUS A numeric movement is close to a mechanical limit. The robot is ready to operate.
S900–II USER MANUAL Version 2.1 |–> III – Setting–up III – 2. Initializing an axis The axes are initialized in adjust mode . X = not ini Y = not ini Z = not ini => then , , Kv = 015% , , or until the message “not ini” disappears. If the message “D_1 : NO POWER – Axi(e)s in overtravel.“ appears, carry out the procedure described in chapter III – 3. page 14. Once you have moved the axis out of overtravel, look for the initialization in the opposite direction. III – 3.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – STARTING–UP IV – 1. Changing production Before changing production, the preceding production must be stopped. IV – 1. 1. Stopping production . Pressing The robot is in automatic mode activates a stop at the end of the cycle. The IMM will be stopped once the last piece has been unloaded and the robot will stop after this final unloading cycle. IV – 1. 2.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up Electrics installation : The robot arm is equipped with a lockable SUB D – 25 pin type connector for rapid connection of the gripper head electric circuits * The Sub D 25 pin connector screws enable the locking and unlocking. Leave the stopper in place if the gripper head does not have an electric connection. For further information concerning electric connections, see the electric diagrams in the Instruction Manual File Q.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 1. 4. Program selection Two situations are possible when changing production : SIMPLE SELECTION SELECTION AND CREATION 1. The mould and the gripper head have never worked together on the IMM with the robot. In this case, the program does not exist and must therefore be created. 2. The mould and the gripper head have already worked together on the IMM with the robot. In this case, the program already exists. See chapter IV – 2. page 23.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up Choosing the SAP source program It is necessary to analyse the application to be run in order to choose the source program (part ejection sequence, type of part grip cycle, type of release ...). Then choose a program that corresponds to the application to be run amongst the existing source programs (see description sheets). CREATE From which SOURCE program ? No. of known SAP source program No.
S900–II USER MANUAL Version 2.1 |–> Naming IV – Starting–up a program Each program has a name. You are advised to choose a clear, simple name for each program created. (For example, the mould number : Cover D120 mould 96032). PRG 03 [ COVER D120 MOULD 96032 –> Associated commentary ENTER or ↓ to confirm Enter the program name using the alphanumeric keys. Confirm by pressing IMM .
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up Printing program points Before teaching the points, it is possible to print the program points. For further information, see chapter VIII – page 48. Print Program Points ? YES | NO | | | It is recommended to print the program points in order to check that all the points have been taught when the cycle is executed. Teaching program points The program has been created and named. You now only need to teach the points’ position.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up Once the robot is in the position marked on the screen, the position must be memorised by pressing . Cross off this point on the print–out. key and keep it held down. Press the When the display indicates “Movements finished“, release and then press the key again. Each time a point must be taught : move the axes concerned to the point to be taught, confirm the position by , continue cycle execution in step by step by pressing .
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up Teaching a stacking sequence A stacking sequence enables the parts manipulated by the robot to be released in a certain order, in X rows, in Y columns and Z layers. The data needed : the number of parts released per axis, the gap separating two parts on an axis. To select the axis PRG 03 [ BOX OF 60 PARTS SP 41 [ OVERMOULDING K98 No. of parts X ” ” ” Y ” ” ” Z : 5 – Gap...: 12 : 2 – Gap...: 20 : 3 – Gap...: 10 ...
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 2. Starting up production IV – 2. 1. Program selection => Enter the program number to be executed then or => => => Selec or => CREATE => To select an SAP source program Figure 23 : Program selection Using a program code : When the program is selected , the robot offers the program number coded on the inputs or given by the IMM. If you try to validate another program, the message “PRG .. imposed by Inputs or HOST“ appears.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 2. 4. Starting up in automatic The execution of the first cycles in automatic can be carried out at a reduced speed. Before moving into automatic mode : => => hold down until desired speed Kv = 017% INPUT 016 = 1, 001 0011 1100 0000 OUTPUT 004 = 0, 110 1110 0000 0000 BIT 000 = 0, 000 0000 0000 0000 COUNTER 0000 = 0000_D WORD 000 = 000000_D WWORD 000 = 0000 0000_D OUT= 0|Out= 1 | Calib.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 4. Operation without the robot This operation mode enables the IMM to operate autonomously. It is possible to select the “Without robot” mode via : the “With or without robot” key on the cabinet, the key on the pendant keyboard and on the BRP (optional). IV – 4. 1. The “without robot” key Note : This key can be found on the pendant keyboard and on the BRP box (optional). This key enables the IMM to be used without the robot.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 5. Visualisation and modification of production data By default, the display shows the following menu. The actual position of each axis as well as the speed coefficient Kv, are always displayed on the pendant display. Arm in free Area |Robot In cycle PRG 10 – [ PLC – [ SP – [ SPP – [ X = 150.3 mm Y = 633.4 mm Z = 804.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up The times display is updated once the robot has executed a complete cycle. The application cycle time : is the cycle time in the IMM. The robot cycle time : is the cycle time, without taking into account the time during which the robot is stopped above the IMM. The robot time in the machine : is the time during which the IMM is immobilised by the robot. It is the length of time between the end of the IMM opening and the IMM cycle restart by the robot.
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 5. 3. The counters It is possible to see counters number 0, 1 and 2 by pressing the function key menu. in the production It is possible to initialize the counters 0, 1 and 2 when they are visible. You must enter the code 1234 to change these counters. X = Y = Z = KV = To move the cursor % Value of counter number 0.......: 000000 Value of counter number 1.......: 000000 Value of counter number 2.......: 000000 To modify the value ...
S900–II USER MANUAL Version 2.1 |–> IV – Starting–up IV – 5. 4. Duration of pneumatic high speeds V 1.3 robot V 0.5 PC Editor Principle : The accelerations of the second arm’s pneumatic axes can be modified : to optimize the movement times of the second arm’s axes, to compensate for the load changes, so that the end of movement damper does not come to a halt too violently.
S900–II USER MANUAL Version 2.1 |–> V – Manual control of the installation V – MANUAL CONTROL OF THE INSTALLATION The mobile pendant can be removed from its support for robot movements in adjust mode . V – 1. Access to the protected area It may be necessary to access the protected zone in order to install an application or for maintenance operations. The safeguard override key and Step by Step on the pendant, authorizes robot movements in adjust mode even if the protection grids are open.
S900–II USER MANUAL Version 2.1 |–> V – Manual control of the installation V – 2. Numeric movement control X+ Y+ Z+ X axis left right continuous movement Y axis backwards forwards movement mm by mm Z axis down up movement 1/10 mm by 1/10 mm : to increase the numeric axes speed (up to 100 %). : to decrease the numeric axes speed (down to 15 %). V – 3.
S900–II USER MANUAL Version 2.1 |–> V – Manual control of the installation V – 4. IMM movement control Robot with 1 IMM Robot with 2 IMMs Ejectors 1 out Ejectors 1 in Ejectors Ejectors 2 out Ejectors 2 in Validation core puller 1_1 Validation core pullers 2_1 Core pullers * Validation core puller 1_2 Validation core pullers 2_2 Figure 27 : Manual control of the IMM movement * Core puller 1 : Injection position according to EUROMAP 12. Core puller 2 : Demoulding position according to EUROMAP 12. V 2.
S900–II USER MANUAL Version 2.1 |–> V – Manual control of the installation V – 6. Output control In an adjust mode screen , the input, output or bit status is marked before the comma, followed by the status of the next 15 inputs, outputs or bits.
S900–II USER MANUAL Version 2.1 |–> V – Manual control of the installation V – 7. Teaching SAP points in adjust mode Once a program has been created from an SAP source program, it is possible to teach the points or the imprecisions (or teach them again) in adjust mode. This method is useful for long and sophisticated programs where the whole program has to be described sequentially (including subroutines and home return). The axes must be initialized. OUT= 0|Out= 1 | Calib.
S900–II USER MANUAL Version 2.1 |–> VI – Changing an SAP marker VI – CHANGING AN SAP MARKER VI – 1. Accessing the SAP menu in extended Monitor mode The robot is in step by step or automatic mode. MAINT | HISTO | PRODUC | Pt xx |MONIT To select monitor mode Direct access to SAP points in current step. See page 36. TIMER | WORD | IMM | DIALOG| To access the SAP menu Point| TIME | VEL | IMP | ../.. VI – 2.
S900–II USER MANUAL Version 2.1 |–> VI – Changing an SAP marker VI – 3. Changing an SAP point Point| TIME | VEL Choose with ↑ ↓ To enter point number | IMP | ../.. (or Number) To see existing points in the list ... Selec To confirm data To select point PRG 03 [ COVER D120 MOULD 96032 P01 – Grip part in the mould To select axis The value to be changed blinks on the screen ... To enter the new position X = 212.7 mm Y = 370.4 mm Z = 933.
S900–II USER MANUAL Version 2.1 |–> VI – Changing an SAP marker VI – 4. Initializing the SAP timers and speeds Point| TIME Choose with ↑ ↓ Enter timer number | VEL | IMP Choose with ↑ ↓ (or Number) Enter speed number ... To see existing timers in the list To confirm data | ../.. (or Number) ...
S900–II USER MANUAL Version 2.1 |–> VI – Changing an SAP marker VI – 5. Changing an imprecise distance Point| TIME | VEL Choose with ↑ ↓ To enter the number of the imprecision | IMP | ../.. (or Number) ... To see existing imprecisions in the list To confirm Selec PRG 05 [ MOULD 796 I01 – Anticipation of Y advance Value (3.0–>400.0 mm) : ...
S900–II USER MANUAL Version 2.1 |–> VI – Changing an SAP marker VI – 6. Changing a gap in a stacking sequence Point| TIME Edit | | VEL | Choose with ↑ ↓ To enter the stacking number STK | IMP | ../.. | | Force (or Number) ... To see the existing stacking subroutines in the list To confirm Selec PRG 03 [ COVER D120 MOULD 96032 SP 41 [ OVERMOULDING K98 No. of parts X ” ” ” Y ” ” ” Z : 5 – Gap...: 12 : 2 – Gap...: 20 : 3 – Gap...: 10 To select axis ...
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – TROUBLE–SHOOTING When there is a fault, it is important to : note the error message marked on the screen, note the status of the signalling on the speed drivers, This will then be useful for a future diagnostic, if necessary. VII – 1. Restarting after a fault VII – 1. 1. Part grip fault in the mould If there is a part grip fault in the mould, the robot will execute a home return in automatic mode .
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 1. 3. Other faults Carry out the following procedure for faults other than the part grip fault in the mould : => Select Step by Step mode => Select Home Return => Hold down until message: Home return finished => Select automatic mode Start the cycle Figure 31 : Restarting after a fault Note : It is sometimes necessary to carry out other procedures to quit certain faults.
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 2. Analysis tool VII – 2. 1. Monitor mode or automatic The robot is in step by step mode. MAINT | HISTO | PRODUC | |MONIT Arm PRG PLC SP SPP in free Area |Robot In cycle 05 [ MOULD 796 – [ – [ – [ X = 1000.0 mm Y = 0377.0 mm Z = 800.
S900–II USER MANUAL Version 2.1 |–> V 2.0 robot VII – Trouble–shooting Information concerning the dialogue between the IMM and the robot can be consulted in the following window. MAINT | HISTO | PRODUC | TIMER | WORD | IMM |MONIT | DIALOG| IMM in AUTO or SEMI–AUTO......E_013= Gate closed...................E_128= Mould open..............E_015/E_007= Mould closed..................E_014= Arm free safety...............S_016= Validation machine cycle S_020= TIMER| WORD | | | 01T01518_1 25.11.
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 2. 2. Extended monitor mode: forcing a variable It is possible to force the status of a bit, an input, an output, or change the value of a counter, a Word or a WWord. This forcing is done in extended monitor mode, accessible in Step by Step or automatic mode. Forcing may lead to an unexpected functioning of the robot, and is therefore dangerous. The robot is in monitor mode.
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 2. 3. Faults historic The robot memorizes the list of the last 25 faults that have triggered a cycle stop. MAINT | HISTO | PRODUC | Fault number |MONIT Fault occurred after 1953h of control cabinet operation (robot powered up) D_010 001953H D_001 001889H D_001 001887H D_010 001882H D_017 001833H Delete|Pr Env.
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 3. 1. Clock In the maintenance menu, the following screen appears if you press [Times] Robot powered up......: 020263 In Automatic mode.....: 017118 Time since restart....: 000125 Times | Date |Language|Config : H 06 Mn H 14 Mn H 43 Mn |Maint Robot powered up : is the accumulated time that the robot cabinet has been powered up. It is the time which is taken into account in the faults memory.
S900–II USER MANUAL Version 2.1 |–> VII – Trouble–shooting VII – 3. 5. Maintenance Times | Date |Language|Config |Maint Axes |Actions| | | Axis....: Distance covered.........: Last maintenance.........: ENTER key = confirm maintenance Axes |Actions| | | Note : The distance covered corresponds to the number of kilometres covered.
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link VIII – USING THE PRINTER LINK This enables the printing of programs, PLCs, parameters and faults. VIII – 1. Type of printer and connection The S900–II control unit is equipped with a printer link as standard, and a second one as optional. Both links are Centronics standard parallel links and do not need any particular configuration. The standard link is on the mobile pendant.
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link VIII – 2.
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link VIII – 3. Printing the robot parameters To select programming mode => PARAM To access robot parameters => Print If 2nd printer option exists “Towards pendant printer ?“ YES | NO Printer ready ? YES | NO => Check that the printer is “ON LINE” To start printing Figure 34 : Printing the robot parameters Note : It is possible to put the robot into production once the printing has started. 50 01T01518_1 25.11.
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link VIII – 4. Printer configuration It is possible to adjust the number of lines per page as well as the interline spacing. MAINT Config To search the options installed on the robot 2nd printer option present............ YES or 2nd printer option present............ NO CR+LF| 1st pulse : [CR] 2nd pulse : [LF] 3rd pulse : [CR+LF] Type of line change : . CR : Enter key . LF : Linefeed .
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link VIII – 5. Printing problems As the Centronics interface does not need any special configuration, the printing problems are simple.
S900–II USER MANUAL Version 2.1 |–> VIII – Using the printer link Parallel inteface connector : Use a PC Compatible SubD 25 Pin standard cable – Centronics.
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S900–II USER MANUAL Version 2.
Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
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