Picker Alfa Manual mp17

INSTRUCTIONS
FOR
SPRUE PICKER
Serial Numbers MP17— & Above
MODEL NO.
SERIAL NO.
© copyright 2020
PLASTIC PROCESS EQUIPMENT

6385 Montessouri Street, Las Vegas, Nevada 89113
, INC. www.ppe.com • e-mail: sales@ppe.com
11218 Challenger Avenue, Odessa, Florida 33556
PPE 702-433-6385 • 800-258-8877 • Fax: 702-433-6388
PPE
727-834-8888 • 800-282-6783 • Fax: 727-834-8873
W E S T SOUTH
8303 CORPORATE PARK DRIVE, MACEDONIA (Cleveland), OHIO 44056, USA Toll Free: USA, Canada & Mexico
PPE 216-367-7000 • Toll Free: 800-321-0562 • Fax: 216-367-7022 • Order Fax: 800-223-8305 800-362-0706
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Contents
CONTENTS
1. SAFETY AND WARRANTY
1.1 Description of Safety....................................................................................... 1-1
1.2 Warranty and Non-warranty ......................................................................... 1-2
2. INSTALLATION
2.1 Handling and Transportation ........................................................................ 2-1
2.2 Installation Dimensions................................................................................. 2-2
2.3 Protective Area ............................................................................................. 2-4
2.4 Measurement of Noise Level........................................................................ 2-5
2.5 Connection with I.M.M .................................................................................. 2-6
2.6 Connection with Pneumatic Supply Source ................................................. 2-8
2.7 Connection with Safety and Function Test .................................................... 2-9
2.8 Procedures for Robot Dismantlement............................................................ 2-9
3. DESCRIPTION OF ROBOT STRUCTURE

3.1 Illustration ...................................................................................................... 3-1
3.2 Specification .................................................................................................. 3-3
3.3 Dimensions .................................................................................................... 3-4
3.4 Explosive Views............................................................................................. 3-6
4. SETTING AND ADJUSTMENT BEFORE BOOTING

4.1 Connection with I.M.M (CE Option) ............................................................... 4-1
4.2 Connection with Pneumatic Supply Source ................................................... 4-2
4.3 The Flowchart of Booting Procedure ............................................................. 4-3
4.4 Adjustment while Mould Changing................................................................. 4-4
4.5 Installation and Adjustment of EOAT ............................................................. 4-10
4.6 Adjustment of Moving Speed......................................................................... 4-11
5. MAINTENANCE
5.1 Maintenance and Repair Safeties ................................................................ 5-1
5.2 Maintenance Schedules ............................................................................... 5-2
5.3 Maintenance Tools ....................................................................................... 5-3
5.4 Lubrications................................................................................................... 5-3
0-1
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Contents
6. PNEUMATIC CIRCUIT DIAGRAM
7. ELECTRICAL SYSTEM
7.1 Power System Layout.................................................................................... 7-1
7.2 Grounding System Layout ............................................................................. 7-2
7.3 Emergency Stop Layout ................................................................................ 7-3
7.4 Description of Input/ Output ........................................................................... 7-4
7.5 GA28-PC2 Joint Illustration ........................................................................... 7-5
7.6 CN6: Connect to I.M.M Diagram.................................................................... 7-6
7.7 Cable Code and Definition ............................................................................. 7-7
7.8 Control Board GA28 Layout (RBD-GA28-PC3) ............................................. 7-8
7.9 Control Key Pad GA28-PC1 Layout (RBD-GA28-PC1) ................................. 7-9
7.10 Relay Board GA28-PC2 Layout (RBD-GA28-PC2)........................................ 7-10
7.11 PC Board JUMP Illustration ........................................................................... 7-11
8. OPERATIONAL PROCEDURE
8.1 Operational Schematic (1) ............................................................................. 8-1
8.2 Operational Schematic (2) ............................................................................. 8-2
8.3 Description of Fixed Mode ............................................................................. 8-3
9. DESCRIPTION OF TIMER AND COUNTER

9.1 Definition of Timer.......................................................................................... 9-1
9.2 Definition of Counter ...................................................................................... 9-2
10. DESCRIPTION OF OPERATIONAL MODE

10.1 Description of Operational Mode ................................................................... 10-1
10.2 Auto/Start – Auto Mode Operation................................................................. 10-3
10.3 Single Cycle................................................................................................... 10-3
10.4 Timer ............................................................................................................. 10-4
10.5 Counter.......................................................................................................... 10-4
10.6 Conveyor/ Spray ............................................................................................ 10-5
11. DESCRIPTION OF MANUAL OPERATION

11.1 Manual........................................................................................................... 11-1
11.2 Input............................................................................................................... 11-2
11.3 Function......................................................................................................... 11-3
11.4 Trouble Record .............................................................................................. 11-4
0-2
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Contents
11.5 File Lock ........................................................................................................ 11-4
11.6 Robot is not Used .......................................................................................... 11-5
12. MODE
12.1 Mode.............................................................................................................. 12-1
12.2 Teach............................................................................................................. 12-3
12.3 Timer ............................................................................................................. 12-4
12.4 Counter.......................................................................................................... 12-5
12.5 Conveyor/ Spray ............................................................................................ 12-6
12.6 Memory.......................................................................................................... 12-6
12.7 Completing of Memory................................................................................... 12-7
13. ZERO CLEANING ............................................................................................. 13-1
14. ALARM AND TROUBLE SHOOTING

14.1 Description of Alarm Error Code .................................................................... 14-1
14.2 Description of Alarm Error Signal................................................................... 14-2
14.3 Alarm Eliminate.............................................................................................. 14-2
14.4 Alarm-Trouble Shooting Flowchart ................................................................ 14-3
0-3
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1. Safety and Warranty
1. SAFETY AND WARRANTY

1.1 Description of Safety
Phoenix series swing-arm robot is designed and manufactured in
consideration for the safety use of horizontal injection molding
machines, therefore the company shall be free from any obligation
and responsibility for any accident or injury incurred with using this
robot with other type of machine or applications. We strongly suggest
you to read the following safety standards thoroughly and observe it
before putting the robot into operation.
(1) The service life of robot is 10 years or 5,376,000 cycles (Say, 10 years x 280 days x
8 hours x 60 minutes x 4 cycles) under normal operating conditions.
(2) The robot has been designed and manufactured in conformity with EN292-1 and
EN292-2.
(3) This robot requires necessary adjustment and maintenance as stipulated in this
manual, therefore we strongly suggest you read this and observe carefully before
any adjustment and maintenance is carried out.
(4) The necessary warning labels are posted on the robot to minimize residual risks.
Please pay attention to read the warning labels before and during operation.
(5) Safety regulations shall be highly concerned while handling and transporting the
robot.
(6) A fully trained operator can only operate the robot.
(7) All operation and adjustment of the robot must be carried out fully accordance with
description of this manual.
(8) Danger working areas are noted in this manual. The system integrator must install
appropriate safeguarding surrounding the danger working areas in conjunction with
an injection molding machine.
(9) Do not operate robot if there is a person working or standing in the danger area.
(10) The controller must be placed outside the danger area.
(11) During maintenance and mould changed, electrical power must be turned off and the
pneumatic source disconnected.
(12) The robot is equipped with trouble detective function. The user may rectify the
problems according to the trouble-shooting guide or contact agent for service.
1-1
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1. Safety and Warranty
1.2 Warranty and Non-warranty

1.2.1 Warranty Period
Within 1 year from the date of installation or 1,000,000 running cycles of operation,
whichever comes first. However, it is not restrictive if there is otherwise specified in the sales
contract between the purchaser and the supplier.
1.2.2 Non-warranty
The following are non-warranty items.
(1) Damage due to personal negligence or mistake in operation.
(2) Damage due to natural disaster such as: earthquake, typhoon, thunderbolt
strike and fire, etc.
(3) Damage due to self-modification and poor adjustment by user.
(4) Consumable item (As listed below, but not limited)
Item Description Warranty Period

1. Shock absorbers 500,000 cycles
2. Proximity sensor 500,000 cycles
3. Gripper sensor 500,000 cycles
4. Magnetic switch 500,000 cycles
5. Vacuum generator 500,000 cycles
6. Suction pad 200,000 cycles
7. End-of-arm tooling 200,000 cycles
1-2
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2. Installation
2. INSTALLATION
2.1 Handling and Transportation
Unit：mm
NOTE: Dimensions shown in ( ) are for telescopic type
Lifting point
CAUTION
Prevent Swing Safety Screw
Please make sure screw to be
locked up before transporting and
taking out the screw before
operating.
NOTE: Pay attention to the gravity center during transporting

with a fork-lift truck and sure to avoid from dropping.
2-1
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2. Installation
2.2 Installation Dimensions

 For the machine platen
operator side
operator side
30
30
50
50
6-M10*1.5P -20D 6-M10*1.5P -20D
20
20
75 75 92 58
150 150
Phoenix 550~650 Phoenix 650W~950 W

~
2-2
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2. Installation
 For the controller supporting structure
2-3
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2. Installation
2.3 Protective Area

■ The system integrator should design and install appropriate safeguarding at user’s
cost.
P950W
2200
1420
P850W
2050
1320
1050
P750W
1900
1220
P650W
1750
1120
A
P650
2060
1100
900
B
P550
1860
1000
P450
1650
900
550
C
P350
1530
800
Model
C
A
B
2-4
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2. Installation
2.4 Measurement of Noise Level
1. Noise measurement is done under noise test environment of 60 dB(A).

2. Measuring equipment model RION NA-24 sound level gauge.
3. Measurement is based on 1m distant from robot and 1m height from floor.
4. Model P550 is measuring sample, also suitable for other type robot.
5. Measurement position as below:
Measurement Noise Level
Position dB(A)
1. 67
2. 65
3. 67
4. 68
2-5
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2. Installation
2.5 Connection with I.M.M

When robot is not used, user can either set the robot to “ROBOT NOT IN USE” or
simply turn the power off. For maximum safety consideration, we strongly suggest
that the power is turned off.
2.5.1 Euro map joint layout (Optional)
2-6
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2. Installation
2.5.2 Description of connection of Euro map

PCB Euro
Joint No. Signal Definition map Description
GA28-PC2 code
3 Emergency 1 The switch contact must be opened when the IMM
Stop of Machine emergency stop is getting started (Refer to EN60204-1).
(ESM) Opening the switch contact to make robot emergency
stop.
1 Mould Open 2 The switch contact must be closed when mould opening
Position (MOP) position is equal or more than required position.
Inadvertent alteration to mould opening stroke smaller
than that required for the handling device/ robot to
approach must be impossible. The signal must remain
closed as long as the mould is open and must not be
interrupted by a change of operation mode or safety
guard opening.
2 Safety Device 3 The switch contact must be closed when safety device
of Machine (e.g. safety guard, footboard and safety, etc.) on the
(SDM) injection moulding machine are operative so that
dangerous movement of the handling device/ robot are
possible. The signal is active in any operation mode.
According to regulation of EN201, it must use limit switch
series as signal contact within mould safety area and the
signal current cannot be greater than 6 Amps.
4 Reference 16,9,11 This is common potential of robot. The code is L－.
Potential (L－)
5,6 Enable Mould 18,26 This switch contact will be closed when robot takes out
Close (EMC) product and ascend to upper position (LS1) in order to
enable mould close. Mould close will be interrupt if robot
alarms during motion.
7,8 Mould Ares 17,32 The switch contact is closed when the handling device/
Free (MAF) robot is outside the mould area and does not interfere
with mould opening and closing movement. The switch
contact must be opened when the handling device leave
its start position. If the switch contact is open neither
opening nor closing of the mould may occur.
11,12 Emergency 19,27 This switch contact must be opened when pressing the
Stop pf Robot emergency stop button on robot operator and also the
(ESR) injection moulding machine. (Please refer to EN60204-1)
9,10 Enable Ejector 22,32 The switch contact must be closed when robot allow
Forward (EEF) I.M.M forward.
2-7
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2. Installation
2.6 Connection with Pneumatic Supply Source

2.6.1 Supply of Pneumatic Source
In order to maintain the robot’s normal operation, please be sure to fit freezing dryer at
the outlet of air compressor to remove the wet and moisture from the air, thus to obtain
the extended service life of robot.
2.6.2 Connection with Pneumatic Supply Source

Output air pressure 5kgf/cm²
Quick fitting – Inlet

Quick fitting
– Outlet
Input air pressure 5kgf/cm²

Pressure gauge
Drain valve
NOTE:
(1) To minimize air pressure loss in the pipe for a long distance source (10 meters
away), be sure to use a rigid pipeline.
(2) After completing the connection, adjust the pressure on the Air Filter/ Regulator
2
until it reaches 5kg f/cm .
(3) Check the water trapped in Air Filter/ Regulator and drain water away everyday.
NOTE: According with CE specification could be added slow start valve.
2-8
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2. Installation
2.7 Connection with Safety and Function Test
After completion of installation of the robot with an I.M.M according to chapter 2.2-2.5,
the following areas must be fully checked for safety link and function of the robot.
【CAUTION】Connection test must be carried out by a fully
trained technician or engineer only. If there is any
problem, please feel free to notify your local
supplier or ALFA.
(1). Signal of Enable Mould Close
(2). Signal of Safety Gate Open
(3). Signal of Mould Open End
(4). Adjustment of Moving Speed for all axes
(5). Detection of Reset
(6). Mould Close Function after removal of mould
2.8 Procedures for Robot Dismantlement

1. Turn off power of I.M.M.
2. Turn off power of robot.
3. Disconnect supply of pneumatic source.
4. Exhaust air pressure from the robot.
5. Loosen mounting bracket of the crosswise cylinder and move arm to make it close
to traverse beam.
6. Move mounting bracket of shock absorber to make it close to arm.
7. Tighten mounting bracket of the crosswise cylinder to make arm unable to be
moved.
8. Disassemble controller.
9. Disassemble connection between I.M.M and robot.
10. Connect the short circuit connector.
11. Disassemble electrical power cable of the robot.
12. Disassemble interlock signals and power cable of I.M.M.
13. Disassemble base mounting screws.
14. Disassemble the robot from machine platen.
2-9
3.
Air Valve
Phoenix350~450
Arm Component Component

3.1 Illustration
Crosswise Base Component

Component
3. Description of Robot Structure
3-1
End-of-arm suction tooling
(Option: “V” with vacuum generator
Electric Control
DESCRIPTION OF ROBOT STRUCTURE
Component
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Controller
Air Valve
Component
Phoenix550~950
Crosswise Arm Component

Component
Base Component
3-2
Electric Control
Component
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End-of-arm suction tooling

(Option: “V” with vacuum generator Controller
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3.2 Specification
Single Stage Telescopic
Model
P350 P450 P550 P650 P650W P750W P850W P950W
Recommended I.M.M
15~30 30~60 50 ~ 150 75 ~ 150 75 ~ 150 100 ~ 200 150 ~ 250 200 ~ 300
(ton)
Vertical Stroke (mm) 350 450 550 650 650 750 850 950
Crosswise Stroke
75 120 120 200
(mm)
Swing Angle (degree) 60-90 60~90 60~90 60~90
Max. Loading (Kg) 2.5 3 3 3
Dry take out Time
0.6 0.7 0.8 0.9 0.8 1 1.2 1.4
(sec)
Dry Cycle Time (sec) 3.8 4.0 4.2 4.4 4.2 4.8 5.2 6
Power Capacity
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
(KVA)
Air Consumption
8.5 10 11.5 13 12 13 14.5 15.5
(Nl/cycle)
Net Weight (Kg) 30 31 35 36 48 49 52 53
Dimension L x W x H
550*285*940 550*285*1040 815*300*1200 815*300*1310 865*300*1100 965*300*1120 965*300*1180 965*300*1260
(mm)
NOTE:
1. Runner/ sprue gripper and wrist rotation mechanism is included as standard features.
2. Option: a. Mode is fitted with vacuum generator and end-of-arm suction tooling are denoted by “V.”
With “V” function, it will require additional air consumption of 5N l/cycle.
b. Platen spacer with 50, 100, 150 or 200mm height according to demands.
3-3
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3.3 Dimensions
3-4
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3-5
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3.4 Explosive Views

3.4.1 Base Component
3.4.1.1 Explosive View of Phoenix350-450 Base
3-6
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Part list of Poenix350~450 base
Item Description Serial No. Q’ty Remark

1 PC300 Base PI03A040 1
2 PC300 Positioning loop PI03A070 1
3 PC300 Base pillar PI03A090 1
4 Positioning pin PI00A080 1
5 Supporting base PI03A010 1
6 Air filter/ regulator AW2000-02G PET2005 1
7 PC300 Rotation axis PI03A030 1
8 PC300 Swing-angle adjusting shaft PI03A060 1
9 Spherical bearing PHS-10 MBG5-PHS10 1
10 Stainless adjustable cushion cylinder PCY32-YC320085S 1
11 PC300 Rotation cylinder shaft PI03A050 1
12 PC300 Rotary cylinder block PI03A020 1
13 Ball bearing 6007ZZ MBG1-6007 2
14 PC300 Setscrew PI03A080 1
3-7
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3.4.1.2 Explosive View of Phoenix550-950 Base
3-8
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Part list of Phoenix550~950 base

1 Supporting base PI00A012 1
2 Base PI00A021 1
3 Rotation axis PI00A030 1
4 Swing angle adjustment knob PI00A040 1
5 Rotation axis of supporting base PI00A051 1
6 Rotation axis for cylinder PI00A061 1
7 Swing angle adjustment bracket PI00A070 1
8 Positioning pin PI00A080 1
9 Spherical bearing PHS12 MBG5-PHS12 1
10 Ratchet wrench PI00A110 1
PCY40-YC400125S 1 P550/P650
11 Swing cylinder
PCY50-YC500120Y 1 P650W-P950W
12 Speed control joint PSP1-0401 2
13 Air filter/ regulator MAFR200-08A PET2005 1
14 Cable fixed head M25*1.5 RXE1002 1
15 Cable fixed head M22*1.5 RXE1001 1
16 Quick fitting PFH0200 1
17 Quick fitting PQL1002 1
19 Nut for ball bearing M40*1.5P MSW8-AN08 1
20 Lock washer for ball bearing MSW8-AW08 1
21 Magnetic switch RSN2004L 2
22 Nut for ball bearing MSW8-AN00 2
23 Lock washer for ball bearing MSW8-AW00 1
25 Spring for ratchet wrench PI00A120 1
26 Mat tube of rotation axis PI00A100 1
27 Outside hexagonal screw M10*40L MSW6-1040 1
28 Plus size of flat washer (M10) MSW8-1031 1
3-9
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3.4.2 Crosswise Component with Single Stage

3.4.2.1 Explosive view of Phoenix350~450
Part list of Phoenix350~450 crosswise
1 Aluminum profile of crosswise MFA-PI03B021 2

2 Mounting bracket of crosswise PI03B010 1
3 Crosswise guide-bar MRD1-YE200350 2
4 Crosswise baffle AI00B070 1
Mounting bracket of crosswise
5 AI00B060 1
cylinder
6 Shock absorber MAR1416 1
7 Crosswise cylinder PCY20-YC200075A 1

8 Crosswise frame AI00B011 1
9 DU dry bearing MBG2-2012 1
3-10
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3.4.2.2 Explosive view of Phoenix550~950
3-11
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Part list of Phoenix550~950 crosswise

2 Aluminum profile of crosswise MFA-PI00B021 2
Mounting bracket of crosswise

4 AI00B060 1
cylinder
5 Crosswise baffle AI00B070 1
7 Eye bolt MSW9-1001 1
9 Crosswise cylinder PCY20-YC200120K 1
3-12
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3.4.3 Crosswise Component with Telescopic
8
1
9
2
3 10
4 11
12
5
6 13
3-13
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Part list of Crosswise with Telescopic

1 Aluminum profile of crosswise MFA-PT07B020 2
Crosswise cylinder connecting 1

3 PT00B040
block
8 Eye bolt MSW9-1001 1
10 Crosswise baffle PT00B020 1
11 Set screws of crosswise cylinder PI00B070 1
Mounting bracket of crosswise 1

12 PT00B010
cylinder
13 Crosswise cylinder PCY20-YC200200K 1
3-14
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3.4.4 Arm component with Single Stage
4 15
6 16
7 17
8 18
9
19
10
20
11
21
12 22
13 23
14
24
25
3-15
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Part list of Arm with Single stage

AI00C120 1
1 Upper protective plate
PI00C080 1
PCY25-YC250350K 1 P350
PCY25-YC250450K 1 P450
PCY25-YC250550K 1 P550
3 Vertical cylinder
PCY25-YC250650K 1 P650
PCY25-YC250750K 1 P750
PCY25-YC250850K 1 P850
4 Down stroke fixed block AI00C140 1
5 Vertical baffle AI00C130 1
6 Protective tube joint MCN2011 1
7 Protective tube supporting frame PI00B030 1
8 Linear bearing MBG4-JB38 4
MLP15-580 1 P350
MLA15-700 1 P450
MLS15-760 1 P550
9 Slide rail
MLP15-880 1 P650
MLP15-1000 1 P750
MLP15-1120 1 P850
10 Slide rail block MLP15B 2
11 Mounting bracket of vertical AI00C013 1
12 Set screws of crosswise cylinder PI00B070 1
14 Safety lock cylinder frame AI00C040 1
3-16
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MCN30100 20 P350
MCN30100 20 P450
MCN30100 24 P550
15 Protective chain
MCN30100 24 P650
MCN30100 30 P750
MCN30100 30 P850
MFA-PI03C020 1 P350
MFA-PI04C020 1 P450
MFA-PI05C030 1 P550
16 Aluminum profile of arm
MFA-PI06C030 1 P650
MFA-PI07C030 1 P750
MFA-PI08C030 1 P850
17 Terminal cover AI00B050 1
18 Arm protective board PI00C070 1
19 Cushion cylinder PCY20-YC200084K 1
21 Cylinder fixed plate AI00C030 1
22 Proximity switch RSN1001 1
23 Proximity switch fixed plate AI00C060 1
24 Down fixed plate of arm AI00D050 1
25 Safety lock cylinder PCY2015M 1
3-17
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3.4.5 Arm Component with Telescopic
2
18
3
4 19
5
20
7 21
22
8
10
23
11 24
12
13 25
14
15
26
16
27
17 28
29
30
31
32
33
34
3-18
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Part list of Arm with Telescopic

1 Upper fixed plate of arm AW00C050 1
MCN3010 12 P550W / P650W
2 Protective chain
MCN3010 13 P750W / P850W
3 Upper protective plate for main arm AI00C110 1
MFA-AW05C030 1 P550W
4 Aluminum profile 2 for telescopic
5 Belt fixed plate AW00C181 1
6 Belt clamping plate AW00C190 2
MLP15-520 2 P550W
MLP15-520 1
P650W
MLP15-580 1
7 Slide rail MLP15-580 1
P750W
MLP15-640 1
MLP15-640 1
P850W
MLP15-700 1
8 Arm protective board PT00B051 1
9 Slide rail MLP15B 4

10 Down fixed plate of arm AW00C040 1
11 Mounting plate of rotating cylinder PT00C010 1
12 Aluminum profile 1 for telescopic
13 Linear bearing MBG4-JB20 4
14 Mounting bracket of vertical (AW,PW) AW00C010 1
15 Safety lock cylinder frame AW00C151 1
3-19
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16 Sensor switch RSN1001 1
17 Safety lock cylinder PCY2015M 1
AW05C040 1 P550W
AW06C040 1 P650W
18 Arm frame
AW07C040 1 P750W
AW08C040 1 P850W
MBT1-8M15 1m P550W
MBT1-8M15 1.12 P650W

19 Belt
MBT1-8M15 1.3m P750W
MBT1-8M15 1.3m P850W

21 AW down stroke fixed block AI00C140 1
22 AW down stroke baffle plate AI00C150 1
23 Crosswise cushion base PT00B030 1
25 Washer AW00C080 2
26 Mounting bracket of vertical cylinder AW00C060 1
27 Proximity switch fixed plate AI00C160 1
MAR2030 1
28 Shock absorber
MAR2050 2
29 Washer AW00C070 1
30 Upper plate of belt pulley AW00C120 2
31 Belt pulley pin AW00C130 2
32 Belt pulley MBTI-YF081501A 2
33 Bearing 6002ZZ MBG1-6002 4
34 Side plate of belt pulley BW00C080 4
3-20
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3.4.6 Jig Component
3-21
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Part list of Jig

1 Wrist assembly body JR01B011 1
2 Side plate of wrist assembly JR01A020 2
3 Pinion of wrist assembly JR01A030 1
4 Positioning rack of wrist assembly JR01A040 1
5 Pinion of wrist assembly JR01A050 1
6 Rotary piston JR01A060 1
7 Bearing 689ZZ MBG1-689 2
8 Jig fixed plate -1 PI00C041 1
9 Jig fixed plate -2 PI00C031 1
Side plate of jig body 1 JC16B040 1

10
Side plate of jig body 2 JC16B050 1
11 Clamping piece JC16B010 2
12 Chain mesh splice JC16B060 2
13 Cylinder driving base JC16B030 1
14 Cylinder seal-capping JC16B070 1
15 Screw MSW7-0516 2
16 Positioning pillar JC16B020 4
17 Jig cylinder JC16R15M 1
18 Magnetic switch of jig 1
19 Small insert core PTF04M5 2
21 Bolt MSW2-0512 2
22 O-shape ring PRG1017 2

24 C-shape retaining ring (Inner) MET2002 1
3-22
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3.4.7 Air Valva Component
3-23
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Part list of Air Valve

1 Cover plate of magnetic valve PI00H010 1
2 Fixed plate of magnetic valve PI00H021 1
3 Magnetic valve PSV1-P54S+1D 1
5 Quick fitting PQU0401 2
7 Copper elbow PFL0101 1
9 Quick fitting PQE0401 2
11 Nipple PTA0101 1
12 Nipple PTA0202 1
14 Check valve PTE1002 1

15 Silencer PET3001 2
16 Air generator PET1001 1 Option with “V” function
3-24
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3.4.8 Electric Control Component
3-25
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Part list of Electric Control

1 Fixed plate for power supply PI00H040 1
2 Electric control box PI00H030 1
3 Power supply RPW2006 1
4 Power switch RBT1001 1
5 Alarm light RLT1002 1
6 Relay board RBD-GA28-PC2 1
7 Fan REL2001 1
8 Buzzer REL1001 1
9 Power filter RPW3002 1
3-26
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3.4.9 Controller
3-27
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Part list of Controller (RBD-GA28)

1 Top cover GA28E010 1
2 Base cover GA28E020 1
3 Control board in controller RBD-GA28-PC3 1
4 Liquid crystal display (LCD) RBD-GA28-PC4 1
5 Emergency stop button RSN4004 1
6 Key-press panel RBD-GA28-PC1 1
7 Film RBT2-GA28E050 1
8 Connecting line of controller RCB1001 1
9 LCD protecting cover GA28E040 1
3-28
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3.4.10 End-of-arm Suction Tooling Component
3-29
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Part list of End-of-arm Suction Tooling (JA05-200A2)

1 Spring plunger JE20R070 4
2 Suction pad JE07-10S1 4 Replaceable
3 Carriage bolts MSW1-1030 2
4 Fixed plate JB01S-036200 1
5 Fixed plate JB01S-030200 2
6 Nut MSW8-1003 2
NOTE: This end-of-arm suction tooling is suitable for P series with

optional “V” function robot.
3-30
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4. Setting and Adjustment Before Booting
4. SETTING AND ADJUSTMENT BEFORE BOOTING

4.1 Connection with I.M.M (CE Option)
Before putting robot into operation, it must be linked with I.M.M by connecting the
Euromap/ SPI-standard interface connector.
NOTE: When robot is not in use, power switch must be turned off or connect
with dummy plug.
4-1
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4.2 Connection with Pneumatic Supply Source
Output air pressure 5kgf/cm²
Quick fitting - Inlet
Quick fitting -
Outlet
Input air pressure 5kgf/cm²
Pressure
gauge
Drain valve
NOTE:
(1) After completing the connection, adjust the pressure until it reaches 5kgf/cm2.
(2) Check the water trapped in Air filter/ Regulator and drain water away everyday.
(3) Pull up pressure tuning knob lightly, turn clockwise to large the pressure; turn
counterclockwise to lessen pressure.
4-2
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4.3 The Flowchart of Booting Procedure
Buzzer
Power switch
Alarm light
Fan
Procedure:
(1) Double check to make sure that safety interlocks between Robot and I.M.M are well
connected, and then turns power switch on.
【 NOTE】 Please make sure the controller and electric box is well connected
before turning ON the power switch.
(2) After power in, the screen of controller will display as below:
ALFA TOBOT
AUTO MANU MODE
(3) If there is no display on the screen after power on, it might be caused by burnt control
fuses. Please check fuses and replaces it if necessary.
4-3
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4.4 Adjustment while Mould Changing
Safety matters After changing mould finished, and ready to

must be fully
observed
adjust the robot, there are some safety matters
must be fully observed:
(1) Do not adjust the robot unless you are fully trained.
(2) Switched the I.M.M to Manual mode and open mould to position, and then
turns power off.
(3) Turns the power off and disconnects pneumatic supply source of the robot.
NOTE: Do not adjust the robot unless above mentioned actions are carried out.
4-4
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4.4.1 Adjustment of Crosswise Stroke
Mounting bracket of
crosswise cylinder
Set screws of Crosswise

mounting bracket of baffle
crosswise cylinder
Set screws of
crosswise
baffle
Crosswise cylinder Safety lock cylinder
Procedure:
(1) Switch the I.M.M to Manual mode and open mould to position.
(2) Loosen set screws on both crosswise baffle and mounting bracket of crosswise
cylinder.
(3) Moves arm horizontally to the middle of mould, put out safety lock cylinder and
then moves arm down to the center of mould.
(4) Pushes arm forward to be able to remove the products without damage the
mould. Locks set screws on mounting bracket of crosswise cylinder tightly with
attention to preserve forward distance of ejector to avoid arm and set screws
loosen during to long run.
(5) Pushes arm toward the injection nozzle until the accessible range of product
removal and within crosswise cylinder moving stroke, and then locks set screws
on the crosswise baffle tightly.
4-5
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4.4.2 Adjustment of Vertical Stroke
Single stage Telescopic
Vertical baffle Vertical baffle
Procedure:
(1) Loosen set screws on vertical baffle.
(2) Adjust vertical baffle to proper position to allow the EOAT (jig) to be able to
remove the product.
(3) Locks set screws tightly.
4-6
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4.4.3 Left and Right Swing Angular Adjustment
Set screw nut of swing

angular adjustment
Dextrorotation 50 ﾟ~90 ﾟ
Levorotation50 ﾟ~90 ﾟ
Swing out
positioning check
Swing back positioning check
Swing out positioning check

Swing back
Set screw nut of swing positioning check
angular adjustment
Dextrorotation 50 ﾟ~90 ﾟ
Levorotation50 ﾟ~90 ﾟ
Procedure:
(1) Loosen the set screw nut of swing angular adjustment.
(2) Swing arm manually to the desired swing-out direction and angle, and adjust
fixing nut of swing angular adjustment.
(3) Pulls out the safety lock cylinder and moves arm down to position to check if
there is any interruption when swinging out. If not, locks fixing nut of swing
angular adjustment tightly.
4-7
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4.4.4 Adjustment of Mould Changing
Positioning pin
Locking screw
Procedure:
(1) Loosen the locking screw with rotary wrench.
(2) Lift up the positioning pin away in order to pivot out arm to facilitate mould
changing.
(3) After mould changing completed, pivots arm back to position and put positioning
pin back into base.
(4) Lock the locking screw tightly.
(5) Adjust strokes according to procedures 4.4.4, 4.4.2 and 4.4.3.
NOTE: Please do not collide with robot while mould changing.
4-8
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Loosen
Right/left-
handed
tenon
Tighten
Ratchet wrench
Loosen
Tighten
Procedure:
(1) Loosen the right/left-handed tenon with ratchet wrench as picture showed.
(2) Lift up the positioning pin away in order to pivot out arm to facilitate mould changing.
(3) After mould changing completed, pivot arm back to position and put position pin
back into base.
(4) Tighten the right/left-handed tenon with ratchet wrench as picture showed.
(5) Adjust strokes according to procedures 4.4.1, 4.4.2 and 4.4.3.
CAUTION: Please do not collide with robot while mould changing.
4-9
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4.5 Installation and Adjustment of EOAT
Wrist assembly
Magnetic switch
Gripper set
(RSN2009)
(JC20R1010)
Insert core
Suction pad
Jig
Procedure:
(1) Adjust magnetic switch till light ON as soon as the gripper tightly clamps the
product/ sprue.
(2) Assembles standard EOAT as picture showed and installs on the gripper set.
(3) Connect red PU tube and standard EOAT with quick fitting.
4-10
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4.6 Adjustment of Moving Speed

4.6.1 Speed Adjustment for Crosswise Forward and Backward
Crosswise back ward

speed control valve
Crosswise forward
speed control valve
Procedure:
(1) Adjust crosswise forward speed control valve when the speed of arm moving
forward to remove the product needs to be changed.
(2) Adjust crosswise backward speed control valve when the speed of arm moving
backward after removing the product needs to be changed.
(3) Turning clockwise to slow down; turning counterclockwise to speed up.
(4) After proper adjustment, please lock the locking nut tightly.
4-11
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4.6.2 Speed and Proximity Switch Adjustment for Arm Down
Arm down cushion

control valve
Arm down speed

control valve
Arm up detector
(Proximity switch)
Procedure:
(1) Adjust arm down speed control valve when the speed of arm moving down
needs to be changed.
(2) Adjust the distance between arm up detector (proximity switch) and arm with
arm being at upper position if the arm up detector (proximity switch) is not
motioned.
(3) Adjust arm down cushion control valve if cushioning effect is not well while arm
moved up and down.
4-12
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4.6.3 Speed and Cushion Adjustment for Swing-back and

Swing-out
Swing out speed Swing out cushion

control valve control valve
Swing back speed Swing back cushion

control valve control valve
Procedure:
(1) Adjusting swing out speed control valve when the speed of arm swings out
(2) Adjusting swing out cushion control valve when the cushion of arm swings out is
abnormal.
(3) Adjusting swing back speed control valve when the speed of arm swings back
(4) Adjusting swing back cushion control valve when the cushion of arm swings
back is abnormal.
4-13
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4.6.4 Speed Adjustment for Wrist Assembly
Wrist assembly rotating Wrist assembly swing

speed control valve back speed control valve
Procedure:
(1) Adjusting wrist assembly rotating speed control valve when the rotating speed of
wrist assembly needs to be changed.
(2) Adjusting wrist assembly swing back speed control valve when the speed of
wrist assembly swinging back needs to be changed.
4-14
5. Maintenance
5. MAINTENANCE
5.1 Maintenance and Repair Safeties
【NOTE】Serviceman should read the following safety

requirements before or during maintenance.
1. Please turn the robot power off before examine and repair the I.M.M.
2. Please turn the robot and I.M.M power off and disconnect pneumatic supply source,
also evacuate residual compressed air before adjusting and maintaining.
3. In addition to the replacement of proximity switches, vacuum and grip sensors, please
contact your local supplier for other repairs and maintenance.
4. Do not make any change or modification to the robot.
5. Please be careful to prevent from hurt by robot during adjustment or mould changing.
6. Please stay away from danger area before testing after adjusting or maintaining
completed.
7. Do not turn the power on or connect pneumatic supply source during maintenance.
5-1
5. Maintenance
5.2 Maintenance Schedules
Please carry out the following necessary inspections, maintenances and replacements
frequently
Item Inspecting Area Period
Check to make sure functions of the gripper, suction pad and Daily
1
EOAT are normal.
2 Draining water from air filter/ regulator. Daily
3 Set screws on jig. Daily
4 Draining water from air compressor. Daily
Check I.M.M connecting line and connecting line of controller are Daily
5
well tightened.
6 Check if any parts loosen or not. Daily

7 Lubricating on bearings and crosswise guide-bar. Weekly
8 Lubricating on vertical slide rail and slide rail block. Monthly
Check if air compression tube and speed adjusting button are Monthly
9
normal or not.
10 Clean appearance Weekly

11 Check the function of vacuum generator. Monthly
12 Check set screws on base. Monthly
13 Check the function of shock absorber. Monthly
14 Replace air compression tube and electric wires. 3 years
5.3 Maintenance Tools

5-2
5. Maintenance
1. Hex wernch 2.5 to 8mm

2. Monkey wrench 8 to14mm
3. Cross-bladed screwdriver and flat-bladed screwdriver
4. Diagonal pliers and long-noes pliers
5. Avometer
6. Air gun
7. Oil gun
5.4 Lubrications
5.4.1 Regular lubrication of the linear slide rails, linear bearings, roller bearings or
other composites are absolutely necessary.
5.4.2 Period of lubrication : Every 50,000 cycles or every month.
5.4.3 Type of grease : with yellow grease or soap base lubrication No. 2 series.
(1) ISEVG32-68……….. or transparent lubricating oil
(2) ALVANIA GREASE NO.2 (SHELL brand).
(3) ALVANIA EP\2 (SHELL brand).
5.4.4 Position of lubricating :
(1) Vertical slide rail and slide block
(2) Crosswise guide-bar and bearing
5.4.5 Way of lubrication :
(1) Slide rail block : To squash grease into slide block for lubricating.
(2) Slide rail and bearing: To paint grease on the surfaces by brush.
5.4.6 No need to lubricate due to oil-free cylinder is utilized on the robot.
5-3
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6. Pneumatic Circuit Diagram
6. PNEUMATIC CIRCUIT DIAGRAM
6-1
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6. Pneumatic Circuit Diagram
■P550~P650 Part List

1 Quick fitting PFL0200 1
2 Air filter/ regulator PET2001 1
4 Quick fitting PQH1002 1
5 Check valve PTE0202 1
7 Nipple PTA0202 1
8 Silencer PET3001 2
11 Magnetic valve set PSV1-P04S 1
13 Quick fitting PQLU0401 2
15 Quick fitting PQH0401 2
17 Copper elbow joint PFL1-0202 1
18 Socket set screw MSW3-PT1/8 1
19 Nipple PTA0101 1
20 Air generator PET1001 1
21 Copper joint PFL0601 1
23 Quick fitting PQE0401 2
26 Concentric reducer PTB0101 2
6-2
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7. Electrical System
7. ELECTRICAL SYSTEM
7.1 Power System Layout
N:Blu e Wire
Ca b le
P E:Ye llo w/Gre e n Wire L:Bla o k Wire
L2 L1
2b 2a 1b 1a
P o we r
2 1
R1
R1 S1
LINE
PE L2 NC R1 S1
EMI
NOIS E
LOAD
TNR
R2 S2
Fu s e 2A AC1 AC2
P OWER
S UP P LY
GA28-P C2 V1 G1
CN4 L+ L-
DC24V
K4
GA28-P C2
CN5
K4A
7-1
○
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7.2 Grounding System Layout
7-2
7.3
Controller Board GA28-PC3-9901 Midway Board GA28-PC2-9901

CPU JUMP1
X9 1
2 CN1/25 K31 CN6/4
3
CN4/25
L-
Y9 JUMP2 JUMP1
1 CN4/11 CN1/11
2 1 K3
3 2
7-3
Emergency Stop Layout
3
L+
CN3/7
JUMP4 CN4/22 CN1/22 JUMP2
JUMP3 1 K31 CN6/3
1
1 2 2
2 3 3
3 4 L-
CN1/1 CN1/2 5 K31
ROBOT EMG STOP
ROBOT EMG SWITCH

R
○
○
R
7.4 Description of Input/ Output
In p u t L+ L-
X1
Arm u p S e n s o r
Mo ld Mo d d le X2
Sens or
S win g In wa rd X3
Sens or
S win g Ou twa rd X4
Sens or K7
Grip X5
Co n firm a tio n
Va c .S u c tio n X6
Co n firm a tio n
S a fe ty De vic e s X7
Of Ma c h in e
Mo u ld Op e n X8
En d
Em e rg e n c y X9
S to p o f IMM
Ou tp u t L+
Y1 Y9
Em e rg e n c y S to p
Arm UP /Do wn K6 K3
o f Ro b o t
Fo rwa rd /Ba c kwa rd Y2 Mo u ld Are a Y10 K1

Fre e
S win g In wa rd Y3 En a b le Eje c to r Y11 K2

Fo rwa rd
Y4
S win g Ou twa rd
Grip p e r Y5
Va c u u m S u c tio n Y6
Y7 K5
Co n v.o r.S p ra y
Y8 LIGHT
Wa rn in g
BUZZER
7-4
○
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7.5 GA28-PC2 Joint Illustration
CN1:Co n n e c t To Co n tro llo r CN2:Bu zze r An d

Wa rn in g Lig h t
CN5/L+ L+
1
L+ L+
2
J 7/X1 CN1/21
X1 3 AL
CN3/X2
X2 4
J 8/X3 BZ
X3 5
J 9/X4,K7
X4 6 L+
J 10/X5
X5 7
J 11/X6 S W2
X6 8
CN6/X7 L+
X7 9
CN6/X8 S W2
X8 10
CN6/3
X9 11
CN5/L-
12
L-
13
J 1/Y1,K6
Y1 14
J 2/Y2
CN3:S p a re P o in t
Y2 15
J 3/Y3 L+
Y3 16 L+
J 4/Y4
Y4 17 CN1/4
J 5/Y5 Mid d le S ig n a l X2
Y5 18
J 6/Y6 L-
Y6 19
K5 L-
Y7 20
CN2/AL
Y8 21 Ca n v Or K5
CN3/Y9,K3 K5
Y9 22 P u ls e
K1 K5
Y10 23
K2 L+
Y11 24 L+
CN5/L-
L- 25 S o ft S ta rt-Up CN1/22
Va lve Y9
CN4:Co n n e c t To P o we r An d
Ea rth in g
E
CN5:Co n n e c t To
E P o we r S u p p ly
E L+
L+
S W1 E L+
Ye llo w/Gre e n Wire Fa n
CN6/6 PE L- P o we r S u p p ly
CN6/5 L-
5 L-
P o we r S a fe ty P o in t(2,2b )
4
R1 P o we r(1)
TNR
S1 P o we r Filte r
N:Bu le Wire
L2
Fu s e 2A
7-5
○
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7.6 CN6: Connect to I.M.M Diagram

CN1/10 CN1/9 CN1/11
X8 X7 X9 L-
K1 K1 K2 K3
K6 K7
S W1
K4 K4A K4A
K4
CN4/4
CN4/5
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 Lin e NO.
d f) p ) r) p
n oM o d
l C o F
E t a) uM t
cE t)
o
n
eD
c S S )
M rF
e oE e
j E
( SRS
e i
v( y S AA M( Ed yE
p ee c M e e
r r c(
o Dc n E d ( l e
l a nt
d ) n e ( l
ue bu bw eo
l P y i g M oe as ar g b
uO t
e h
c
r
e M MrF nol no r
eo
oM EC
M(
f
aa m I
f
EF mR
SM E o Efo
7-6
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7.7 Cable Code and Definition
Cable No. Definition Remark

1 Mould open position
2 Safety device of machine
3 Emergency stop of machine
4 Reference potential (L-)
5 Enable mould close
6 Enable mould close
7 Mould area free
8 Mould area free
9 Enable ejector forward
10 Enable ejector forward
11 Emergency stop of robot
12 Emergency stop of robot
7-7
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7.8 Control Board GA28 Layout (RBD-GA28-PC3)
7-8
○
R
7.9 Control Key Pad GA28-PC1 Layout (RBD-GA28-PC1)
7-9
○
R
7.10 Relay Board GA28-PC2 Layout (RBD-GA28-PC2)
7-10
○
R
7.11 PC Board JUMP Illustration
7-11
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8. Operational Procedure
8. OPERATIONAL PROCEDURE
8.1 Operational Schematic (1)
10 12 13 14
Au to F1 S ta rt F1 Co u n t An d Ch a n g e p a g e
Re c ko n By
Tim e F1 16 16
Co u n t F2 Re s e t F1
12 17 12
Exit ES C Ca rry F2 Re c ko n By
Tim e F1
1 12 12
S to p F2 Exit ES C Exit ES C
0 1 11 12
S ys te m S ys te m Orig in a l S in g le S ta rt F1
Te s t No rm a l P a g e Cyc le F2
2 3 11
Re c yc le F2
Em e rg e n c y S to p ,P le s e Re s to re
P u s h Re s e t In to Ma n u a l Mo d e
Exit ES C
20 21 22 21 22
Ma n u a l I/O F1 In p u t Ou tp u t In p u t P a g e
F2 P a g e /DN P a g e /DN 20
Exit ES C
20
Exit ES C
20
Exit ES C
24 25 24
Fu n c tio n Bre a kd o wn Exit ES C
F2 Re c o rd F1
26 24
Lo c k File Exit ES C
F2
20
Exit ES C
8-1
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8.2 Operational Schematic (2)
8-2
○
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8.3 Description of Fixed Mode
8-3
○
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8-4
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9. Description of Timer and Counter
9. DESCRIPTION OF TIMER AND COUNTER

9.1 Definition of Timer
：Crosswise backward delay: Starting time counting after previous motion
completed, and then crosswise backward after time counting completed.
：Crosswise forward delay: Starting time counting after previous motion

completed, and then crosswise forward after time counting completed.
：Arm up delay: Starting time counting after previous motion completed, and then
arm up after time counting completed.
：Arm down delay: Starting time counting after previous motion completed, and
then arm down after time counting completed.
：Arm swing back delay: Starting time counting after previous motion completed,
and then arm swing back after time counting completed.
：Arm swing out delay: Starting time counting after previous motion completed,
and then arm swing out after time counting completed.
：Arm pick up delay: Starting time counting after previous motion completed, and
then arm pick up after time counting completed.
：Arm release delay: Starting time counting after previous motion completed, and
then arm release after time counting completed.
：Arm suck delay: Starting time counting after previous motion completed, and
then arm suck after time counting completed.
：Arm suck release delay: Starting time counting after previous motion completed,
and then arm suck release after time counting completed.
Eje: Ejector delay: Starting time counting after mould open completed, and then
ejector forward allowed after time counting completed.
Time: Time delay of conveyor or spray.
9-1
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9. Description of Timer and Counter
9.2 Definition of Counter

（１）Time of cycle: 8 digits. Robot will add one time on every cycle and calculate
amount of total cycling times. It can be according to this amount to do
the regular maintenance.
（２）Number of mould setting: 4 digits. The produced mould number will be set. When
accumulated number reaches to setting times, robot will give E80
alarm signal. Setting 0000 means this function is invalid.
（３）Present mould number: 4 digits. After number of mould setting finished, reset the
present mould number to zero. The mould number will add up after
robot finishing every one cycle. When the accumulated number
reaches to setting times, robot will give E80 alarm signal.
（４）Times: Conveyor or spray motion can be set according to mould number.
9-2
○
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10. Description of Operational Mode
10. DESCRIPTION OF OPERATIONAL MODE

10.1 Description of Operational Mode
0
  GA28
  ALFA
ROBOT
 Turn on the power and the monitor displays page 0.

 Please wait for internal system test if it is normal, the monitor displays page 1.
 Press emergency stop button for emergency stop and the monitor displays page 2.
1
ALFA ROBOT
GA28
AUTO MANU MODE
 Enter into initial page when the system is normal.

 There are F1, F2 and MODE keys to operate functions.
 F1: AUTO – Automatic mode. Operating mode, time, counter, mould memory, conveyor and
signal run test functions can be set under this mode. The monitor displays page 10.
 F2: MANU – Manual operate. I/O check, function setting and alarm code functions can be
set under this mode. The monitor displays page 20.
 MODE: The user can set up mode, product detecting type, mould memory and timer/ cycle
changed, etc. The monitor displays page 30.
10.1.1 Setting Parameter:

（１）Press ←, → to move cursor.
（２）Press ＋, － to change value.
（３）After changing value, the changed information is saved directly.
10-1
○
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10.1.2 Emergency Stop

2
ALFA
『EMERGENCY STOP』
PLEASE RESET
 System abnormal with 『EMERGENCY STOP』, please reset the emergency stop button
and the monitor displays page 2.
 Release emergency stop button to reset and the monitor displays page 3.
3
Press 『Reset』
Run System in Manual Mode
 Please press Reset to run system and enter into manual mode.
 System will be unable to operate if not pressing Reset button.
10.1.3 Automatic Mode – Mould No. Select

10
Mold No. 01 AUTO

Prog 01 READY
Check Grip
F1 START F2 S-CYC
（１）Press F1 under page 10 to turn into START mode, and monitor displays page 12.
（２）Mold No.: Select 01 to 50. (Only show content under this page.)
（３）Press F2 under page 10 to turn into S-CYC mode, and monitor displays page 11.
（４）Prog: Built-in standard mode 01 to 08. Free teaching mode by user 09 to 20.
（５）Check Method: Grip – Grip accurately and magnetic switch ON. Grip inaccurately and
magnetic switch OFF.
Vac – Vacuum switch
Grip & Vac simultaneously – Grip & Vac check simultaneously.
（６）Press ESC to exit to return to initial page 1.
（７）When setting Grip & Vac simultaneously, please refer to page 3 for time of suck and
release.
10-2
○
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10.1.4 Under page 10, there are 3 selections:

（１）Press F1 to start robot with full auto mode and the monitor will displays page 1.
（２）Press F2 S-CYC to display one cycle automatically and then stop. The monitor will
display page 11.
（３）Press ESC to return to page 1.
10.2 Auto/ Start – Auto Mode Operation

12
AUTO START
COUNT : 00 50
F1 TIM/CUN F2 STOP
（１）Press F1 under page 10 to turn into START mode, and monitor display page 12.
（２）Number or mould refers to operation times.
（３）Please open safety gate or press RESET if there is alarm.

（１）Press F1 TIM/CUN to adjust timer, counter, etc. The monitor displays page 13.
（２）Press F2 STOP to stop robot right after robot motion completed and the monitor
displays page 1.
10.3 Single Cycle

11
Mold No. 01 AUTO
Prog 01 S-CYC
Check Grip
F1 START F2 S-CYC
（１）Press F2 under page 10 to start a single cycle running of robot. The monitor displays
page 11.

（１）Press F1 START to start robot auto motion, and the monitor will display page 12.
（２）Press F2 S-CYC and robot will execute another single cycle running and the monitor
displays page 11.
（３）Press ESC to exit and return to page 1.
（４）Please open the safety gate or press RESET if there is alarm.
10-3
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10.4 Timer
 0. 03  0. 04 AUTO  0. 03 0. 03 AUTO
0. 04  0. 04  1 0. 03 0. 03  2
 0. 04 0. 04 0. 03 0. 03
 0. 04 0. 04 CUNT 0. 03 0. 03 CUNT
（１）Press F1 TIM/CUN under page 12 to adjust time. The monitor will display page 13.
（２）There are 2 pages of Timer, page 14 and page 15.
（３）Please refer to TIM/CUN for time definition.
10.4.1 Setting Parameter

（１）Press ,  to move cursor.
10.4.2 Under page 13, 14 and 15, there are 3 selections:

（１）Press F2 CUNT to adjust counter. The monitor will display page 16.
（２）Press page/DN to go to next page to adjust time.
10.5 Counter
16
P_SET ： 00 00 AUTO
RUN ： 05 64 CUNT
EJE ： 0 .08
F1 ZERO 1 F2 CONV
（１）Press F2 CUNT under TIM/CUN to adjust counter setting. The monitor will display
page16.
（２）Please refer to TIM/CUN for counter definition.
（３）EJE 0.08 refers to allow ejector ejecting time 0.08 sec.
（４）The mould number will add up after robot finishing every one cycle. When the
accumulated number reaches to setting times, robot will give E80 alarm signal and
stop.
（３）After changing value, select ENTER to finish setting.
10-4
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（１）Press F1 Zero to reset the present mould number to zero.
（２）Press F2 CONV to adjust stop time and time setting of conveyor or spray. The monitor
will display page 17.
10.6 Conveyor/ Spray

17
COUN ： 00 CONV
TIME ： 00 00 SPRY
F1 TIME
（１）Press F2 CONV under page 16 to adjust conveyor parameter. The monitor will display
page 17.
（２）Please refer to TIM/CUN for time and counter definition.


（１）Press F1 TIME to adjust time setting, and the monitor displays page 13.
（２）Press ESC to exit and return to page 12.
10-5
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11. Description of Manual Operation
11. DESCRIPTION OF MANUAL OPERATION

11.1 Manual
20
ALFA ROBOT
MANUAL MODE
F1 I/O F2 FUNC
功
（１）Press F2 MANU under page 1 to turn into manual operating mode. The monitor will display
page 20.
（２）
Functional key: Please operate with selected functions.
Functional key: Please operate with selected functions.
Functional key: Please select it to enter into mode operation setting.
To change pages.
To exit each function page.
Arm up
Arm down: The mould open position signal is required to manual operate arm
down.
Crosswise backward (toward the fixed mould)
Crosswise forward (away from the fixed mould)
Swing in: Arm swing into mould.
Swing out: Arm swing outside mould.
Grip clamp: To clamp product and detective lights on.
Grip release: To release grip.
Suck vacuum: Vacuum generator acts.
Suck release: To release suction.
11-1
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When there is alarm, press this RESET button to dismiss alarm.
Enter key to save data.
To increase, decrease time parameter or various functional settings.
To move cursor.

（１）Press F1 I/O to check all input signals from robot. The monitor will display page 21.
（２）Press F2 FUNC to set special function. The monitor will display page 24.
11.1.2 Description of LED Indicator Light
11.2 Input
21 27
● ARM UP MANU ● GRIP MANU

○ M-PLAT INPUT ○ VACUUM INPUT
● SWIN-IN ● G-OPEN
○ SWIN-OUT P1 ○ M-OPEN P2
（１）Press F1 I/O under page 20 to examine input signal changes. The monitor will display
page 21.

（１）Press Page/DN to examine output signals. The monitor will display page 27.
11-2
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11.2.2 Output
22 28
○ ARM DOWN MANU ○ GRIP MANU

○ SWIN-IN OUTPUT ○ VACUUM OUTPUT
○ SWIN-OUT ○ MC Able
○ Kick Fwd P1 ○ CONV P2
（１）Press Page/DN under page 27 to examine output signal changes. The monitor will
display page 22.

（１）Press Page/DN to examine input signals. The monitor will display page 28.
11.3 Function
24
XDATE : 98 03 01
CYCLE : 00 00 .0 01 0
VER : 98 -03 -01
F1 ALARM F2 LOCK
（1）Press F2 FUNC under page 20 to examine total number of running, error record, ex
factory date. The monitor will display page 24.

（1） Press F1 ALARM to examine and track alarm record content. The monitor will
display page 25.
（2） Press F2 LOCK to select robot in use or robot not in use, displayed language and
file lock protection or not. The monitor will display page 26.
（3） Press ESC to exit and return to page 20.
11-3
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11.4 Trouble Record

25
00 00 00 00 ALRM
00 00 00 00 CODE
00 00 00 00
01 01 01 01
（1） Press F1 ALARM under page 24 to enter into Alarm page. The monitor will display
page 25.
11.5 File Lock

26
CHINESE LOCK
File Unlock
Robot in use SG_REST
Pulse SG-ON-DN
（1） Robot in use or Robot not in use

Robot in use: When setting this function, robot will interlock with IMM to operate.
Robot not in use: When setting this function, robot will not control any motion of
IMM.
（2） Language select: Chinese and English switches
Chinese: The monitor displays Chinese.
English: The monitor displays English.
（3） Lock – Mode locked or Mode is not locked
Mode locked: Mode page is locked that any change is disabled.
Mode is not locked: Mode page is opened that any change is allowed.
（4） Pulse signal: When arm up to position, there will give pulse output signal.
Conveyor: After taking out product and return to position, conveyor motions and
counts time until stops.
Spray: After taking out product and upward to position, spray motions until stops.
（5） SG-ON-DN: Robot will descend to take out product only if safety gate is closed.
SG-OFF: Robot will descend to take out product even if safety gate is opened.
（6） SG-REST: If opened the safety gate when robot arm is at take-out side, robot will
reset and return to waiting position. If opened the safety gate when robot arm is at
placing side, robot will stop the motion and will continue the following motion after
closing safety gate.
SG-STOP: Robot will stop the motion if opened the safety gate. Robot will continue
the motion after safety gate is closed.
11-4
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（1） Press ,  to move cursor.
（2） Press ＋, － to change value.
11.5.2 Under page 26, there is 1 selection:

11.6 Robot is not Used

23
ALFA
ROBOT IS NOT IN USE
Press for operating again
（1） The screen shows that robot not in use. The user can press F1 and robot will operate
normally.
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12. Mode
12. MODE
12.1 Mode
30
Mold No. : 01 MODE

Prog. : 01 GRIP
Setting: OK ENTER
F1 TEACH F2 TIM/CUN
（1） Press MODE under page 01 to set running mode. The monitor will display page 30.
（2） Mold No.: Select 01 ~ 20.
（3） When mold no. is changed, M-arm, S-arm, product check, each taking-time, etc. are the
memory value under the mold number.
Mode: 01~08 are built-in standard model.
09~20 are teachable mode (set by user).
Check selection:
Suction (vacuum) pad: Vacuum switch check
Grip: Magnetic switch check
Vacuum and grip simultaneously: Check at the same time
12.1.1
32
Move arm to de-

Fine Home posi
Then press ENTER
( + - )
      MODE  MODE
   TEACH TEACH
    
F1 PG-DN F2 END F1 PG-DN F2 END
（1） Under teach mode, arm needs to be moved to waiting position first. After setting, arm
needs to be returned back to waiting position to finish the setting.
（2） Under teach mode, the “mode open finished signal” and “mold close allowed signal” are
needed to be set, otherwise the teach mode is not completed.
（3） Press F1 TEACH under page 30 to operate mode teaching setting. (Please refer to
operational key for action symbols)
（4） Operating with white manual operational key and press  (enter key) when executing
every step and action symbols will be displayed on screen.
（5） Maximum carried out motion is 9 steps in one page. After 9 steps, it will turn to next page
automatically.
12-1
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12. Mode
（6） After setting finished, press F2 END to save the settings.
（7） Under teach mode, user can teach the settings according to requirement.
（8） Maximum procedure of teaching mode is 20 sequence motions.
（9） If teaching motion is not correct, user has to re-start teaching.
ATTENTION
“MO” or “MC” must
Be enter as
Teach motions
ATTENTION
Incomplete Teach
Seq arm must
Return to Home

（1） Press F2 END to finish the teaching and save teaching moves into memory.
（2） Press ESC to exit without saving and return to mode page. The monitor will display page
30.
12-2
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12. Mode
12.2 Teach
35
ALFA
TEACH MODE ( 9 – 2 0 )
Select Prog. : 09
F1 OK
（１）Press F2 END under page 32 to finish teaching motion and the monitor will display
page 35.
（２）If the teaching motion is correct, press -ENTER to finish saving motion.

（1） Press -ENTER to continue saving motion and the monitor will display page 36.
（2） Press ESC to quit saving and exit TEACHING page. The monitor will display page 30.
12.2.2 Teach Successful

36
ALFA
『TEACH SUCCESSFUL』
   
（１）Above screen shows the teaching is saved into memory successfully.

（２）It will display above 5 sec and return to page 30 automatically.
12-3
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12. Mode
12.3 Timer
37
 0. 03  0. 03 MODE  0. 03 0. 03 MODE
0. 03  0. 03 1 0. 03 0. 03 2
 0. 03 0. 03 0. 03 0. 03
 0. 03 0. 03 COUN 0. 03 0. COUN
0. 02 0. 02 MODE
0. 02 0. 02 3
0. 02
0. 02 COUN
（1） Press F2 TIM/CUN under page 30 to change time settings and the monitor will display
page 37.
（2） There are 3 pages of Timer, page 37, 38 and 39.
（3） Please refer to Chapter 9 for timer definition.
（4） When suck and grip are action simultaneously, please refer to page 3 of timer
definition for time of suck and release.

（3） After setting value, press -ENTER to finish setting.
12.3.2 Under page 37, 38 and 39, there are 3 selections:

（1） Press F2 COUN to adjust counter setting. The monitor will display page 40.
（2） Press page/DN to turn to next page for time setting.
12-4
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12. Mode
12.4 Counter
40
SET :0 00 0 MOLD
RUN :0 00 0 CTR
REJ :0 00 0
F1 ZERO F2 CONV
（1） Press F2 COUN under page 37, 38 and 39 to adjust counter setting. The monitor
（2） Please refer to Chapter 9 for counter definition.
（3） REJ is to set the ejector action time.
（4） Press F1 ZERO, the present mould number is reset to zero.
（5） The mould number will add up after robot finishing every one cycle. When the
accumulated number reaches to setting times, robot will give E80 alarm signal and
stops.

（3） After setting value, press ENTER to finish setting.

（1） Press F1 ZERO, the present mould number is reset to zero.
（2） Press F2 CONV to adjust conveyor move and time setting. The monitor will display
page 41.
12-5
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12. Mode
12.5 Conveyor/ Spray

41
COUN : 00 CONV
TIME : 00 00 SPRAY
（1） Function on page 41 is available only if setting conveyor or spray function under
functional page.
（2） Press F2 CONV under page 40 to adjust conveyor or spray parameter. The monitor
（3） Please refer to number and time counting chapter for count and time description.

（3） After setting value, press ENTER to finish setting.

（1） Press F1 TIME to adjust time setting and the monitor will display page 37.
12.6 Memory
42
DATA INPUT OKAY?

Press enter to
Save or Press ESC
To exit
（1） Press ENTER under page 30 for preparatory motion of save. The monitor will display
page 42.
（2） Press ESC under page 30 to return to page 1.
（3） This is saving page to save all setting functions.

（1） Press ENTER to enter into mode saving finished page. The monitor displays page 43.
（2） Press ESC to exit without saving setting information. The monitor displays page 30.
12-6
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12. Mode
12.7 Completing of Memory
   
『SAVE SUCCESSFULLY』
   
The set info is saved successfully when monitor displays “SAVE SUCCESSFULLY,” and
8 smiling faces appears accordingly, the monitor will display directly return to mode page,
page 30.
12-7
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13. Zero Cleaning
13. ZERO CLEANING

13.1
50
『REALLY WANT TO
ERASE SYSTEM DATA? 』
   
F1 ZERO
（1） Press accordingly under initial page 1 to enter into ZERO page.
（2） Press F1 ZERO to clear system data.
13.1.1 Zero Motion

51
EPROM CLEAR
Press F1 ZERO under page 50 to clear all stored data to zero and the monitor will display
page 51. After zero cleaning, please re-start the machine to set data.
13-1
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14. Alarm And Trouble Shooting
14. ALARM AND TROUBLE SHOOTING

14.1 Description of Alarm Error Code
(1) E01: Arm up sensor
(2) E02: MID sensor
(3) E03: Swing-in sensor
(4) E04: Swing-out sensor
(5) E05: Grip sensor
(6) E06: Vac sensor
(7) E11: Arm solenoid
(8) E13: Swing-in sol
(9) E14: Swing-out sol
(10) E16: Swing error
(11) E17: In or out NG
(12) E38: Emerg-Stop
(13) E80: Set complet
(14) E92: NO MO signal
(15) E93: MO signal int (Robot is not finish a cycle but IMM has starting next cycle of mould
open. Robot motion is too slow that is unable to coordinate with IMM.)
14-1
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14.2 Description of Alarm Error Signal

Warning signal is not mechanical failure but unqualified operation.
(1) W01: Operate err – When robot descends the swing-in and out action is not allowed.
(2) W04: Machine has not selected – If operation mode is not selected, press AUTO
START and W04 will appear.
(3) W05: Motion error – If robot fails to operate accordingly, W05 will appear.
(4) W10: Not reach home pos – When robot does not reach home position to pick up
products, W10 will appear when user press AUTO START.
(5) Warning signal: Incomplete TEACH, seq. arm must return to HOME – Teaching
incomplete and not back to waiting position.
(6) Warning signal: “MO” “MC” must be entered as teach motions – Teaching incomplete
and not teaching mold open position or enable mold close.
14.3 Alarm Eliminate

(1) Turn back to page 0000 to dismiss the alarm error codes listed on 14.1.
(2) Trouble shooting according to alarm signal.
(3) When there is E05 or E06 error code, it can be dismissed through opening safety
gate or pressing RESET button.
14-2
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14.4 Alarm-Trouble Shooting Flowchart

E01: Arm up Sensor
NO
Check if the distance between sensor Adjusting the distance between sensor
and induction plate is within 2~3 mm. and induction plate within 2~3 mm
(light on means normal).
YES
NO
Check if (proximity) sensor lights on or Sensor is breakdown.
not.
YES
Check if upper signal is 1 at I/O page. NO Sensor is breakdown.
YES
NO Inform ALFA company or Agent.

Check if arm up speed is too slow.
YES
Adjust arm up speed control valve to

normal speed.
E03: Swing-in Sensor

Trouble shooting flowchart is same as E01.
E04: Swing-out Sensor

14-3
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E02: MID Sensor
NO
Check if distance between sensor and Adjusting the distance between sensor
induction plate is within 2~3 mm. and induction plate within 2~3 mm.
(light on means normal)
YES
NO
Check if (proximity) sensor lights on or Sensor is breakdown.
not.
YES
NO
Check if upper signal is 1 at I/O page. Sensor is breakdown.
E05: Grip Sensor
NO
Check if jig pick up product exactly. Open safety gate and wait robot return
to waiting position. Adjust the jig.
YES
Check if magnetic switch motion is NO Re-adjust

normal or not.
Pick up product: light on
Not pick up: light off
YES
NO
Check if tube breaking. Re-adjust to right position.
YES
Change or connect back again.
14-4
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E06: Vac Sensor
NO
Check if main arm hold/ suck product Open safety gate and wait robot return
exactly. to waiting position. Adjust the jig.
YES
NO
Check if air leaking or tube breaking. Vacuum detector is breakdown or limit
switch is breakdown.
YES
Change or connect back again.
E11: Arm Solenoid
NO
Check if robot down to position. Adjust speed control valve and then check
if arm down.
YES NO YES
Check if upper signal is 1 at I/O page. NO Solenoid valve or The adjustment of

speed control valve speed control valve
is breakdown. is not proper.
YES
NO
Proximity switch is breakdown. Inform ALFA company or Agent.
E13: Swing-in Sol

E14: Swing-out sol

14-5
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E16: Swing Error
NO
Check if magnetic switch light of Check if swing-in, swing-out signal is 1
swing-in, swing-out is on or not. at I/O page.
YES
YES NO
If light on swing-in position, the Inform ALFA company or Agent.

magnetic switch of swing-out is
breakdown.
If light on swing-out position, the
magnetic switch of swing-in is
breakdown.
E17: In or Out NG
NO
Check if magnetic switch light of Check if swing-in/ swing-out signal is 0
swing-in/ swing-out in on or not. at I/O page.
YES
YES NO
If light on swing-in position, the Inform ALFA company or Agent.

magnetic switch of swing-out is
breakdown. If light on swing-out
position, the magnetic switch of
swing-in is breakdown. Adjust magnetic
swicth up and down.
E38: Emerg-Stop
Under AUTO START mode, press red button of Emergency Stop to stop the robot in place.
To dismiss the alarm is to loosen switch.
Press Reset Enter into Manual mode Operate robot to position
14-7
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E80: Set Complet
Clean the molding number to zero or reset the setting.
E92: No MO Signal
NO
Check if mold open finished signal is 1 Please check I.M.M mold open finished
or not. signal.
YES
Check if mold open finished signal is NO Inform ALFA company or Agent.

flicker or not.
YES
Please check mold open finished

signal.
E93: MO Signal Int

Please check if mold open finished signal of I.M.M is ON-OFF-ON.
14-7

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INSTRUCTIONS

Serial Numbers MP17— & Above

PLASTIC PROCESS EQUIPMENT

3. DESCRIPTION OF ROBOT STRUCTURE

4. SETTING AND ADJUSTMENT BEFORE BOOTING

6. PNEUMATIC CIRCUIT DIAGRAM

9. DESCRIPTION OF TIMER AND COUNTER

10. DESCRIPTION OF OPERATIONAL MODE

11. DESCRIPTION OF MANUAL OPERATION

13. ZERO CLEANING ............................................................................................. 13-1

14. ALARM AND TROUBLE SHOOTING

1. Safety and Warranty

1. SAFETY AND WARRANTY

1. Safety and Warranty

1.2 Warranty and Non-warranty

Item Description Warranty Period

NOTE: Dimensions shown in ( ) are for telescopic type

NOTE: Pay attention to the gravity center during transporting

2.2 Installation Dimensions

Phoenix 550~650 Phoenix 650W~950 W

 For the controller supporting structure

2.3 Protective Area

2.4 Measurement of Noise Level

1. Noise measurement is done under noise test environment of 60 dB(A).

Measurement Noise Level

2.5 Connection with I.M.M

2.5.1 Euro map joint layout (Optional)

2.5.2 Description of connection of Euro map

2.6 Connection with Pneumatic Supply Source

the extended service life of robot.

2.6.2 Connection with Pneumatic Supply Source

Quick fitting – Inlet

Input air pressure 5kgf/cm²

2.7 Connection with Safety and Function Test

(1). Signal of Enable Mould Close

(2). Signal of Safety Gate Open

(3). Signal of Mould Open End

(4). Adjustment of Moving Speed for all axes

(5). Detection of Reset

(6). Mould Close Function after removal of mould

2.8 Procedures for Robot Dismantlement

Arm Component Component

Crosswise Base Component

Crosswise Arm Component

End-of-arm suction tooling

3. Description of Robot Structure

3. Description of Robot Structure

3. Description of Robot Structure

3. Description of Robot Structure

3.4 Explosive Views

3. Description of Robot Structure

Part list of Poenix350~450 base

Item Description Serial No. Q’ty Remark

3. Description of Robot Structure

3.4.1.2 Explosive View of Phoenix550-950 Base

3. Description of Robot Structure

Part list of Phoenix550~950 base

3. Description of Robot Structure

3.4.2 Crosswise Component with Single Stage

Part list of Phoenix350~450 crosswise