alfa robot Phoenix Series User manual

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Release Date: Feb 04 2015
Version: １.01
Alfa Industrial Group
Suzhou : Alfa Industrial Corporation. No.3366 Changyang road, weitang town, Xiangcheng District, Suzhou
TEL: [phone] FAX: [phone]
Dongguan: Dongguan Alfa Automation Technology Limited. NO.29,6th Yumin street,Xiangwei Community,Dalang Town, Dongguan
TEL: [phone] FAX: [phone]
Service Hotline in china: 400-8620-218
Phoenix Series
Swing-armRobots
(IncludesTRC-800 control)
Version:EuroEnglishVersion

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TABLE OF CONTENTS
Part1：Mechanism

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1. SAFETY AND WARRANTY
1.1 Safety
Description..........................................................................3
1.2 Warranty and Non-warranty..............................................................4
2. INSTALLATION
2.1 Handling and Transportation...........................................................5
2.2Installation Dimensions ............................................................6
2.3 Protective Areas...................................................................7
2.4 Measurement of Noise Level.............................................................8
2.5 Connection with Injection Moulding Machine...........................................9
2.6 Connection with Pneumatic Supply Source............................................13
2.7 Connection Safeties and Function Test..................................................14
2.8 Procedures for Robot Dismantlement.....................................................14
3. DESCRIPTION OF ROBOT ARM
3.1 Illustration .......... ..............................................................15
3.2 Specifications........................................................................17
3.3 Dimensions............................................................................18
3.4 Explosive Views.......................................................................19
3.4.1Base Compartment.....................................................................19
3.4.2 Crosswise Compartment...............................................................23
3.4.3 Arm Compartment.....................................................................26
3.4.4 Gripper Compartment.................................................................31
3.4.5 Pneumatic Box Compartment............................................................33
3.4.6 Electric Control Compartment.........................................................35
3.4.7 Standard Sorption Fixture Group.....................................................36
4. SETTING AND ADJUSTMENT BEFORE OPERATING
4.1 Connection with Injection Moulding Machine (CE Optional Accessoires)....................37
4.2 Supply of Pneumatic Source............................................................38
4.3 Turning ON Electrical Power Source.....................................................39
4.4 Adjustment while Mould Changing.......................................................40
4.4.1 Adjustment of Crosswise Stroke.......................................................40
4.4.2 Adjustment of Vertical Strokes.......................................................41
4.4.3 Adjustment of Swing Angle ..........................................................42
4.4.4 Arm Pivoting for Mold Changing........................................................43
4.5 Installation and Adjustment of Gripper and Headwork (EOAT)...............................45
4.6 Adjustment of Moving Speeds............................................................46
4.6.1 Speed Adjustment for Crosswise Forward and Backward...................................46
4.6.2 Speed and Cushion Adjustment for Arm Down.............................................47
4.6.3 Speed and Cushion Adjustment for Swing-in and Swing-out.............................. 48
4.6.4 Speed Adjustment for Wrist Rotation..................................................49
5. MAINTENANCE
5.1 Maintenance and Repair Safeties...................................................50
5.2 Check Project and Schedules of Maintenance............................................51
5.3 Maintenance Tools.................................................................52
5.4 Lubrications......................................................................52
6. Pneumatic Circuit Diagram...............................................................53
1. SAFETY AND WARRANTY

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1.1 Safety Description
Phoenix series swing-arm robots have been designed and manufactured by
ALFA AUTO in consideration for the use with any make of horizontal plastics
injection moulding machines, therefore the company shall be free from any
obligation and responsibility for any accident or injury incurred while using
this robot with other type of machine or applications. We strongly suggest you
to read the following safety standards thoroughly and observe them before
putting the robot into operation:
(1) This robot has been designed and manufactured for the operating of 5,000,000 cycles (Say,
10 years x 280 days x 8 hours x 60 minutes x 4cycles = 5,000,000 cycle) under normal
operating conditions.
(2) This robot has been designed and manufactured in conformity with EN292-1 and EN292-2
standards.
(3) This robot requires necessary adjustment and maintenance as stipulated in this manual;
therefore we strongly suggest you to read and observe the notices carefully before any
adjustment and maintenance are carried out.
(4) The necessary warning labels are stuck on this robot. Please pay attention to read the
warning labels before and during operation.
(5) Safety regulations shall be highly complied while handling and transportation of the robot.
(6) A well-informed and fully trained operator only can operate this robot.
(7) All operation, adjustment and control of this robot must be carried out in full accordance
with description of this manual.
(8) Risk working areas are noted in this manual. System integrator must install appropriate
safeguarding surrounding the risk working areas.
(9) Do not operate this robot in case there is a person working or standing in the risk areas.
(10) The hand-held pendant must be hung and operated outside the risk areas during
operation.
(11) During maintenance or a mold change, electrical power must be turned off and the
pneumatic source is disconnected.
(12) This robot is equipped with trouble detective function. The user may rectify the problems
according to the trouble-shooting guide themselves or contact your local supplier for
service. The trained operator is allowed to handle only.
(13) In addition to the replacement of proximity switches, vacuum and grip sensors, please
contact your local supplier for other repairs and maintenance.
1.2 Warranty and Non-warranty
1.2.1 Warranty Period

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(1) Within ONE (1) year from the date of installation
(2) 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 items. (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 switches
500,000 cycles
5.
Vacuum generator
500,000 cycles
6.
Suction cups
200,000 cycles
7.
Other headwork or end-of-arm tooling
200,000 cycles
2. INSTALLATION
2.1 Handling and Transportation

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Unit：mm
2.2 Installation Dimensions
For the Machine Platen:
Remark: Dimensions shown in ( ) are for the telescopic version
CAUTION: Pay close attention to the gravity center during handling with a
fork-lift and sure to avoid from dropping.
Lifting Point
CAUTION
Prevent Swing Safety Screw
Please make sure screw to be locked up
when transportation and take out the
screw before operation.

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~
2.3 Protective Areas
An appropriate safeguarding area should be designed and installed to the
protective areas by the system integrator.
Phoenix 550~650 Phoenix 650W~950 W
150
6-M10*1.5P -20D
75
50
20 30
75
6-M10*1.5P -20D
92
150
operator side
50
20 30
58
operator side

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Model P350 P450 P550 P650 P650WP750WP850WP950W
A550 900 1050
B
C
1530 1650
800 900
1860
1000
1750 1900 2050 2200
1120 1220 1320 1420
2060
1100
2.4 Measurement of Noise Level
1. Noise Measurement is taken under noise test environment of 60 dB(A).
2. Measuring equipment model RION NA-24 sound level meter.

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3. Measurement is based on 1m distant from robot and 1m height from floor.
4. Model P550 is measured, and is applicable to other models robot arms.
5. Measurement positions are shown below
Measurement
Position
Noise Level - dB(A)
1.
67
2.
65
3.
67
4.
68

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2.5 Connection with Injection Molding Machine
Standard models are without joint，and direct access to the injection molding machine.
Users can choose EURO 12 or 67 which based on European standards. When the robot is not
used, turn the power off, and the robot will automatic reset and injection molding machine will
not be controlled by it anymore. If the robot can’t automatic reset when turning the power off,
please contact agents or the company.
Deployment Diagram of models based on European standards
(Optional)

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Europe 12 Contact Definition：
Signal from molding machine to Arm
Machine
Signal from Arm machine to molding
machine
1,9, Emergency stop of machine
17, Enable mold closure
2, Mold open position
18，26，Mold area free
3,11, Safety device
19,27, Emergency stop of robot
4, Ejector back position
20，Handing device operation mode
5，Ejector forward position
21, Enable ejector back
6，Core pullers in position 1
22，Enable ejector forward
7，Core pullers in position 2
23，Enable movement of core pullers to
position 2
8，Reject
24，Enable movement of core pullers to
position 1
10，Automatic
25，Reservation
12，Mold Closed
28, Enable full mold opening
13，Reservation
29，30，31，Reservation
14，Intermediate mold opening position
32，IMM reference potential
15, Reservation
16，Handing device reference potential
Europe 67 contact definition：
Signal from molding machine to Arm
machine
Signal from Arm machine to molding
machine
ZA1,ZC1 ,emergency stop 1 of IMM
A1,C1, emergency stop 1 of robot
ZA2,ZC2, emergency stop 2 of IMM
A2,C2, emergency stop 2 of robot
ZA3,ZC3, safety device 1
A3,C3, molding area free
ZA4,ZC4, safety device 2
A4,C4, reservation
ZA5, Reject
A5, reservation
ZA6, mold closed
A6, enable mold closure
ZA7, molding open position
A7, Enable full mold opening
ZA8, intermediate mold opening position
A8, Reservation
ZA9, Handing device 24VDC
A9, IMM 24VDC
ZB2, automatic
B2, Handing device operation mode
（Connected with IMM）
ZB3, Ejector back position
B3, Enable ejector back
ZB4, Ejector forward position
B4, Enable ejector forward

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ZB5, Core pullers 1 in position 1
B5, Enable movement of Core pullers 1 to
position 1
ZB6, Core pullers 1 in position 2
B6 Enable movement of core pullers 1 to
position 2
ZB7, Core pullers 2 in position 1
B7, Enable movement of core pullers 2 to
position 1
ZB8, Core pullers 2 in position 2
B8, Enable movement of core pullers 2 to
position 2
ZC5,ZC6,ZC7,ZC8, reservation
C5,C6,C7,C8, reservation
ZC9, Handing device 0V DC
C9, IMM 0V DC
Europe 12 contact definition：
Name of Signal
Euro Contact
No.
Description
Emergency Stop of
IMM (ESM)
1
During operation of ESM (refer to EN60204-1), such
contact must be opened. When switch contact is turned
on, it makes an emergency stop of robot.
Mould Open Position
(MOP)
2
When mold position is pending for mouldings removal,
such contact must be closed. If range of careless change
of mold opening position is smaller than necessary
mouldings pick up position of robot. such condition must
be avioded from happening. Contact must be kept closed
and may not causing interruption of I.M.M due to the
changing of operational mode of ejector or opening of
protective fixture (such as: safety gate).
Safety Devices of
Machine (SDM)
3
During operation of safety fixture of machine (such as
safety door, protective safety equipment, foot pedal and
safety equipment etc), such contact must be closed and
thus causing possible dangerous action of robot.
However, such signal must have action under any mode
of operation. According to EN201, signal contact of safety
fixture in mould area must use limit switch and current
may not be over 6A.
Common Point (L-)
16,9,11
Such point is common electricity of robot input point and
its code is L-.
Mould Area Free
(MAF)
18, 26
When robot arm move to fully up position, this contact is
closed to permit starting closing of mould. If there is alarm
(in addition to E06: Vacuum suction signal is missing)
during robot operation, the mould closing will be
interrupted.
Enable Mould
Closure (EMC)
17, 32
Operational condition is same as MAF NO. 18,26
MAF
26,18
Operation is the same as EMC.
ESR
19,27
The contact must be turned on when pressing the red
emergency stop button on the robot (see EN60204-1),
and the injection machine stops for an emergency.
EEF
22,32
The joint is closed when the robot is allowed thimble.

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Europe 67 Contact Definition：
Name of
signal
EURO 67
contact
number
Instruction
ESM 1
ZA1
When the injection machine emergency stop device is running, the
joint must be opened. When the joint is open, the robot will
emergency stop.
MOP
ZA7
When the machine opening position is equal to the injection position
need to extract, this joint must be closed. The mold opening stroke is
changed without notice and it less than the required position of robot
to extract. It must be prohibited this case. The joint must be kept
closed, and can’t interrupt the signal because operating mode of the
injection machine is changed or security device (such as a security
door) is open.
SDM1
ZA3
This joint must be closed, when security device of injection machine
(eg. Exit, protective safety equipment, pedal safety equipment) is
running. And therefore, there may be dangerous movements of
robot. This signal must be operated in any operation mode.
According to the EN201, the signal joint of the die area safety device
must be used in the limit switch series, and the current capacity is not
more than 6A.
Reference
potential
ZA9,ZC1,
ZC2,ZC3,
ZC4
This point is the public side of the robot input, and the code is L－.
EMC
A6,A9
When the robot fetches successfully and vertical up to the top value
signal, injection mold is allowed if the joint is closed. The off mode
action will be interrupted if alarm occurs during the robot’s action.
MAF
A3,C3
Operation is the same as EMC.
ESR
A1,C1
The contact must be turned on when pressing the red emergency stop
button on the robot (see EN60204-1), and the injection machine
stops for an emergency. (A2 and C2 of ESR 2 short sub)
EEF
B4,A9
The joint is closed when the robot is allowed to move the top needle,

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2.6 Connection with Pneumatic Supply Source
Supply of Pneumatic Source
In order to maintain the robot's normal operation, be sure to fit refrigerating 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.
AIR COMPRESSOR Refrig
Dryer
Output
5kgf/cm2
Air Filter
Connection with Pneumatic Source of Supply
Important:
(1) To minimize air pressure loss in the pipe for a long distant source (10 meters away), be
sure to use a rigid pipeline.
(2)After completing the connection, adjust the pressure on the Air Filter/Regulator until it
reaches 5 kgf/cm2
(3) Check the water trapped in Air Filter/Regulator and removes it every day.
Note: CE specifications can be equipped with a slow start valve.
Tube Fitting
–Outlet
Tube Fitting–Inlet
Input Pressure 5kgf/cm²
Output Pressure 5kgf/cm²
Pressure Gauge
Drain Button

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2.7 Connection Safeties and Function Test
After completion of installation of the robot with an injection molding machine in
accordance with the instructions stipulated in paragraph 2.2 to 2.5 of this chapter, the
following areas must be fully checked for the test of safety link and function of the
robot:
[Attention] 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 our company.
(1).
“Mold Close Permit” signal,
(2).
“Safety Gate Open” signal
(3).
“Mold Open End” signal
(4).
Adjustment of Moving Speed
(5).
Detection of “Reset Function”
(6).
“Mold Close Function” after removal of moldings.
2.8 Procedures for Robot Dismantlement
1. Turn OFF power of I.M.M.
2. Turn OFF power of the robot.
3. Disconnect pneumatic source of supply.
4. Exhaust air pressure from the robot.
5. Loosen mounting bracket for the crosswise cylinder and move arm to make it
closer to traverse beam.
6. Move mounting bracket for shock absorber to make it closer to arm.
7. Tighten mounting bracket for the crosswise cylinder and make arm unable to
be moved.
8. Dismantle hand-held control pendant.
9. Dismantle connection between the robot and I.M.M.
10. Disconnect electrical power cable to the robot.
11. Dismantle interlock signals and power cable from I.M.M.
12. Dismantle base mounting screws.
13. Dismantle the robot from machine platen.
14. Dismantle the robot arm

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3. DESCRIPTION OF ROBOT STRUCTURE
3.1 Illustration
Phoenix350~450
Base Compartment
Control Box
Crosswise Compartment
Pneumatic Compartmen t
Headwork (EOAT) (For model denotes “V” only)
Arm Compartment

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Arm
Compartment
Base
Compartmen
t
Electric
Control
Compartment
Crosswise
Compartment
Manipulator
Headwork (EOAT)
(For model denotes
“V”only)
Phoenix550~950
Control Box

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3.2 Specifications
Model
Single-Stage
Telescopic
P350
P450
P550
P650
P650W
P750W
P850W
P950W
Suitable IMM
Tonnage (ton)
15~30
30~60
50 ~ 150
75 ~ 200
75 ~ 200
100 ~
250
150 ~
300
200 ~
400
Vertical Stroke
(mm)
350
450
550
650
650
750
850
950
Crosswise
Stroke (mm)
75
120
200
SwingOut Angle
(degree)
60-90
60~90
60~90
Max. Crosswise
Position (mm)
230
420
430
Max.Payload
(Kg)
1
2
2
Minimum Take
Out Time (sec)
1.2
1.3
1.5
1.7
1.7
1.8
1.9
2.0
Minimum Dry
CycleTime
(sec)
3.8
4.0
4.2
4.5
4.5
5.0
5.8
6
Power
Consumption
(KVA)
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
Air Consumption
(Nl/cycle)
1.5
1.5
1.6
1.7
2.2
2.5
2.8
3
Net Weight
(Kg）
30
31
35
36
42
43
44
45
Dimension
L x W x H (mm)
550*285*1015
550*285*1135
815*300*1390
815*300*1490
965*300*1250
965*300*1300
965*300*1450
965*300*1500
Remarks:
1. Runner/sprue gripper and wrist rotation mechanism is included as standard features.
2. Options: 1) Models fitted with vacuum generator and suction headwork (EOAT) are denoted by ‘V’.
Note: These models require additional air consumption of 5Nl/cycle.
2) Platen spacer of 50, 100, 150 and 200mm height.

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for plastics m ouldingmachinery
R
R
for plastics m ouldingmachinery
3.3 Dimensions

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3.4 Explosive Views of Compartments
3.4.1 Base Compartment
Phoenix350~450 Base Explosive Views