SAMPLE OPERATIONAL MANUAL ALISA AXTMAN

VersaBuilt VBX-160
Operator’s User Manual
 
Operator Manual Version 1.1 VersaBuilt VBX-160 12/2015

1 Overview 1.............................................................................................................
1.1 VBX-160 Overview 1......................................................................................
1.2 Operator Manual Overview 1.........................................................................
1.3 Technical Support 1........................................................................................
2 Safety 2..................................................................................................................
2.1 Intended use of VBX-160 2............................................................................
2.2 General Safety Precautions 2........................................................................
2.3 Electrical Safety 2...........................................................................................
2.4 Operator Safety 3...........................................................................................
2.5 Robot Safety 4................................................................................................
2.6 Modiﬁcations to Equipment 4.........................................................................
3 Introduction to the VBX-160 5.............................................................................
3.1 VBX-160 Cell 5...............................................................................................
3.2 VBX-160 Rack System 6................................................................................
3.3 Rinse and Dry 9..............................................................................................
3.4 Robot 10.........................................................................................................
3.5 MultiGrip Soft Jaws 12..................................................................................
3.6 Air/Electrical Panel 13....................................................................................
3.7 VBX-160 CNC Components 16......................................................................
3.8 VBX-160 Positioning 17.................................................................................
3.9 The VBX Controller 19...................................................................................
4 Processing Parts with the VBX-160 30...............................................................
4.1 Preparing to process parts 30........................................................................
4.2 Processing parts 31........................................................................................
5 Recovery 45...........................................................................................................
5.1 Introduction 45................................................................................................
5.2 Recovery Process 49.....................................................................................
6 Preventative Maintenance 52...............................................................................
6.1 Daily Maintenance 52.....................................................................................
6.2 Weekly Maintenance 54.................................................................................

6.3 Monthly 55......................................................................................................
6.4 Annually 55.....................................................................................................
Glossary 56..............................................................................................................
Appendix 1 Status/Control Button Key 59............................................................
Appendix 2 Shelf Slot Color Key 63.......................................................................
Appendix 3 Stack Light Status Key 64..................................................................
Appendix 4 Action Panel Messages 66..................................................................

1 Overview
1.1 VBX-160 Overview
The VersaBuilt VBX-160 is a robotic machine tending system. This is a flexible system designed
to automatically load and unload parts for processing in a CNC machine. The VBX-160 consists
of a cell with a rack system, a robot that is located in the cell, a VBX Controller (VBXC) that
interfaces with the robot and CNC, and a rinse and dry system to clean parts. The VBX-160 also
utilizes MultiGrip vises and MultiGrip soft jaws (MGSJ) to hold and transfer parts.
1.2 Operator Manual Overview
This VersaBuilt VBX-160 operator manual is written for equipment operators who are running
jobs using the VBX-160 interfaced with a CNC.
This operator manual describes how to set up and run jobs using the VersaBuilt VBX-160. This
manual also describes how the operator should care for and maintain the VBX-160 equipment.
Organization of the manual:
The VersaBuilt VBX-160 operator manual is organized with the following chapters:
• Safety
• Introduction to the VBX-160
• Processing Parts with the VBX-160
• Recovery
• Preventative Maintenance
• Glossary
• Appendices
1.3 Technical Support
VersaBuilt: support@versabuilt.com (208) 269-9482
Business hours are Monday through Friday 9am to 5pm Mountain Time
When you contact technical support, a picture of the screen, the error message and/or details
such as how and when the error occurred will expedite the support process.
Operator Manual Version 1.1 1 VersaBuilt VBX-160 12/2015

2 Safety
2.1 Intended use of VBX-160
The VersaBuilt VBX-160 is intended to be used only by trained personnel in a professional
machine shop environment.
2.2 General Safety Precautions
Only authorized and trained personnel should operate this equipment. You must act in
accordance with the operator manual, safety decals and instructions for safe machine operation.
Read and understand all referenced safety manuals before operating equipment. Users must
use appropriate eye and ear protection while operating the equipment.
2.3 Electrical Safety
• The electrical power must meet the following specifications:
Voltage: 208-240VAC/3Phase, 50/60Hz
- Full load: 15 Amps
- Largest load: 10 Amps
• Attempting to run the machine from any other source can damage the equipment and void the
warranty
• The electrical supply must meet the rating of the robot as well as other devices.
• Do not reset a circuit breaker until the reason for the fault is identified and remedied

2.4 Operator Safety
General Safety Information:
• Do not operate the equipment unless the doors are closed and the safety circuit is functioning
properly
• Do not operate the VBX-160 without proper training
• Clearly understand the different control requirements for operating the equipment; these
include the safety circuit, Cycle Start, Feed Hold, DNC Sync, Part Stop and Op Stop
• Do not attempt to alter the safety circuit sensors
• Operator should locate the main power switch and be familiar with the operation of this switch
• Use appropriate eye and ear protection while operating the VBX-160. ANSI-approved impact
safety goggles and OSHA-approved ear protection are recommended
• Use extreme caution when moving the VBX-160 cell, risks to personnel may include crushing,
pinching, and severing as well as other bodily injury
• Check for damage to parts prior to operating the VBX-160. Do not operate the VBX-160 if any
of the components do not appear to be functioning correctly
• Read and understand all safety information provided in this manual
• Read and understand all relevant user manuals before operating the VBX-160, including
manuals for Robot safety and operation of the CNC and additional components
VBX-160/CNC Door Interlock Information:
The VBX-160 and the CNC machine both have safety circuits that are intended to protect
humans while allowing necessary communications to occur between the two systems for robotic
processing.
Haas CNC machines have a door interlock safety circuit that prevents the mill from operating
when the CNC door is open. When the mill is processing, there is an interlock solenoid that
energizes and pneumatically engages a piston that physically locks the CNC door to prevent it
from being inadvertently opened.
The VBX-160 has a safety circuit that connects sensors on the VBX doors and gate post where
the VBX-160 can be pivoted away from the CNC. If any of these sensors are interrupted, the
‘motors on’ light on the robot arm will go out and robot motion will be stopped.
There is a second sensor on the VBX-160 gate post that is interrupted when the VBX-160 is
pivoted away from the CNC. This second sensor communicates to the CNC controller. If the
CNC door is open and the VBX-160 cell safety circuit is open, then the CNC stops processing.
If the CNC door is closed and a part is processing, the CNC will continue to process the part if
the cell safety circuit is opened.

2.5 Robot Safety
Robot Dangers/Risks may include:
Important! All personnel who are working within the range of the robot arm must read the ABB
Robot General Safety manual and the ABB Robot Emergency Safety manuals before working in
the range of the robot. These manuals contain important safety information specific to the robot.
• Any moving manipulator is a potentially lethal machine
• Robot movements are performed with great force and may seriously injure personnel/and or
equipment located within the working range of the robot arm
• Risks to personnel may include: crushing, entanglement, pinching, and severing as well as
other bodily injury
Robot precautions:
• Orange light on robot indicates motors are on and robot can move at any time; avoid being
between the robot arm and other objects
• Robot moves can be unexpected
• Gravity may cause any parts or objects held by the robot to drop
• Opening any cell door stops robot motion
• The robot brake release located on the back side of the robot should only be pressed by
qualified service personnel or in an emergency
• When the brake release button is activated it releases or deactivates the brakes on each robot
axis, causing the robot to move freely
Warning: this can cause the robot to collapse under its own weight.
• The Robot Communication Cable allows the VBX controller to communicate with the robot
controller
Warning: the robot communication cable should never be plugged into an ethernet hub
connected to a LAN with other computers attached
2.6 Modifications to Equipment
• DO NOT modify or alter this equipment in any way
• Modifications of the equipment without authorization from VersaBuilt could lead to personal
injury and equipment damage
• Modifications of the equipment without authorization from VersaBuilt will void the equipment
warranty

3 Introduction to the VBX-160
3.1 VBX-160 Cell
The VBX-160 cell is the enclosure for the robot, the rack system, the robot controller and the IO
panel. The cell is on casters and can be rotated away from the CNC to allow the operator
access to the robot or to the interior of the CNC. The VBX Controller is mounted to the exterior
of the cell on the operator’s side. An operator door allows access to the interior of the cell. The
interior rack shelves are accessed through 2 exterior doors. The Robot Controller access panel
and the IO access panel are located toward the bottom of the cell’s exterior. A stack light,which
conveys the cell status, is located on the roof of the cell. Refer to appendix 3 for the stack light
status key.
FIGURE 3-1 VBX-160 CELL 
Rack 2 DoorRack 1 Door
VBX-160 Controller
Screen
Stack Light
Operator Door
Robot Arm
Robot Controller
Access Panel
IO Access Panel

3.2 VBX-160 Rack System 
The VBX-160 contains 2 racks with 8 shelves
on each rack. The top shelf of each rack has
3 slots that are designed to hold the MultiGrip
soft jaws. The remaining 14 shelves have
slots designed to hold parts. Each of the part
shelves is individually configurable to
accommodate particular part sizes and
shapes. A configurable shelf template is
engraved with graduated markings to show
where to place the part blanks for robot
transfer. Part locators may be used on the
shelves to allow operators to quickly locate
parts.
FIGURE 3-2 VBX-160 RACK SYSTEM 
MultiGrip soft jaw storage on top shelves
Parts stored on shelves below MultiGrip
soft jaws

A. Shelf Template
The shelf template is a sheet of material such as plastic that is engraved with graduated
markings. The markings indicate where to place the material blanks for robot picking. A shelf
template is positioned on the top of each shelf.
FIGURE 3-3 SHELF TEMPLATE
 
Shelf template detail showing
graduated markings

B. Part Locator
A physical part locator is an optional and completely customized feature that allows the operator
to easily locate parts. While it allows for quicker part location, it is less flexible than the shelf
template and does take time to change out when necessary. A part locator can be placed on
each rack shelf.
FIGURE 3-4 PART LOCATORS 
3 PART LOCATOR
STACKED 4 PART LOCATOR

3.3 Rinse and Dry
Rinse and Dry is the process used by the robot to rinse coolant and chips off of a finished part
and then dry the clean part. The Rinse and Dry tank and air knife are located in the VBX-160
cell. A pump and filter are located in the tank. Note: The operator must insure that the rinse tank
contains adequate rinse solution to properly clean parts. For wet machining, the recommended
solution is 4 - 6 inches of water. (Optionally, one ounce of Dawn dish detergent and/or a rust
inhibitor may be used in the tank.)
Warning: Never allow the water to fall below the top of the pump. Inadequate water level may
damage the pump.
FIGURE 3-5 RINSE AND DRY SET UP
 
Air Knife
Water Valve Lever
Rinse Nozzles

3.4 Robot
An IRB 140 6 Axis Industrial Robot is installed in the VBX-160 cell. The robot uses a
MultiGripper to hold MultiGrip soft jaws. The robot uses the MultiGrip soft jaws to pick parts off
of a shelf and place them in the MultiGrip vise within the CNC. After a part is machined, the
robot removes the completed part and returns it to the shelf. The robot has a “motor’s on” light
which indicates that the robot can move at any time. A brake release is located at the base. A
drip tray is located between the robot and the CNC door to catch dripping coolant and chips.
Warning: The brake release should only be pressed by qualified service personnel. Review 2.6
Robot Safety for more information about the brake release.
FIGURE 3-6 ROBOT
 
FIGURE
Brake Release
Motor’s on Light

FIGURE 3-7 ROBOT MULTIGRIPPER 
MultiGrip Soft Jaws in the MultiGripper
MultiGripper Plungers

3.5 MultiGrip Soft Jaws  
MultiGrip soft jaws (MGSJ) are field
machinable jaws for holding a part. They are
both the robot end effector and the part’s
work holding in the MultiGrip vise. They have
an interface for the robot MultiGripper and for
the MultiGrip intermediate jaws in the
MultiGrip vise. This allows for repeatable
transfer of the MGSJ and the part into the
CNC vises. MGSJ come in three versions,
one for outer diameter (OD) clamping, one
for inner diameter (ID) clamping and a pallet
version. 
Part - The material to be processed by the
CNC. The VBX-160 supports virtually any
shape and material type.
MultiGrip soft jaws - The robot end effector
and the work-holding in the MultiGrip vise.
They have an interface for the robot gripper
and for the intermediate jaws in the MultiGrip
vise. This allows for repeatable transfer of
the MGSJ and part into the CNC vises.
Offered in versions for clamping outer
diameters (OD) or inner diameters (ID).
MultiGrip Intermediate Jaws - Consist of a
set of serrations and dovetails that clamp the
jaws and part into the vise.
MultiGrip Vise - Engages MGSJ and part for
processing. The VBX controller is configured
for OD or ID clamping for both the vises and
the robot gripper. 
FIGURE 3-8 MULTIGRIP SOFT JAWS, MULTIGRIP INTERMEDIATE JAWS AND MULTIGRIP VISE
 
Part
MultiGrip Vise
MultiGrip Intermediate Jaws
MultiGrip Soft Jaws

3.6 Air/Electrical Panel
The air/electrical panel is mounted on a post near the cell. The panel controls the air and power
supply to the VBX-160 system. The main power switch for the VBX-160 is located on the
outside of the panel. The panel also has air pressure gauges for the CNC door opener/closer,
vise 1 and vise 2.
FIGURE 3-9 EXTERIOR OF THE AIR/ELECTRICAL PANEL
 
Chuck 2 Air
Pressure
Chuck 1 Air
Pressure
Power Switch
Air/Electrical Panel Gauges
Air/Electrical Supply Lines

FIGURE 3-9 EXTERIOR OF THE AIR/ELECTRICAL PANEL CONTINUED
 
Input Lines and Switches
Input Power 1
110 VAC
Air Shut-off
Input Power 2
220 VAC

FIGURE 3-10 INTERIOR OF THE AIR/ELECTRICAL PANEL
 
Terminal Blocks DeviceNet IO
System
VBX-160
Main
Power
Switch
Air
System
Filter
Circuit
Breakers
Air System
Lubricators
Vise Solenoid
Valves
Analog
Regulators

3.7 VBX-160 CNC Components
The VBX-160 components that operate as part of the CNC include:
• MultiGrip vise: A vise with MultiGrip intermediate jaws for clamping MultiGrip soft jaws
• G-Code macros in CNC controller provided by VersaBuilt as well as customer provided
FIGURE 3-11 MULTIGRIP VISE
 

3.8 VBX-160 Positioning
The VBX-160 cell can be pivoted away from the CNC to allow operator access to either the
robot or the CNC. If possible, wait for the robot to finish picking or placing parts. Unlock the gate
pin and roll the cell away from the CNC. To resume processing, roll the cell back into position in
front of the CNC and lock the gate post with the pin.
The cell can also be moved completely away from the CNC:
• Power down the VBX Controller
• Turn off the power for air
• Disconnect the control cables
• Remove the pivot pin in addition to the gate pin.
• The cell can be rolled to another location or moved with a fork lift using the fork lift tunnels.
Note: When the cell is pivoted away from the CNC a safety circuit will be opened. The robot will
not be able to move, but the CNC can continue processing as long as the CNC door remains
closed. Refer to Chapter 2 section 2.4 to review information regarding the safety circuit.
Warning! Use extreme caution when moving the VBX-160 cell; risks to personnel may include
crushing, pinching, and severing as well as other bodily injury. Review the safety information in
Chapter 2 prior to moving the VBX-160 cell.
FIGURE 3-12 VBX-160 PIVOTED AWAY FROM CNC
VBX-160 Cell CNC
Gate PostPivot Post

FIGURE 3-13 LOCKED CELL   VIEW OF DETAIL FROM CNC SIDE
 
POST DETAIL
Pivot
Post
VBX-160 Cell
Pin
PIVOT POST
Pin
Sensor
Gate Post
Gate Post
VBX-160 Cell
CNC
VBX-160 Operator Side
Gate Post
Pivot PostGate Post
Fork Lift Tunnels

3.9 The VBX Controller
The VBX Controller (VBXC) is the operator interface for controlling the VBX-160 system and the
CNC via DNC sync. The VBXC operates with two primary screens: the Operation Screen and
the Configuration Screen. The operator works primarily with the Operation Screen to enter and
run jobs. The Operation Screen consists of various panels which are described in detail below.
The Configuration Screen is typically used by a machinist to configure the VBX-160. The
Configuration Screen is described in the Machinist User Manual.
Tool Tips: Hover the mouse pointer over the various symbols and sections of the screen, and a
pop-up tip appears and describes the element.
FIGURE 3-14 VBX CONTROLLER
VBX-160 Controller Screen
VBX-160 Controller Keyboard and
Mouse

A. Operation Screen Overview
The primary screen used by the operator is the Operation Screen. Using this screen, the
operator manages jobs and controls processing with the VBX-160. The Operation Screen is
accessed via the screen selection menu. The Screen contains 4 panels: Status/Control, Actions,
Active Jobs, and Racks. Each panel is described in detail below.
FIGURE 3-15 JOBS SCREEN
Tool Tips- hover the mouse pointer over
the various symbols and sections of the
screen and a pop-up tip appears.
Screen Selection
Menu
Status/ControlPanel
Active Jobs List Actions Panel
Rack Status Panel

B. Operation Screen Panels
1. Status/Control Panel
The Status/Control Panel appears at the top of all VBX-160 controller screens. The buttons that
appear may change based on the current state of processing. The figures below show the
Status/Control panel buttons in various states of processing.
Note: Refer to Appendix 1 for a complete description of the Status/Control Panel buttons
FIGURE 3-16 STATUS CONTROL PANEL SHOWING VBX-160 “READY TO PROCESS JOB”
FIGURE 3-17 STATUS CONTROL PANEL SHOWING “PARTS PROCESSING” STATE
Start Processing
Parts
Op Stop DisabledDNC
Connected
Safety Circuit Closed
Parts are Processing Robot Speed Vise Pressure
Indicates
Processing

FIGURE 3-18 STATUS CONTROL PANEL DURING RECOVERY WITH ACTIONS REQUIRED
FIGURE 3-19 OP STOP STATUS
Clicking on the Op Stop button accesses the options below:
Op Stop disabled
Op Stop enabled
VBXC will feed hold when milling op has
finished processing
Part Stop enabled
VBXC will feed hold when part has finished
processing
Parts Processing
Interrupted,
Complete Red Tasks
Reset the
Robot
Control Robot
and CNC

2. Racks Panel
The Racks Panel provides a view of the VBX-160 racks. The Racks Panel shows the racks from
two views. The In view shows the perspective of looking through the operator door. The Out
view shows the perspective of looking through a rack door. The Racks Panel has a Templates
button. Clicking on the Templates button will bring up a display that is used to select the
template for each shelf.
FIGURE 3-20 RACKS PANEL AND TEMPLATE SELECTION PANEL
View
Selection

The VBX Controller uses symbols and colors to show the status of each slot in the Racks Panel,
including the current location of MultiGrip soft jaws and parts:
MultiGrip soft jaw slots: represented by
rectangles on shelves 1 and 9
• MultiGrip soft jaws in vise: mauve
• MultiGrip soft jaws on shelf: violet
• MultiGrip soft jaws in gripper: purple
• MultiGrip soft jaw slot is empty: white
• MultiGrip soft jaw transferring: blue
• MultiGrip soft jaw error: red
• MultiGrip soft jaw cancelled: yellow 
Part slots: represented by circles or
rectangles on shelves 2-8 and 10-16
• Part waiting in slot: violet
• Part is milling: represented by pink
• Part on shelf ready to unload: green
• Part slot is empty: white
• Part held by robot: purple
• Shelf transfer: blue
• Part error: red
• Part cancelled: yellow 
Note: Refer to Appendix 2 for a complete shelf slot color key.
FIGURE 3-22 RACK DISPLAY
OF PART SLOTS
FIGURE 3-21 RACK DISPLAY OF MULTIGRIP
SOFT JAW SLOTS
Tool Tips- hover the mouse pointer over
the various symbols and sections of the
screen and a pop-up tip appears.

3. Actions Panel
The Actions Panel displays a list of actions for the operator to perform in order to keep the
VBX-160 processing. Actions appear as tasks, and the tasks are color coded to indicate their
urgency. Refer to Appendix 4 for an explanation of action tasks/messages that may appear in
the VBX-160 Actions Panel.
• A task highlighted in red in the Actions Panel stops production until the red task is completed
• A task with a white background in the Actions Panel needs to be done, but it is not urgent. A
white task will not stop the processing
• A task highlighted in yellow is not urgent and will not immediately stop the processing, but it
could cause processing to stop if it is not addressed soon
• When the operator completes a task, selecting the Done button next to the task will remove it
from the list
• If a task references shelf slots, clicking on the Highlight button will put a blue highlight in the
Racks Panel around the slots or symbols that are associated with that particular task
• Change the size of text by clicking on the AA button
FIGURE 3-23 ACTIONS PANEL
FIGURE 3-24 ACTIONS TASKS WITH WHITE BACKGROUND
FIGURE 3-25 ACTIONS TASK WITH RED BACKGROUND
Size Text

4. Active Jobs Panel
The VBX Controller lists and manages jobs
in the Active Jobs Panel The operator
enters new jobs, cancels jobs and reviews
current jobs in the Active Jobs Panel. Jobs
are processed in the order that they are
entered in the VBXC
The following information is entered or
displayed in the Active Jobs Panel:
• Order: an identifier for the job
• Part: identifies the part number for the part
that is being processed
• Processing: identifies the number of parts
that are currently in the cell for a specific
job
• Remaining: identifies the number of parts
that are waiting to be loaded for a specific
job 
Add JobCancel Job
FIGURE 3-26 ACTIVE JOBS PANEL

5. Recovery Panel
The operator can manually initiate the recovery mode from the feed hold state by clicking on
Recovery in the Control Panel or by cancelling a job that is currently processing This is
typically done if the operator detects a problem and needs to cancel the current processing.
Recovery can also be initiated by the VBX Controller when a problem is detected. Once the
system is in a recovery mode, a series of actions must be completed in order to exit recovery
mode and resume processing. During Recovery, a Recovery Panel with control buttons is
displayed in the top right section of the Operation Screen. The recovery tasks appear in the
Actions Panel. Recovery buttons that appear as grey are unavailable in the system’s current
state. Gripper is the only control available to use in the feed hold state. The other controls
become functional during various states of recovery.
FIGURE 3-27 RECOVERY PANEL
Tool Tips - Hover the mouse pointer over the various symbols and sections of the screen and a
tool tip will appear.
FIGURE 3-28 TOOL TIPS

FIGURE 3-29 RECOVERY PANEL CONTROLS
 
Home- Moves robot to its home position
Arm- Control buttons to move the robot
gripper along the cells x,y and z axes
Wrist- Controls for wrist rotation and angle
Float- Relieves pressure when the arm
crashes into something and is pressing
against it in a way that makes it difficult to
move with the Arm or Wrist buttons.
Movement- Adjusts the movement speed
Gripper- Controls for open, close, float and
release
Wash- Controls to wash and/or dry part
Door- Control buttons to open and close CNC
door
Vise - Control button to open and close vise,
float or eject part from vise
FloatHome

FIGURE 3-30 RECOVERY PANEL CONTROLS CONTINUED
Movement: Control for
distance of robot arm
and wrist movement
Green dots may appear in the Recovery
Panel. The dots help the operator
determine the current status of various
system components. A green dot next to
the Home button in the arm control
indicates that the robot is in the “home”
position. A green dot in the gripper, door,
wash or vise controls indicates current
status.

4 Processing Parts with the VBX-160
4.1 Preparing to process parts
Important! Review chapter 2 for safety precautions prior to working with the machinery.
The following steps should be taken prior to processing parts with the VBX-160:
• Review chapter 2 for safety instructions
• Verify that the rinse tank (if being used for this process) is filled properly with clean solution
and is free of chips
• Verify that the MultiGrip vise, the MultiGrip soft jaws and the MultiGrippers are free of chips
and do not show signs of wear
• MultiGrip vise is installed in the CNC
• CNC door pathway is free of chip build up
• CNC spindle, walls and ceiling are free from drip build up
• Chip output banding systems are enabled and have sufficient capacity to handle the parts to
be processed
• Sufficient CNC consumables such as coolant to process parts
• Verify that the CNC has adequate tool life that is needed to process jobs
• VBX-160 cell is in the locked position (refer to figure 3-13)
• Verify that the required job programs are loaded into the CNC
• Power on to cell
• Turn air on to cell
• Be prepared with specific job information, including:
order ID
part #
part quantity

4.2 Processing parts
A. Power
Power up:
Verify that power is on for the following:
• VBX Controller (VBXC)
• Illuminated power button is on the
central processing unit, (CPU)
• Main power on Air/electrical Panel
• CNC
Power down:
The VBX-160 should be powered down
before it is unplugged or before the power
supply is shut off. Failure to power down
could corrupt the VBXC data.
If the VBX-160 is currently processing parts
and needs to be powered down:
1. Enter recovery mode
2. Complete DNC sync
3. Move robot home
4. Clear vise and MultiGrip soft jaws
5. Complete recovery tasks (refer to
chapter 5 Recovery)
6. press the illuminated power button on
the VBXC CPU
If the VBX-160 is not processing parts and
needs to be powered down, then press the
power button on the VBXC CPU.
B. Complete DNC Sync
When using a Haas CNC:
1. Press the MDI button on the CNC until
the CNC main screen shows 'Waiting For
DNC".
2. Click on the DNC Sync button on the
VBXC.
3. The VBXC asks you to verify that the
correct CNC machining programs are in
the CNC controller. (make sure they are
loaded)
4. Click the Done button on the VBXC.
5. The VBXC asks you to "Start Cycle The
CNC".
6. Press the green Cycle Start button on
the CNC Controller.
7. The CNC screen shows that it's
connected to DNC.
8. The green plug symbol appears in the
Status/Control Panel indicating that the
VBXC and CNC are synced.  
CPU

C. Create a Job in the VBX Controller
step 1 In the Status Control Panel click on the Screen Selection Menu button and select
Operation.
Note: Typically the VBX controller will “rest” with the Operation Screen displayed, and this step
will not be necessary.
FIGURE 4-1 SCREEN SELECTION MENU BUTTON
step 2 In the Active Jobs Panel, click on the + symbol to create a job.
FIGURE 4-2 CREATE A JOB BUTTON
Create a Job

step 3 Click on Part and select a part from
the drop down menu.
step 4 Click on Order and enter an order ID.
step 5 Click on Quantity and enter the # of
parts required for this order.
step 6 When all of the required information
is entered in the appropriate fields, click on
Save to complete and save the job entry.
After the job is saved, the VBXC returns to
the Active Jobs Panel, and the newly created
job appears in the Active Jobs list. 
Click here to save job information in the VBXC

D. Shelf Template Selection
If you see this message after you add a job, then you need to select one or more shelf
templates that are configured for the part.
step 1 Verify that the required template(s) is on the shelf.
step 2 Click on the Templates button in the top right corner of the racks panel. The Shelf
Template Selection tool appears. 

step 3 Using the Shelf Template Selection tool, locate the shelf or shelves that you would like to
use for this part, and then locate the required template. Click on the dot that corresponds with
the shelf and the template.
Note: You cannot change a template that is being used for a job that is currently processing.
The shelves for MGSJ cannot be altered or used for part templates.
step 4 Once you have selected a template, the OK button is available. Click on OK when you
have finished selecting templates.
Note: If you add a job and the VBXC has assigned parts to a template, you should not change
that template to one that does not work for those parts. If you change a template that is
assigned to a job, then the VBXC gives you an actions task of selecting a template for that job
again. You can not change the template for a job that is currently processing parts. 

E. Loading MultiGrip soft jaws and parts to run a job
When the VBX Controller (VBXC) determines that there is capacity to run a job, it lists actions or
tasks for the operator to complete. The VBXC first lists actions relevant to loading the correct
MultiGrip soft jaws (MGSJ) for the job, and then when those actions are completed, it lists
actions to load parts for the job.
Actions Related to Loading MultiGrip Soft Jaws (MGSJ)
• Each action related to a MGSJ specifies a MGSJ part number and the designated shelf
location
• The VBXC allows MGSJ to be shared among jobs
• Load each set of MGSJ into the assigned location following steps 1 through 4 
step 1 Review the shelf slots designated for
the MGSJ by clicking Highlight. The VBXC
highlights the designated slot locations with
a blue outline. The task specifies which
MGSJ should be loaded in each slot by
using a part # to ID the MGSJ.
step 2 Open the rack doors to access the
shelves. 
Click here to
highlight locations

step 3 Place the MultiGrip soft jaws in the
assigned location.
Note: Place the MultiGrip soft jaws with the
serrated side on the shelf and with the robot
gripper interface facing into the cell so that
the robot can pick up the MultiGrip soft jaws
with the gripper.
step 4 Click the Done button next to the
completed action after each item in the
actions list is completed. The VBXC removes
the task from the Actions list. New tasks are
displayed if they are required.
Note:
A green rectangle is displayed in the Racks
Panel to indicate the location of the MGSJ
on the shelf. 
FIGURE 4-3 PROPER ORIENTATION OF
MULTIGRIP SOFT JAWS ON SHELF
MultiGrip Soft Jaws
Shelf
Gripper

Actions Related to Loading a Part
Each action that is related to loading a part
tells the operator:
• The number of parts to load
• The relevant part ID
• The relevant order ID
Load each part following steps 1-4 below:
step1 Review the assigned shelf location for
each part. Click on Highlight in the Actions
Panel to highlight the locations in the Racks
Panel.
step 2 Place parts in the assigned slots
using either the shelf template (shown) or a
part locator to correctly align the center and
side of each part. Be sure to properly orient
rectangular part material. The jaws are
designed to pick rectangular material from a
specific orientation on the shelf.
Note: The operator should verify that the
material does not exceed height limits. 
 
Designated part locations
are highlighted
Click here to highlight
locations

step 3 Close and latch both rack 1 and rack
2 doors.
step 4 Return to the VBXC, and click on
Done for this task. The VBXC removes the
completed task from the task list. New tasks
are displayed if they are needed
Note: A violet circle displayed in the rack
panel indicates that the part is loaded on the
shelf and waiting for processing 
F. Cycle Start
In the Status Control Panel, click on the Cycle Start button. The robot begins processing.
Check the Actions Panel for any additional actions/tasks.
Note: A task that has a red background stops the processing.
FIGURE 4-4 CYCLE START BUTTON

G. Monitoring Part Processing
During part processing, the rack display uses various colors to indicate the current status of
each slot in the racks. As the part or MGSJ move through the process, the slot color changes.
Checking the racks display on occasion endures the maximum efficiency of the VBX-160
system. Refer to Appendix 2 for a complete shelf slot color key.
FIGURE 4-5 PART PROCESSING SLOT COLORS
Purple circle
indicates the part is
held by the robot
Bright pink circle
indicates part is in
vise and/or milling
Green circle
indicates the part
has finished
processing and is
ready to unload
Blue circle indicates the
part is in transfer

H. Unloading parts or MultiGrip soft jaws from the VBX-160 cell
When an Actions Panel message indicates that parts or MGSJ are ready to unload, follow steps
1-6 below.
step 1 Review the slot locations of the parts or MultiGrip soft jaws that need to be unloaded.
Note: When the Actions Panel displays a task telling the operator to unload parts or MultiGrip
soft jaws, the slots for those items are green, and they are outlined with a blue highlight when
the Highlight button is clicked with the mouse.
FIGURE 4-6 ACTIONS SCREEN SHOWING A TASK TO UNLOAD PARTS
FIGURE 4-7 RACKS PANEL SHOWING
LOCATION OF PARTS TO UNLOAD.
FIGURE 4-8 RACKS PANEL SHOWING
LOCATION OF MGSJ TO UNLOAD
Task tells operator to
unload parts
Locations of parts ready to
unload shown with highlighted
green circles
Locations of MGSJ ready to
unload shown with highlighted
green squares

step 2 Open the rack door that corresponds
with the location of the completed parts or
MGSJ.
Note: If the robot is currently processing
parts, it safety stops when the door is
opened.
step 3 Remove the parts and/or MGSJ from
the shelf as indicated in the Actions list.
step 4 Close and latch the shelf door.
step 5 Locate the completed task in the
Actions Panel and click on Done. The
VBXC removes the completed task from the
list.
step 6 If the job requires additional parts,
the VBXC prompts the operator with a new
task in the Actions Panel.
Note: Refer to Appendix 4 for an explanation
of all action tasks/messages that may appear
in the Actions Panel. 
I. Multiple Jobs
Multiple jobs can be entered and saved in the VBXC. The VBXC works from the top of the job
list down to fill slots.It begins a new job and prompts the operator to place parts or MGSJ on the
shelf when slots are available for processing. The system is designed so that the operator can
load and/or unload parts when they are available. There is no need to wait for an entire job to be
completed before clearing the finished parts related to that job. The VBXC alerts the operator if
a different template is needed for a job.
FIGURE 4-9 MULTIPLE JOBS LISTED IN THE ACTIVE JOBS PANEL
 

J. Cancelling a Job
An existing job is cancelled by using the Edit Job List button in the Active Jobs Panel. You can
cancel a job anytime after it has been saved. The elements of a saved job can not be edited. If
the elements need to be changed, then cancel the job and re-enter it with the desired changes.
Follow steps 1-4 below to edit the job list.
Note: When a job is cancelled while a part is held by the robot and/or a part is in a vise, the
VBXC enters Recovery mode. This enables the system to be restored to a normal state and the
job re-entered if desired. If there is no part currently held and/or in a vise, then the job is simply
cancelled and normal processing continues for other active jobs in the VBXC. To stop a part
from processing, click on the Op Stop button to access the Part Stop button. Click on the Part
Stop button to stop the part from processing. Click on it again to resume processing. The button
then becomes the Op Stop button again.
step 1 Click on the Edit Job List button in the top right corner of the Active Jobs Panel. The
VBXC displays a list of all active jobs.
step 2 Find the job that you need to cancel. Review the job information to validate that it is the
correct job to cancel. If the information matches, then click on the Cancel button next to the job.
To exit the edit mode without canceling a job, click on the Done button in the top right corner of
the Active Jobs Panel.

step 3 Refer to the Actions Panel for tasks associated with canceling a job. Tasks may include
unloading parts or unloading jaws. The slots of cancelled parts are yellow in the rack panel.
Additional tasks may be Recovery related and involve actions such as removing items from the
gripper and/or vise and moving the robot arm to Home. Refer to “Chapter 5 Recovery” for
information related to these types of tasks if the VBXC enters recovery mode after a job is
canceled.
FIGURE 4-10 TASKS ASSOCIATED WITH CANCELING A JOB
FIGURE 4-11 RACKS PANEL SHOWING LOCATION OF CANCELED PARTS

5 Recovery
5.1 Introduction
Important! Review chapter 2 for safety precautions prior to working with the machinery.
A.Initiating Recovery
Recovery occurs when the robot stops processing in response to an error or the operator
initiates recovery by either clicking on the Recovery button or cancelling a job that is currently
processing. The Recovery button is visible on the Status/Control Panel when the system is in a
feed hold state. If the operator is initiating recovery, they must first click on the Feed Hold button
to access the Recovery button. Once recovery is initiated, the actions for recovery are displayed
in the Actions Panel. All recovery related actions must be completed before processing can
begin again. Initiating the recovery state clears the current processing state of the VBX
Controller. This cancels all parts and MultiGrip soft jaws that are held by the robot or in the
vises. Communication with the robot and CNC is reset.
FIGURE 5-1 FEED HOLD BUTTON AND RECOVERY BUTTON
FIGURE 5-2 INITIATING RECOVERY MESSAGE

FIGURE 5-3 RECOVERY ACTION MESSAGES
Note: For a complete list of action messages, please see Appendix 4

B. The Recovery Panel
When recovery is initiated, a Recovery Panel appears in the Operation Screen.
FIGURE 5-4 RECOVERY PANEL
Note: For a complete description of the Recovery Panel buttons, please refer to Chapter 3,
section 3.9-B5.
Control For Movement
and Speed
Robot Home
Button
Robot Arm
Controls
Robot Wrist
Controls
Gripper
Controls
Door
Controls
Wash
Controls
Vise
Controls

C. Using the Status/Control Panel Buttons During Recovery
When recovery is initiated the icons on the Status/Control Panel change. Control buttons that
are used to reset the robot and enable robot and CNC commands become available. Clicking
the Enable button enables the robot to move. When the robot is enabled, the Pause button
appears. Pause is used to pause the CNC and robot commands. The status icons indicate that
processing has been interrupted, DNC is disconnected and part stop is enabled.
FIGURE 5-5 STATUS /CONTROL PANEL AFTER RECOVERY INITIATED
Note: For a complete description of the Status/Control Panel buttons, please see Appendix 1
DNC Disconnected
Part Processing
Interrupted
Part Stop Enabled

5.2 Recovery Process
A. If the operator is initiating recovery:
step 1 Click on the Feed Hold button to stop
processing
Step 2 Click on the Recovery button,
Step 3 The VBXC confirms that you wish to
continue to recovery. Click OK.
Note: All parts that are currently processing
are cancelled when the system goes into the
recovery mode. After the recovery mode is
initiated by either the operator or the VBXC,
the operator must complete steps 4-10 to
complete and exit recovery so that
processing can resume.
B. For all recovery situations:
Complete the tasks in the Actions Panel. The
Actions Panel lists out the 4 primary steps to
complete and the tasks that are associated
with each step are listed in order below the
first pane.
Step 1: Enable the cell by clicking on the
Enable button. This allows robot and CNC
commands. Now the operator can control the
robot movements as well as the CNC door.
Note: Use the Pause button if there is a
need to pause robot and CNC commands.
The operator can toggle between Enable and
Pause as needed while in recovery mode.
Only the gripper open/close buttons are
operable when the system is paused. The
Recovery Panel buttons appear grey when
they are not currently operable.

Step 2: Return the robot to the home
position. This is done with the buttons on the
Recovery Panel. Clicking on the home button
returns the robot to home unless the robot
has been in a collision or in the event that the
MultiGrip soft jaws are entangled with a shelf
or vise. These types of situations are referred
to as movement errors.
Note: In the case of a movement error:
• Use the arm jog buttons when the arm or
something that the arm is holding is in
contact with an obstacle. Once the arm is
no longer in contact, then the home button
can be used.
• The movement slider controls how much
the arm and wrist jog buttons move the
robot. Use the smallest movement
increment when moving the arm out of a
collision state. Additional motion errors or
collisions may occur during this process.
This is normal; proceed slowly and move
the arm away from the point of contact
using the arm and wrist jog buttons.
• Use the gripper buttons to release the
MGSJ if necessary. Do not drop the MGSJ
on the floor or onto other objects or people
when releasing them from the gripper. It
may be helpful to have a second person
available to catch the MGSJ when they are
released from the gripper.
Step 3: Complete a DNC sync. Refer to
chapter 4, section 4.2B to review the steps
for DNC sync. Once the CNC controller is in
DNC mode, click the done button next to the
task on the VBXC. If the sync is successful,
then the prompt disappears from the screen,
if the prompt remains, retry the steps.
Step 4: Address and clear the listed errors.
Put away anything held in the gripper and/or
vise. There are two ways to do this:
• Manually with the controls,(open, close,
float)
• Using the eject button. The eject button will
have a green dot by it if it is available for
use. When the eject button is used, the
robot puts the MGSJ and/or parts back on
the shelf.
Eject Buttons

• Continue clearing any errors that are listed
in the Actions Panel.
Step 8: Verify that all of the recovery actions
are completed,and click on Done. The VBXC
exits recovery mode and is ready to resume
normal processing. The VBXC exits recovery
mode in a feed hold state.
Step 9: Click on Cycle Start to exit the feed
hold state and begin processing parts.
Note: For a complete description of recovery
messages/signals, refer to Appendix 4. 

6 Preventative Maintenance
6.1 Daily Maintenance
Important! Review chapter 2 for safety precautions prior to any maintenance activities.
Complete the following tasks at least daily, or more often if indicated:
A. Rinse and Dry system
• Inspect the rinse and dry nozzles looking for proper adjustment to keep solution contained in
the tank
• Empty and refill rinse solution daily or more often if needed
• Inspect the tank filters and remove debris or replace if needed
• Fill rinse tank with enough water to cover the pump. (Optionally, a solution of Dawn dish
detergent or rust inhibitor and water may be used.)
• Do not use solvents in the rinse solution
• Rinse tank replacement pump filters:
Manufacturer: McMaster-Carr
Manufacturer Part #: 2514K28
Description: 600 or 800 microns, High Capacity Tie-on Mesh Filter Bag, polyester, 11”
diameter, 24” high
VersaBuilt Part #: 5001210
B. Inspect MultiGrippers, intermediate jaws and MultiGrip soft jaws
• Look for signs of wear
• They should be free of chips or other debris
• If dry machining, then lubricate the MGSJ cross pin with silicone spray (fig. 6-1)
C. Inspect the VBX-160 Cell
• Clean off chips, coolant and any debris
D. Inspect robot
• Inspect robot cabling, look for wear/damage
• Clean chips, coolant and debris from the robot
E. Inspect Vises
• Clean out chips and other debris
FIGURE 6-1: MGSJ CROSS PIN

F. Chip Management
Chip management is extremely important. Monitor chip accumulation and remove as needed.
Keep these tips in mind for chip management:
• Clear chips from MGJ, intermediate jaw and part. Chips between the MGJ and the
Intermediate Jaw or between the part and the MGJ can have a detrimental effect on
processing efficiency.
• Empty the chip output system before starting extended processing.
• Chips fall onto the vise when they dry out. Blow chips off surfaces on and above the vise.
• 5th axis vise sensors are sensitive to chips. Vise wash should rotate vise and blast out chips.
Blow accumulations of chips away from vise.
• Periodically blow out door tracks. Chips can accumulate in door tracks preventing the door
from moving and stopping production.
• Wash bucket is critical to chip management between part and MGJ and between MGJ and
intermediate jaws.
• Vise wash is critical to managing chips between MGJ and intermediate jaws that will cause
concentricity and flatness errors.

6.2 Weekly Maintenance
Complete the following tasks at least weekly, or more often if indicated:
A.Robot Controller Air Filter Maintenance
The Robot Controller air filter is located on the outside of the cell below the operator door.
Inspect the filter for dirt and debris. If the filter is dirty, then remove and replace.
Manufacturer: McMaster-Carr
Manufacturer Part #: 2209K611
Description: Pleated Panel Air Filter, Merv 8, 10 x 10. Trade size, 1” thick, pack of 2
VersaBuilt Part #: 5001257
FIGURE 6-2 ROBOT CONTROLLER AIR FILTER
B. Air/Electrical Panel
• Inspect air filter and fill lubricators on air/electrical panel
Filter

6.3 Monthly
Lubricate vises
• Use a grease gun with a needle grease tip
• Grease 2 points on the right side of vise, 1 point on the back and one point in front
• Pump the grease on 1-2 times then open and close the vise and repeat 1-2 times for each
point
• If a grease point overflows, then it is full
6.4 Annually
• Inspect robot damper axes 2,3 and 5
• Inspect robot timing belts
• Oil change: gear box axes 5 and 6
• See ABB documentation for additional information on IRB-140 Annual maintenance
B. Intermediate jaws
• Lubricate intermediate jaws, by applying … to surface.
• Clean out chips and other debris
C. Air/Electrical Panel
• Inspect air filter and fill lubricators on air/electrical panel

Glossary
Action List: A list of actions for the operator to perform to keep the VBX-160 processing.
Active Job List: A list of jobs that are currently active in the VBX-160 system.
Air/Electrical Panel: Supplies air and power to the VBX and the door vise control circuit.
Air Knife: blows air on the finished part to clean and dry.
Brake Release: A button on the back side of the robot. When this button is activated it releases
or deactivates the brakes on each robot axis, causing the robot to move freely. Note: this can
cause the robot to collapse under its own weight. This button should only be pressed by
qualified service personnel.
CNC Pneumatic Door Control: Opens and closes CNC door to allow robot access.
Configuration Screen: This is where the system and parts are configured. Accessed via the
screen selection menu.
Cycle Start Button: This button is visible when the system is in a feed hold state. It is used to
start or continue processing.
DNC Cable: A cable that connects the VBX controller to the CNC for communication.
DNC Sync Button: This button is used to tell the VBX-160 controller that the DNC connection
to the CNC has been interrupted. For example: when the CNC is reset. Using this button will
activate the DNC synchronization process.
Door Open/Close Sensors: Allow the VBX-160 to determine if the door is in the open or close
position.
Drip Tray: A tray that is located in front of the robot to catch dripping coolant.
Feed Hold Button: This button is visible when the system is processing. It is used to pause
processing.
Gate Post: The post that locks the cell in position for processing.
Grease Zerk: Fitting for adding grease to the MultiGrip vise.
Gripper: The part of the robot that engages the MultiGrip soft jaws or pallets.
Gripper Float Button: When this button is activated, if the robot is holding MultiGrip soft jaws, it
will drop them.
Gripper Interface: The side of the MultiGrip soft jaws with MultiGrip pins.
Gripper Sensors: Sensors on the gripper that help the robot identify if MultiGrip soft jaws are
attached and if a part is being held.

Intermediate Jaws: Intermediate jaws are bolted to the vise and interface with MultiGrip soft
jaws or pallets.
IO Access Panel: Located on the CNC side of the VBX-160 cell, provides access to robot IO
wiring panel for service.
Job: The processing of one or more preconfigured parts in the VBX-160.
Jobs Screen: The main screen on VBX-160 controller, allows operator to manage jobs and
control the VBX-160. Accessed via the screen selection menu.
Machinable Face: The top portion of the MultiGrip soft jaws or pallet that will be machined to
hold a part.
Manual Vise Valve: A handle valve that allows the vise to be opened or closed manually. Note:
handle must be returned to center position to allow the robot to control the vise.
Motor’s On Light: A light on the upper robot arm. When this light is illuminated the robot motor
is on, and the robot can move at any time.
MultiGrip soft jaws: Machinable jaws for holding a part. MultiGrip soft jaws come in two
versions, one for outer diameter (OD) clamping and one for inner diameter (ID) clamping.
MultiGrip Vise: A vise with MultiGrip intermediate jaws for clamping MultiGrip soft jaws or
pallets.
Operator: A person trained to load, operate and maintain CNC machines and VBX-160s
Pallet: A one piece version of the MultiGrip soft jaw used for fixturing multiple parts or parts that
cannot be reliably picked from the shelf. Requires the operator to secure the part to the pallet.
Part Family: A group of similar parts that can be processed with the same MultiGrip soft jaws or
pallets and tooling.
Part: Generally referring to material to be processed.
Part Locator: A sheet with cutouts to easily locate a specific part size and shape accurately on
the shelf.
Pivot Pin: A pin that connects the VBX-160 cell to the pivot post.
Pivot Post: The hinge where the cell rotates from the CNC.
Pivoted: When the cell is pivoted away from the CNC to allow access to the CNC or robot.
Power Cable: A black cable that supplies power to the VBX-160 cell from the air/electrical
panel.
Pre Op: An operation to cut probing features for a second op and a dovetail interface for a first
op MultiGrip soft jaw.
Probing: Using a CNC tool to measure the location of a part in the CNC or the size or shape of
a machined feature of the part.

Recovery Button: This button is used by the operator to manually initiate recovery mode to
clear the current processing state of the controller, typically after an error has occurred.
Rack System: The racks contained in the VBX-160 cell. The cell contains two racks with 8
shelves on each rack
Recovery State: When the robot stops processing in response to an error.
Red Task: A task highlighted in red in the Actions Panel; it is urgent. The robot will stop
processing until the red task is completed
Rinse Bucket: A bucket that holds a cleaning solution and a pump for washing the finished
part.
Robot Communication Cable: A cable that allows the VBX controller to communicate with the
robot controller. Note: the robot communication cable should never be plugged into an ethernet
hub connected to a LAN with other computers attached.
Robot Controller Access Panel: A removable panel on the operator side of the cell that
provides access to the IRC5 Compact Controller.
Safety Sensor: The VBX-160 cell has 4 sensors. one on each door and one on the gate post
Safety Stop: When a door is opened or if the robot has a hard collision, the robot will enter a
safety stop state. In the safety stop state, the robot is unable to move and the motors on light
will be off. The safety stop state will need to be cleared by the operator to continue processing.
Screen Selection Menu: Located in the upper left hand corner of all screens. The menu has a
drop down list to select one of the following screens: jobs, configuration.
Shelf: there are a total of 8 shelves on each rack in the VBX-160 cell
Shelf Slot: The location on a shelf where the robot will pick a part or pallet.
Shelf Template: A black plastic sheet engraved with graduated markings to show where to
place the material blanks for robot picking. A shelf template is positioned on the top of each
shelf.
Signal Cable: A yellow cable that connects low voltage signals between VBX-160 cell and air/
electrical panel.
Vise Sensors: Used to determine if the vise is holding a part.
VBX-160 Cell: The enclosure of the robot and all of its components
VBX Controller: The operator interface for controlling the CNC.
White Task: A task highlighted in white in the Actions Panel, needs to be done, but it is not
urgent. A white task will not stop the robot.
Yellow Task: A task highlighted in yellow is not urgent and will not immediately stop the
processing, but it could cause processing to stop if it is not addressed soon.

Appendix 1 Status/Control Button Key
CONTROL BUTTONS
The Control Buttons appear in the upper right corner of the VBX Controller. The control button
display will change based on the current state of the VBXC.They are operable independent of
other activities on the screen except when modal dialogs are displayed.
DNC Sync: This button is visible when the
system in in a feed hold state. The operator
uses this button to tell the VBX Controller
(VBXC) that the DNC connection to the CNC
has been interrupted. This will initiate the
DNC synchronization process. The VBXC
controls the CNC via DNC.
Cycle Start: This button is visible when the
system is in feed hold state. It is used to start
or continue processing. Within recovery
mode, commands which cause movement of
the robot arm or CNC will be disabled
(greyed out) until Cycle Start is invoked.
Recovery mode gripper manipulation is
available while the cell is in a feed hold state.
Outside of recovery mode, Cycle Start will
start or continue part processing if there are
parts ready for processing. Cycle Start will
be disabled if the safety circuit is open.
Feed Hold: This button is visible when the
system is processing. It is used to pause
processing. When feed hold is initiated, the
VBXC will stop sending actions to the robot
and CNC. The CNC will complete its current
action before stopping.

Recovery: This button is visible when the
system is in feed hold state. The operator
uses this button to manually initiate recovery
mode to clear the current processing state of
the VBXC. It will cause parts and MultiGrip
soft jaws held by the robot or in vises to be
cancelled. It also resets communication with
the Robot and CNC. It can also be useful
while in recovery mode to reset the robot
should it become unresponsive.
Enable: This button appears in recovery
mode. Clicking on this button will enable
robot and CNC commands. When Enable is
clicked, the button will change to Pause.
Pause: This button appears in recovery
mode after the enable button has been
clicked. Clicking on pause will pause robot
and CNC commands. When Pause is
clicked, the button will change to Enable.
Reset: This button appears in recovery
mode. Clicking on this button will clear any
pending robot motions and get the robot back
to a starting state. This is useful in the rare
case when the robot becomes unresponsive.
For example: If you tell the robot to eject the
vise, but the robot is unresponsive, then you
can clear that command using the Reset
button.This button will not move the robot
arm to the home position. The robot arm is
moved in the Recovery Screen.

STATUS ICONS
The status icons icons appear at the top of the screen to the left of the control buttons. Status
icons communicate the status of the cell.
Op-Stop Disabled: op-stop is disabled. Click
icon to cycle op-stop modes.
Op-Stop Enabled: Single op enabled. The
VBXC will feed hold itself when a milling op
has finished processing. Click icon to cycle
op-stop modes.
Op-Stop-Part Stop: Part Stop enabled. The
VBXC will feed hold itself when a part
finishes processing. Click icon to cycle op-
stop modes.
Rack Light On/Off: Click on the light bulb to
turn the rack lights on or off, Black light bulb
indicates that light is turned off. White light
bulb indicates that the light is on.
Safety Circuit Closed: The cell safety circuit
is closed. This status is required to move the
robot or initiate CNC operations.
Safety Circuit Open: The cell safety circuit
is open. This is caused by cell door or pivot
sensors being opened. The cell cannot begin
processing until the safety circuit is closed.
Error Action: An error has occurred. Refer
to the Action Panel for tasks related to the
error
Robot Speed: shows current speed of the
robot.
 

DNC Connected: The VBXC is synchronized
with the CNC DNC connection.
DNC Disconnected: The VBXC is not
synchronized with the CNC DNC connection.
The VBXC detects DNC disconnect by
testing the DNC connection before sending a
command to the CNC. DNC disconnect is
also caused by invoking DNC sync. When
this is active, there will be DNC sync actions
in the action list.
Running: The system is processing parts.
This icon will be present when the VBXC is
processing parts from the rack. It remains
present in the feed hold state.
Vise Pressure: These gauges show the
current pressure for the vises. The vise
pressure can be adjusted in part
configuration. The gauges are always visible
in the Status/Control Panel.
 

Appendix 2 Shelf Slot Color Key
Note: Key includes color/slot status
Red/error
The slot had an error
Blue/transferring
The part is on the shelf
waiting for op to op
transfer.
Blue Violet/waiting
the slot has a part/
MultiGrip soft jaws on
the shelf waiting for
processing
Green/part done
The part is complete, on
the shelf waiting to be
unloaded
Purple/holding
the part/MultiGrip soft
jaws is held by the robot
Yellow/cancelled
The part is cancelled
and held by the robot
Bright Pink/milling
The part/MutliGrip soft
jaws from the slot is
currently milling
White/empty
The slot is empty
Mauve/in vise
The part is in the vise

Appendix 3 Stack Light Status Key
Action List System State Messages: These are messages that will appear in the action list
which reflect the overall state of the VBX Controller
Message Color/Image Action Buttons System State Description
Press Cycle
Start to
begin
processing
parts
Press Cycle
Start to
continue
processing
parts
Press
Enable to
begin
controlling
the robot and
CNC.
Initializing.
Please
wait...
Red None Shut Down This message can appear while the
VBX Controller software is starting
up.
The part
processing
server is
shutting
down.
Please
wait....
Red None Shut Down This message will appear while the
VBX Controller is shutting down
The part
processing
server is
shut down.
Restart to
proceed.
Red None Shut Down This message will appear while the
VBX Controller is shut down.
Connecting
to robot
controller.
Please
wait...
The cell is in
test mode.
Exit tests to
proceed.
Red Done Test This message will be displayed
when the VBX cell is in development
testing mode. It should not appear in
normal operation.

The stack light on the roof of the VBX-160 cell indicates cell status as follows:
Illuminated Green: Running
Illuminated green and blinking: Running, but in feed hold
Illuminated red and flashing: Error has occurred
Not illuminated: Idle

Appendix 4 Action Panel Messages
Action List System State Messages
Message Color/image Action Buttons System State Description
The robot
controller firmware
must be updated
to be compatible
with this
application.
Use the teach
pendant or Robot
Studio to restore
the controller
backup called
UPDATE.
Red Done Update This message
appears when the
robot controller
software version is
incompatible with
the VBX Controller
software version.
Contact Technical
Support if you see
this message.
The robot
controller firmware
is updating to be
compatible with
this application...
Red Done Update This message
appears when the
robot controller
software version is
incompatible with
the VBX Controller
software version. It
indicates that the
VBX Controller is
updating the robot
controller software.
This should only
take a few
minutes. Part
processing or
other robot actions
are not available
while this message
is present.

Verify that the
vises in the CNC
are cleared of
parts and jaws.
There was a
communication
error between the
VBXC and the
robot controller.
• Verify that the
Ethernet
connection
between the
VBXC and the
robot controller is
connected.
• Shut down the
VBXC, then turn
off the power to
the cell air/
electrical panel
for 60 seconds,
then turn it back
on.
• If the problem
persists, call
technical
support.
Red None Recovery When the VBX
Controller
experiences errors
communicating
with the robot
controller, it enters
recovery mode
with this message.
Attempting to exit
recovery mode
from this state will
retry robot
communications. If
robot
communications
are successful, this
message will be
cleared and the
normal recovery
exit process will
proceed. If robot
communications
are still
unsuccessful, this
message will
persist. Try using
the Reset button in
Recovery to clear
any pending robot
motions and get
the robot back to a
starting state.

The system is
entering recovery
mode.
Red Done Recovery The system has
encountered an
error or the user
has manually
invoked an error
and the system is
working on
entering recovery
mode. This
message may
appear briefly
while the system
enters recovery.
The following
actions must be
performed to exit
recovery mode:
• Enable the cell
• Move the robot
arm to CNC
home.
• Reconnect DNC.
• Address and
clear the listed
error actions.
White Done Recovery This message is
present while the
VBX Controller is
in recovery mode.
It tells the user
what general steps
need to be
performed in
recovery. Other
action messages
will indicate
specific actions to
be addressed.
Selecting Done
invokes a check
that the steps
listed have been
performed and a
self test. If
successful, the
VBX Controller
will exit recovery
mode. If not
successful, the
user will be
prompted by pop-
up dialog of the
actions to be
performed.

Initiate DNC mode
on the CNC control
panel.
Red Retry Recovery,
Running, Idle
Message
requesting that
DNC
communications
be established or
re-established with
the CNC. Press
the Done button in
the actions list to
begin the DNC
connection
process.
Start cycle on the
CNC.
Message
requesting that the
CNC Cycle Start
button be pressed
on the CNC to
complete the
establishment of
DNC
communications.
The robot has an
emergency stop.
• Verify robot
estop buttons
are reset.
• Verify teach
pendant
interface is
terminated.
Red None Recovery,
Running, Idle
This message
indicates an
emergency stop on
the robot. This can
be caused by the
eStop button on
the front of the
robot controller
enclosed in the
robot controller
compartment or by
the estop button
on the teach
pendant if
attached.

The safety circuit
is active.
1. Pivot cell to
CNC.
2. Verify that cell
doors are
secure.
3. Check the door
sensors for
alignment and
damage.
4. Check safety
circuit for
damage.
Red Done Recovery,
Running, Idle
The cell safety
circuit is open.
This is caused by
cell door or pivot
sensors being
opened. The cell
cannot begin
processing until
the safety circuit is
closed. Press
Cycle Start to
continue after
closing doors.
The robot
controller is in
manual mode.
Turn the key on
the robot
controller, (inside
the controller
compartment) to
automatic mode.
Red Done Recovery This message
appears when the
key on the front of
the robot controller
enclosed inside of
the robot controller
compartment is set
to manual
operation. The key
must be set to
automatic before
processing can
continue.
There was a
collision.
The robot collided
with an object. The
system enters
Recovery mode.
The robot must be
brought back to its
home position
before processing
can continue.

There was a
motion error.
The robot collided
with an object. The
system enters
Recovery mode.
The robot must be
brought back to its
home position
before processing
can continue.
There was a
fumble error
A part was fumbled
in the jaws. If the
fumble occurred
while picking or
placing the part
within the CNC,
processing will
continue unless
too many fumble
errors occur. If the
fumble happens in
the CNC,
processing will
stop to protect the
CNC from a loose
part.

The pneumatics
self test failed.
1. Check the
sensed
actuator for
mechanical
damage.
2. Use the
pneumatics
control buttons
in the recovery
panel to check
the movement
of the sensed
actuator.
3. Check the
condition and
adjustment of
the indicated
sensor.
4. Check the
condition of the
wiring to the
indicated
sensor.
5. If a gripper
sensor had a
float error,
verify that the
gripper stays
open and stays
closed when
floated.
6. For further
information,
see the
Pneumatics
Adjustment
and
Troubleshootin
g Guide

There was an error
moving the CNC
door. Check the
door movement
and sensors.
Red None Recovery If the CNC door is
commanded to
open or close and
the corresponding
sensor does not
indicate
completion of the
action within ten
seconds, this error
will be generated.
Exiting recovery
mode will perform
a system self test
and clear this error
on successful test.
Waiting for vise
pressure to
stabilize…
There was a vise
pressure error.
Red None Recovery The system was
unable to achieve
a target pressure
on the vises.
Exiting recovery
mode will perform
a system self test
on successful test.

Check the supply
pressure and
check the
pneumatic
systems leaks.
There was a
communication
error between the
VBXC and the
robot controller.
• Verify that the
ethernet
connection
between the
VBXC and the
robot controller is
connected.
• Shut down the
VBXC, then turn
off the power to
the cell at the
sell air/electrical
panel for 60
seconds, then
turn it back on.
• If the problem
persists, call
technical
support.

There was a
communication
error between the
VBXC and CNC
communication
hardware.
• Verify that DNC
RS232
communication
hardware is
connected and
undamaged.
• Shut down the
VBXC, then turn
off the power to
the cell at the
cell air/electrical
panel for 60
seconds, then
turn it back on.
• If the problem
persists, call
technical
support.
Red Done
Highlight
Recovery This message
indicates that the
VBX Controller
was unable to
open its local
RS232 port. This
can be caused by
hardware failure or
system
misconfiguration.
Restart the VBX
Controller to exit
this state.
There was a
sensor error.
Check the sensors
on the gripper and
vises.
Red None Recovery There are a few
places where the
robot sensors are
checked during
part processing
where unexpected
reading can be
attributed to a
mechanical failure
of the cell as
opposed to the
state of the part
being processed.
Exiting recovery
mode will perform
a system self test
on successful test.

A system error has
occured.
Shutdown system
and restart.
• Shut down the
VBXC, then turn
off the power to
the cell at the
cell air/electrical
panel for 60
seconds, then
turn it back on.
• If the problem
persists, call
techinical
support.
Red None Recovery This message
indicates that the
VBX Controller has
detected an
unexpected state
of the VBX
Controller
software or the
robot controller
software. Power
cycling the cell
may clear this
error. Report these
errors to VersaBuilt
technical support.
An IO error has
occurred on the
robot controller.
• Check for
damage to
control and
sensor wiring.
• Check for
damage or
modifications to
air/electrical
panel wiring.
• Shut down the
VBXC, then turn
off the power to
the cell at the
cell air/electrical
panel for 60
seconds, then
turn it back on.
• If the problem
persists, call
technical
support.
Done
Highlight

Action List Single Slot Messages
The part from shelf
( ) slot( ) had an
error.
• Remove the part
from the cell.
Red Done
Highlight
Recovery The part had an
error. Remove the
part from the cell.
The part from shelf
( ) slot( ) had a
motion error.
• Remove the part
from the cell.
Red Done
Highlight
Recovery The part had a
motion error.
remove the part
from the cell.
The part from shelf
( ) slot ( ) had a
collision error.
• Remove the part
from the cell.
Red Done
Highlight
Recovery The part had a
collision error.
Remove the part
from the cell.
The part from shelf
( ) slot ( ) was
fumbled.
• Remove the part
from the cell.
Red Done
Highlight
Recovery The part was
fumbled (dropped).
Remove the part
from the cell.
Unable to pick part
from shelf ( ) slot
( ).
• Remove the part
from the cell.
Red Done
Highlight
Recovery The robot was
unable to pick the
part from the shelf.
Remove the part
from the cell.
There was an error
milling the part
from shelf ( ) slot( )
in vise ( ).
• Use the vise
open/close
buttons to
manually remove
the part, or
• Use the “remove
items from vise”
button to have
the robot place
the part in the
jaws on the
shelf.
Red Done
Highlight
Recovery There was an
error from the
milling program
for the part.
Remove the part
from the cell.

Remove the part in
the gripper from
the cell.
• Use the gripper
open/close
buttons to
manually remove
the part, or
• Use the “place
held items”
button to have
the robot place
the part in the
jaws on the
shelf.
Red Done
Highlight
Recovery There is a part in
the gripper which
needs to be
removed from the
cell. The user can
either manually
remove the part by
floating the gripper
or automatically by
using the “place
held items” (eject)
button.
Remove the part in
vise from the cell.
• Use the vise
open/close
buttons to
manually remove
the part, or
items from vise”
button to have
the robot place
the part in the
jaws on the
shelf.
Red Done
Highlight
Recovery There is a part in
the vise which
needs to be
removed from the
cell before
proceeding. The
user can either
manually remove
the part by using
the manual vise
valves or
automatically by
using the “clear
vise” (eject) button.
Replace cancelled
jaws on shelf ( )
slot ( ).
Red Done
Highlight
Recovery Cancelled
MultiGrip soft jaws
in the gripper or
vise need to be
placed in their
shelf slot.
Jaws from shelf ( )
slot ( ) had an
error.
• Replace the jaws
on the shelf.
Red Done
Highlight
Jaws from shelf ( )
slot ( ) had a
motion error.
• Replace jaws on
the shelf.
Red Done
Highlight
moving the
MultiGrip soft jaws
and had a motion
error. Place the
MultiGrip soft jaws
back in their slot.
Jaws from shelf ( )
slot ( ) had a
collision error.
• Replace Jaws on
the shelf.
Red Done
Highlight
moving the
MultiGrip soft jaws
and had a collision
error. Place the
MultiGrip soft jaws
back in their slot.

Jaws on shelf ( )
slot ( ) are holding
a cancelled part.
• Remove the part
from the cell.
on the shelf.
Red Done
Highlight
Recovery When the robot
places cancelled
MultiGrip soft jaws
which are holding
a part on the shelf,
the cancelled part
must be removed
from the cell.
The jaws from
shelf ( ) slot ( )
were fumbled.
on the shelf.
Red Done
Highlight
Recovery The robot tried to
pick up the
MultiGrip soft jaws
but was
unsuccessful.
Place the MultiGrip
soft jaws back in
their shelf slot and
press the done
button.
There are
canceled jaws
from shelf ( ) slot
( ) in the gripper.
• Use the gripper
float button to
manually remove
the jaws, or
• Use the “place
held items”
button to have
the robot place
the jaws on the
shelf.
Red Done
Highlight
Recovery There are
MultiGrip soft
jaws in the
gripper which
need to be
placed in their
shelf slot before
proceeding. The
user can either
manually place
the MultiGrip soft
jaws on the shelf
by floating the
gripper or
automatically by
using the “place
held
items” (eject)
button.

There are
canceled jaws in
vise ( ) from
shelf ( ) slot ( ).
• Use the vise
open/close
buttons to
manually remove
the jaws, or
items from vise”
button to have
the robot place
the jaws on the
shelf.
Red Done
Highlight
Recovery There are
MultiGrip soft
jaws in the vise
which need to be
placed in their
shelf slot before
proceeding. The
user can either
manually place
the MultiGrip soft
jaws on the shelf
by floating the
gripper or
automatically by
using the “clear
vise” (eject)
button.
Unload completed
jaws from shelf ( )
slot ( ).
White Done
Highlight
Recovery,
Running, Idle
The MultiGrip soft
jaws in the slot are
no longer needed
for processing of
active jobs.
Remove the
MultiGrip soft jaws
from the shelf and
select the done
button on the
action.

Action List MultiSlot Messages
Unload ( ) of
completed part
( ) for order ( ).
White Done
Highlight
Recovery,
Running, Idle
Unload the
completed parts
from the cell and
confirm via the
Done button.
Unload ( ) of
canceled part( ) for
order( )
White Done
Highlight
Recovery,
Running, Idle
Unload the
cancelled parts
from the cell and
confirm via the
Done button.
Load jaws ( ) onto
shelf ( ) slot ( ) for
order ( ).
White Done
Highlight
Recover, Running,
Idle
Load MultiGrip soft
jaws for a job.
Load ( ) ( ) for
order( ).
White Done
Highlight
Recovery,
Running, Idle
Load parts into
the slots for
processing.
The ( ) for job ( )
requires an
additional slot of
one of the
following shelf
templates before it
can be queued to
run on the system.
White Done
Highlight
Recovery,
Running, Idle
There are not
sufficient template
slots configured in
the cell (available
or not) for the job
to ever run.
The template shelf
must handle tall
parts
• ( )
No pending
actions.

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