Comau Robotics C5G User Maintenance Manual
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Comau Robotics C5G User Maintenance Manual

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Comau Robotics
Instruction Handbook
Control Unit
Standard Version
Maintenance
Help to problem-solving
Preventive maintenance plan to guarantee the C5G functionality over time
Preventive and special maintenance procedures
Spare part list
CR00757598_en-00/0411

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Summary of Contents for Comau Robotics C5G

  • Page 1 Comau Robotics Instruction Handbook Control Unit Standard Version Maintenance Help to problem-solving Preventive maintenance plan to guarantee the C5G functionality over time Preventive and special maintenance procedures Spare part list CR00757598_en-00/0411...
  • Page 2 The information contained in this manual is the property of COMAU S.p.A. Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A. COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation. Copyright ©...

  • Page 3: Table Of Contents

    SUMMARY GENERAL SAFETY PRECAUTIONS ........9 Responsibilities .
  • Page 4 How to use the Brake Release module C5G-OBR ....... . .
  • Page 5 Spare parts for the C5G basic model........
  • Page 6 Manual content limits – Symbols in the manual. Reference documents This document refers to the C5G Control Unit. The complete set of manuals concerning the C5G control units consists of: Comau C5G Control Unit – Technical Specification – Transport and installation –...
  • Page 7 Preface Content of the C5G Control Unit manuals Device Manuals Contents C5G Control – Technical – Description and main features of the Control Unit Unit Specification – Guide to Control Unit model selection – General description about the expanding possibilities in...
  • Page 8 Symbols in the manual Find below the symbols highlighting WARNING, CAUTION and NOTES together with their meaning This symbol applies to operating procedures, technical information and precautions that are to be complied with and/or properly performed to prevent possible injuries. This symbol applies to operating procedures, technical information and precautions that are to be complied with and/or properly performed to prevent possible equipment damages.

  • Page 9: General Safety Precautions

    CE markings of the system are the responsibility of the Integrator. – COMAU Robotics & Service shall in no way be held liable for any accidents caused by incorrect or improper use of the Robot System (Robot and Control...

  • Page 10: Safety Precautions

    General Safety Precautions 1.2 Safety Precautions 1.2.1 Purpose These safety precautions are aimed to define the behaviour and rules to be observed when performing the activities listed in the Applicability section. 1.2.2 Definitions Robot System (Robot and Control System) The Robot System is a functional unit consisting of Robot, Control Unit, Programming terminal and possible options.

  • Page 11: Applicability

    General Safety Precautions Putting Out of Service and Dismantling Putting out of service defines the activities involved in the mechanical and electrical removal of the Robot and Control System from a production unit or from an environment in which it was under study. Dismantling consists of the demolition and dismantling of the components that make up the Robot and Control System.

  • Page 12: Operating Modes

    General Safety Precautions 1.2.4 Operating Modes Installation and Putting into Service – Putting into service is only possible when the Robot and Control System has been correctly and completely installed. – The system installation and putting into service is exclusively the task of the authorised personnel.
  • Page 13 – The C5G Control Unit manages internally the main safety interlocks (gates, enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the line safety circuits, taking care to connect them as required by the Safety standards. The safety of the interlock signals coming from the transfer line (emrgency stop, gates safey devices etc) i.e.
  • Page 14 General Safety Precautions Programming Mode – The robot is only to be programmed by the authorised personnel. – Before starting to program, the operator must check the Robot System (Robot and Control System) to make sure that there are no potentially hazardous irregular conditions, and that there is nobody inside the protected area.
  • Page 15 Maintenance and Repairs – When assembled in COMAU Robotics & Service, the robot is supplied with lubricant that does not contain substances harmful to health, however, in some cases, repeated and prolonged exposure to the product could cause skin irritation, or if swallowed, indisposition.
  • Page 16 – When loading the software (for example after replacing electronic boards) the original software handed over by COMAU Robotics & Service is to be used. Scrupulously follow the system software loading procedure described in the specific product Technical Documentation; after loading always run a test cycle to make sure, remaining outside the protected area –...
  • Page 17 – Before starting dismantling operations (disassembly, demolition and disposal) of the Robot and Control System components, contact COMAU Robotics & Service, or one of its branches, who will indicate, according to the type of robot and Control Unit, the operating methods in accordance with safety principles and safeguarding the environment.

  • Page 18: Performance

    General Safety Precautions 1.2.5 Performance The performances below shall be considered before installing the robot system: – Stop distances – Mission time (typ. case). Stop distances – With Robot in programming modality (T1), if you press the sttop pushbutton (red mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you will obtain: Tab.

  • Page 19: Maintenance Prescriptions

    Maintenance prescriptions MAINTENANCE PRESCRIPTIONS This chapter deals with the following topics: – Precautions before starting – Precautions while carrying out maintenance activities – Precautions at the end of the maintenance activities – Maintenance staff – Equipment and tools necessary – Torque wrench settings.

  • Page 20: Precautions At The End Of The Maintenance Activities

    2.5 Equipment and tools necessary The components fastening items (screws, nuts) have been standardized as much as possible. The minimum equipment necessary to carry out maintenance activities on the C5G Control Unit is divided according to the maintenance typology: –...

  • Page 21: Help In Trouble Shooting

    – Traceability for replacement purposes – Replacing the components 3.2.1 Problem analysis The C5G Control Unit delivers information about the system status using: – LEDs, located on the modules and cards – diagnosis messages, displayed through he programming terminal. Depending on the plant condition, one or both means (LEDs, messages) may be useful to detect possible faults: –...

  • Page 22: Diagnosis Messages

    Help in Trouble Shooting 3.2.2 Diagnosis messages The diagnosis messages are coded using numerical codes matched to a short description and are displayed through the programming terminal. To better understand the message, identify the cause that led to it as well as the suitable method to remove it, use the WinC4G software.
  • Page 23 Help in Trouble Shooting – ----- (the message is not stored) – 28808 (error numerical code) – 10 (seriousness level) – Gate safety (message text featuring the fault detected on the plant). 3.2.2.2 Alarm quitting Find below the quitting procedures as a function of the alarm seriousness level: Tab.
  • Page 24 Help in Trouble Shooting Tab. 3.2 - Seriousness level and corresponding quitting procedure (Continued) Seriousne Meaning Impact on the system Quitting procedure ss level Driving devices off DRIVE OFF – Quit the fault pressing the RESET (Ctrl + HOME keys on WinC4G) (stop according to category 0, in compliance with norm EN –...

  • Page 25: Identification Items And Abbreviations For Connectors, Cables And Modules

    Help in Trouble Shooting 3.2.3 Identification items and abbreviations for connectors, cables and modules All connectors and cables in the Control Unit are supplied with clear abbreviations and characterized univocally, to allow a rapid identification of the connection as well as the Traceability for replacement purposes (see par.

  • Page 26: Replacing The Components

    Help in Trouble Shooting 3.2.5 Replacing the components To replace the components, we recommend to identify the damaged ones through the Identification items and abbreviations for connectors, cables and modules, such as to be able to replace them with an identical spare part. Find in Chap.9.
  • Page 27 Help in Trouble Shooting 400 Vac, 24 Vdc Power supply distribution Internal main connections HS-RC-C5E-MAN_02.fm 00/0111...
  • Page 28 Help in Trouble Shooting Vd c SDM MODULE SDM MODULE X102 X103 24V INTP 24V INTP 24V INT. 24V INT. 24V EXT. 24V EXT. FIELD BUS FIELD BUS 24V EXT. 24V EXT. INT./EXT. X106 24V I/O 24V I/O 24V SAFE 24V SAFE X122 X124...

  • Page 29: Comau Customer Center

    Help in Trouble Shooting 3.4 Comau Customer Center The Comau Customer Centre will be at your disposal at the following addresses: Section Address Service available To get help for troubleshooting and request Cause and solution service.robotics@comau.com software options Spare parts spares.robotics@comau.com To request spare parts To request intervention for repairing...

  • Page 30: Switching Off The Power Supply

    – If installed, connector X120 shall not be used for the power supply sectioning (C5G-MCK option). – To increase the battery life do not switch off the Control Unit before carrying out the software shutdown.

  • Page 31: Switching Off The Power Supply

    Switching off the power supply 4.2 Switching off the power supply Status: – Unimportant Material: – Padlock diameter min. 5 mm / max 8 mm (min. 0.19 in / max 0.31 in), (not supplied) Equipment: – Not required Preliminary procedures / notes –...
  • Page 32 Switching off the power supply Operating procedure (Continua) Press lever (B) to access the slot. Fit the padlock in the slot available on the switch control. Remove the padlock only after completing the maintenance activities. The padlock is not supplied together with the electric box. With main switch open, the connector X120 and the cable up the main switch are energized.
  • Page 33 Switching off the power supply Operating procedure (Continua) Incoming voltage off (if the optional connector X120 is not installed) Perform the power supply off-switching as specified in Main switch open (OFF). Open and padlock the main switch up the Control Unit. The padlock is not supplied together with the Control Unit.

  • Page 34: How To Reach The Modules

    How to reach the modules HOW TO REACH THE MODULES This chapter deals with the following topics: – Precautions before starting – Risks associated with the module reaching procedures – Module location and reaching methods 5.1 Precautions before starting – Read carefully the instructions in Chap.2.
  • Page 35 How to reach the modules Tab. 5.1 - Module / component list and access point (Continued) Module / componente Access point ACC - CPU, power supplies and power Front door (see par. 5.3.1 on modules page 36) Front door (see par. 5.3.1 on CIP - Connector Interface Panel (CIP) page 36)

  • Page 36: Front Door

    How to reach the modules 5.3.1 Front door Equipment Supplied fist key Fastening screws Not required Be careful – Terminals are in protection category IP2x Precautions – if possible, turn the power off before starting to work inside the cabinet. Front door opening procedure Turn the supplied key by 90°...

  • Page 37: Upper Panel

    How to reach the modules 5.3.2 Upper panel Equipment Allen spanner 3 mm Fastening screws TSEI M5 no. 2 Be careful – Terminals are in protection category IP2x – The X120 terminal board is energized also when the main switch is off Precautions –...

  • Page 38: Rear Panel

    How to reach the modules 5.3.3 Rear panel Equipment Allen spanner 3 mm Fastening screws TCEI M4 no. 2 Be careful – Rotating fan – Hot surfaces Precautions – Always disconnect the power before reaching the rear panel. – Be careful to hot surfaces: recovery resistance and dissipator.

  • Page 39: How To Move The Robot When The Control Unit Is Damaged

    – The brake releasing Module C5G-OBR powers the engine brakes with a 24Vdc current from an outside source. This command may therefore give rise to possible dropping risks (refer to par.

  • Page 40: How To Use The Brake Release Module C5G-Obr

    6.2 Risks associated with the Robot handling with Control Unit disconnected on page –The brake release Module C5G-OBR option includes a movable plug suitable for the panel socket located on the module rear side. Before the first usage, prepare a powering cable with plug suitable for the power supply source available in the operating area.
  • Page 41 How to move the robot when the control unit is damaged Operating procedure (Continued) • Connect the movable connector (A) to the connector X2 by the Robot base. The movable connector (B) is not to be used and can be left on the floor.
  • Page 42 How to move the robot when the control unit is damaged Operating procedure (Continued) Select the axis to be released on the selector switch (E). Keep tight the ropes that are used the support the axes subject to gravity. To release Robot axes 1 to 6: •...

  • Page 43: Preventive Maintenance

    In case of poor or missing preventive maintenance activities during the warranty period, this will be regarded as prejudicial to the warranty itself. 7.2 Equipment and tools required The minimum equipment to carry out preventive maintenance activities on the C5G Control Unit is: Tab. 7.1 - Equipment and tools required...

  • Page 44: Preventive Maintenance Plan

    – enabling push button (enabling device) checking the actual functionality of the two channels. The C5G diagnosis system checks the efficiency of the related safety circuit and, in case of fault, displays a corresponding message on the programming terminal.

  • Page 45: Acc: Door Closing And Seal Efficiency Check

    Preventive maintenance - ACC 7.4 ACC: door closing and seal efficiency check Arm Controller Cabinet Status: – Irrelevant Material: – Not required Equipment: – Not required Front view Preliminary procedures / notes – The cabinet door shall remain closed to guarantee the efficiency of the cooling system and prevent contamination from entering in the cabinet.

  • Page 46: Aco: Cleaning The Condenser

    Preventive Maintenance - ACO 7.5 ACO: cleaning the condenser Air Conditioner Option Status: – Main switch open (OFF) Material: – Not required Equipment: – Crossheaded screwriver – Soft bristle brush – Vacuum cleaner – Ecological solvent Front view Preliminary procedures / notes –...
  • Page 47 Operating procedure In cas the thermostat setting gets accidentally modified, reset the default value of 45 °C. Replace the cover restoring the earth wire connection. Screw back in place the cover fastening screws. Follow-up procedure – Not required HS-RC-C5E-ACO_01.fm 00/0211...

  • Page 48: Aco: Emptying The Condensate Collectiong Can

    Preventive Maintenance - ACO 7.6 ACO: emptying the condensate collectiong Air Conditioner Option Status: – Unimportant Material: – Not required Equipment: – Not required Front view Preliminary procedures / notes – The emptying frequency depend on the environment humidity, therefore shall be adjusted accondingly.

  • Page 49: E110: Fan Cleaning

    Preventive maintenance - E110 7.7 E110: fan cleaning Status: – Main switch open (OFF) Material: – Not required Equipment: – 3-mm allen spanner – Soft bristle brush – Vacuum-cleaner – Gloves Front view Preliminary procedure/ notes – To ensure the control unit smooth operating, it is necessary to guarantee the efficiency of the cooling system.
  • Page 50 Operating procedure The area to be cleaned is the fan (A) one. Be careful and make sure the X120 terminal board is not powered. Remove the dirt using the brush, in particular on the fan (A) blade inside area. Mount the Upper panel (see par.

  • Page 51: E111

    Preventive maintenance - E111..E114 7.8 E111..E114: fan cleaning Status: – Main switch open (OFF) Material: – Not required Equipment: – 3-mm allen spanner – Soft bristle brush – Vaccum-cleaner – Gloves Rear view Preliminary procedures / notes – To ensure the control unit smooth operating, it is necessary to guarantee the efficiency of the cooling system.
  • Page 52 Operating procedure The area to be cleaned is the fan (A) and dissipator (B) one. careful, recovery resistance may be very hot. Remove the dirt using the brush, in particular on the fan (A) blade inside area. Remove the dirt from the panel grids (C).

  • Page 53: Ups: Replacing The Battery

    Preventive maintenance - UPS 7.9 UPS: replacing the battery Uninterruptible Power Supply Status: – Irrelevant *¹ Material: – Battery (see Tab. 9.2 - Uninterruptible Power Supply (UPS) on page Equipment: – Cross-headed screwdriver Front view Preliminary procedures / notes Handle the battery with care. Use only batteries supplied as spare parts.
  • Page 54 Operating procedure (Continued) Remove the fuse before acting on the module C5G-UPS (1). Loosen the cover fastening screw by 4-5 turns (2). If it is not removed completely, it will be easier to mount it back. Lift and remove the battery cover (3).
  • Page 55 Operating procedure (Continued) If one or more modules have been removed: m.1 Fasten the UPS module on the omega guide. m.2 Mount back the removed option panel. Transfer the flat batteries to the suitable waste collection sites. For further details, please refer to Chap.

  • Page 56: Special Maintenance

    Comau qualified staff. 8.2 Equipment and tools required The minimum equipment necessary to carry out special maintenance activities on the C5G Control Unit is: Tab. 8.1 - Equipment and tools required Flat blade screwdriver set Cross-headed screwdriver set...

  • Page 57: Modules Subject To Special Maintenance Activities

    Special maintenance 8.3 Modules subject to special maintenance activities To replace possible damaged items, follow the procedures described in the maintenance sheets below. The sheets, in alphabetical order following the abbreviations, are to be found in Tab. 8.2. Tab. 8.2 - Special maintenance activities Activity / Sheet Ref.¹...

  • Page 58: Aco: Replacement

    Manutenzione straordinaria - ACO 8.4 ACO: replacement Air Conditioner Opzion Status: – Main switch open (OFF) Material: – Conditioner coplete with box roof (see Tab. 9.6 - Conditioning) Equipment: – M8 male eyebolts, supplied with the conditioner – Lifting system with 40 kg capacity (ex. crane), with 2 1-m long ropes with hook / shackle (Note: inside diamter of conditioner eyebolt is equal to 20 mm)
  • Page 59 Operating procedure On the C5G, unscrew and remove the 4 M12 female eyebolts (C) on the roof. On the C5G, unscrew the 2 TSEI M4 unlosable screws (D). Disconnect conditioner connection cable inside the box. it may be necessary to...
  • Page 60 Operating procedure By means of 2 ropes and a suitable lifting sustem, anchor to the 2 eyebolts on the conditioner. Lift perfectly vertical, such as not to damage the threaded bars that come out the Control Unit, seat of the removed eyebolts.
  • Page 61 The connection is on the lower side. Restore the connsction of the roof eaarth wire. On the C5G, crew in the 4 M12 female eyebolts (C) on the roof, that are supplied with plastic washers.
  • Page 62 Operating procedure condensate drainage pipe in the eyebolt and then in the collecting can. Be careful to the pipe path, that shall go downwards. Cut the pipe eccess length. Lift the conditioner front blind panel and make sure the value is set at 45 °C (default value).

  • Page 63: Ams-Apc820: Module Replacement And Compact Flash Recovery

    Manutenzione straordinaria - AMS-APC820 8.5 AMS-APC820: module replacement and Compact Flash recovery Acopos PC Status: – Main switch open (OFF) Material: – Module AMS-APC820 (see Tab. 9.3 - CPU, power supplies and power modules a pag. Equipment: – Balde-headed flat screwdriver, short (4 x 25) –...
  • Page 64 Operating procedure (Continued) Unscrew the Allen screw (F) and remove it. Unscrew the Allen screw (G) until it idles. The screw is of unsalable type and shall not be removed. Remove the module by slightly moving away the lower part, then lift it.
  • Page 65 Operating procedure (Continued) Wear the antistatic arm band. Remove the Compact Flash fitted in slot 1. carry out the removal procedure you shall open door (H), that contemporaneously lifts the Compact Flash (L). AMS-APC820 module fit the removed Compac Flash back in slot 1 (M). Make sure the module bottom wall and the supporting area on the dissipator are both perfectly clean.
  • Page 66 Operating procedure (Continued) Tighten the Allen screw (F) by 5 Nm. Place back all connectors (A), making sure the fitting is followed by a sharp “click” indicating the fitting has been completely accomplished. Place back possible other connectors and Flash Disk USB that may have been removed previously.
  • Page 67 (Load)” and confirm by pressing the Enter key v.4 The “File” field automatically highlights the configuration file name and the related path (i.e. UD:\sys\cnfg\NJ1_01007.C5G v.5 Confirm the loading using the OK softkey (key F5). The loading is confirmed by the message “Activity in progress”...
  • Page 68 Enter key w.4 The “File” field automatically highlights the configuration file name and the related path shown previously (e.g. UD:\sys\cnfg\NJ1_01007.C5G w.5 Confirm the saving using the OK softkey (key F5). The loading is confirmed by the message “Activity in progress”...

  • Page 69: Ams-Asm32: Module Replacement

    Manutenzione straordinaria - AMS-ASM32 8.6 AMS-ASM32: module replacement Auxiliary Supply Module Status: – Main switch open (OFF) Material: – Module AMS-ASM32 (see Tab. 9.3 - CPU, power supplies and power modules a pag. Equipment: – T-shaped 5-mm Allen wrench, length 250 mm Front view Preliminary procedures / notes...
  • Page 70 Operating procedures (Continua) Unscrew the Allen screw (G) until it idles. The screw is of unloseable type and shall not be removed. Remove the module by slightly moving the lower part, then lift In case of resistance due to the friction with adjoining...
  • Page 71 Operating procedures (Continua) Mount the new module in the slot hooking it first from the upper part, then lower it while pushing against dissipator. Tighten the Allen screw (G) by 5 Nm. Tighten the Allen screw (F) by 5 Nm. Place back all connectors (A).

  • Page 72: Ams-Iam: Module Replacement

    Manutenzione straordinaria - AMS-IAM 8.7 AMS-IAM: module replacement Inverter Axis Module Status: – Main switch open (OFF) Material: – Modul AMS-IAMI (see Tab. 9.3 - CPU, power supplies and power modules a pag. Equipment: – Blade-headed flat screwdriver, short (4 x 25) –...
  • Page 73 Operating procedure (Continued) Disconnect the connectors on the module lower side by removing the connectors (D). Unscrew the screws (E), lift the terminal and move it away from the module. Unscrew the Allen screws (F) and remove them. Unscrew the Allen screws (G) until they idle.
  • Page 74 Operating procedure (Continued) Remove the module by slightly moving away the lower part, then lift it. In case of resistance due to the friction with adjoining modules: – loosen all Allen screws of the adjoining module. – If that is not sufficient, keep on loosening all screws of all installed modules.
  • Page 75 Operating procedure (Continued) Open the front door (L) by prizing on the upper area using a screwdriver. Record the IP address of module AMS-IAM available on the rotating selector switches (M) to be able to set it in the new module.
  • Page 76 Operating procedure (Continued) n.2 Remove the module (K) while keeping on pushing gently. n.3 Repeat the procedure for the second module. Make sure the module bottom wall and the supporting area on the dissipator are both perfectly clean. Mount the new module in the slot hooking it first from the upper part, then lower it while pushing...
  • Page 77 Operating procedure (Continued) Place back all connectors (C), making sure the fitting is followed by a sharp “click” indicating the fitting has been completely accomplished. Place back the connectors (B). Place the connectors (A) back and the corresponding screws (tighten the screws without overdoing).

  • Page 78: Ams-Pps8: Module Replacement

    Manutenzione straordinaria - AMS-PPS8 8.8 AMS-PPS8: module replacement Passive Power Supply Status: – Main switch open (OFF) Material: – Module AMS-PPS8I (see Tab. 9.3 - CPU, power supplies and power modules a pag. Equipment: – T-shaped 5-mm Allen wrench, length 250 mm Vista frontale Preliminary procedures / notes...
  • Page 79 Operating procedure Disconnect the connectors on the module upper side. Depending on the connector type, it may be necessary: – (A): to carry out the direct removal (connector without fastening systems) – (B): to press the tongue and keep it pressed during the removal Disconnect the connectors on the module lower side by...
  • Page 80 Operating procedure (Continued) Remove the module by slightly moving away the lower part, then lift it. In case of resistance due to the friction with adjoining modules: – loosen all Allen screws of the adjoining module. – If that is not sufficient, keep on loosening all screws of all installed modules.
  • Page 81 Operating procedure (Continued) Tighten the Allen screws (G) by 5 Nm. Tighten the Allen screws (F) by 5 Nm. Place back all connectors (B), making sure the fitting is followed by a sharp “click” indicating the fitting has been completely accomplished. Place back all connectors (A) and (D).

  • Page 82: Hmk: Replacing The Hour-Counter

    Special maintenance - HMK 8.9 HMK: replacing the hour-counter Hour Meter Kit Status: – Main switch open (OFF) Material: – Hour-counter (see xxxxxxxxxxxxxx) Equipment: – Flat blade screwdriver Front view Preliminary procedures / notes – The hour-counter module records the Robot working hours. Record the value displayed by the removed hour-counter and take it into account in the future Robot periodic maintenance sessions.
  • Page 83 Operating procedure (Continued) Slip off the frame (B) while acting on the levers. Push hour-counter outwards. Connect the wires to the new hour-counter. Place the new hour-counter in its seat and orient it properly. Place the plastic frame back, while keeping the hour-counter in its seat, and push it firmly in position.

  • Page 84: Sdm: Module Replacement

    Manutenzione straordinaria - SDM 8.10 SDM: module replacement Safety Distribution Module Status: – Main switch open (OFF) Material: – Module SDM (see Tab. 9.4 - Safety Distribution Module (SDM) a pag. Equipment: – Flat blade-headed screwdriver, short (4 x 25) –...
  • Page 85 Operating procedure (Continue) Disconnect the connectors on the module lower side: – (B): press the tang and keep it pressed during the removal. Unscrew by 2-3 turn the Allen screw (F), but do not remove it. Remove the module by slightly lifting the lower part, then move it away.
  • Page 86 Operating procedure (Continue) At the stand, remove possible connectors still available on the module and serving as plugs or without connections, such as to guarantee the same functionalities and performances for the new module as well (in particular connectors with bridges). Fit them on the new module complying with the original position.
  • Page 87 Operating procedure (Continue) Place back connectors (A). Place back all connectors (B), making sure the fitting is followed by a sharp “click” indicating the fitting has been completely accomplished. Place back all connectors (C) and screw the corresponding screws (tighten the screws without overdoing).
  • Page 88 Tab. 8.3 - Time to be set depending on the Robot family Time to be set on SDM module Robot family (preferential depending on the Robot family and typical applications) SMART 5 Six / NS SMART 5 NM 1.5 seconds *¹ SMART 5 NJ Square YZ-500 2 seconds...

  • Page 89: Ups: Replacing The Module

    8.11 UPS: replacing the module Uninterruptible Power Supply Status: – Main switch open (OFF) Material: – Complete Module C5G-UPS (refer to Tab. 9.2 - Uninterruptible Power Supply (UPS) on page Equipment: – Cross-headed screwdriver Front view Preliminary procedures / notes Handle the module with care as it hosts a battery.
  • Page 90 Operating procedure (Continued) Remove the upper (1) and lower (2) connectors. Replace the UPS module. Connect the connectors back to the original position. Fasten the UPS module on the omega guide. If one or more modules have been removed: g.1 Mount back the removed option panel. Transfer the UPS module and battery to the suitable waste collecting sites.

  • Page 91: Spare Parts

    Find in this chapter the spare part list divided per module. If not clearly specified, the spare part suits all Unit Control sizes. Use only original spare parts for the C5G Control Unit, in particular for the devices installed in the status and safety circuits.

  • Page 92: Spare Parts For The C5G Basic Model

    Tab. 9.2 - Uninterruptible Power Supply (UPS) Item Comau code Description CR10140583 C5G-UPS complete CR10142483 C5G-UPS blade fuse 30 A (green) CR10142283 C5G-UPS battery 12 V 5 Ah, 70 x 106 x 90 mm (W x H x D) HS-RC-C5E-MAN_06.fm 00/0411...
  • Page 93 Spare parts Tab. 9.3 - CPU, power supplies and power modules Item Comau code Description AMS-APC820 CR10140783 (identified on the module front part as ACOPOS multi APC820) AMS-PPS8 Passive Power Supply 8 KVA CR10140383 (identified on the module front part ACOPOS multi P0220) AMS-ASM32 Auxiliary Supply Module 32 A / 24 Vdc CR10140483 (identified on the module front part ACOPOS multi C0320)
  • Page 94 C5G-APC Lithium Battery 3V 950 mAh Fuse 30A, 600V, fast, 10.3 x 38 mm CR19191128 C5G-ERR Energy Recovery Resistance 15 ohm 2 kW *¹ Position and no. depending on the installed axes power *² Alternative, depending on the type of transducer on the motor *³...
  • Page 95 Spare parts Tab. 9.5 - Internal ventilation system Position Comau code Description CR17430981 C5G-IFK Inside fan kit (E110) CR17431081 C5G-FCK Cooling fan kit (E111, E112, E113, E114) HS-RC-C5E-MAN_06.fm 00/0411...
  • Page 96 Codice: COMAU CR17133680 Position Comau Code Description C5G-ACG Conditioner Unit complete with conditioner, metallic CR17431880 roof and powering cable for conditioner. Bipolar limit switch 1NO+ 1NC, NEW ELFIN 50F11 Note: the limit switch model is identical also when installed in the Application Box IMagneto.thermal switch curve D 2,5-4A, SQUARE D - GV2-P08...

  • Page 97: Setting Out Of Work And Dismantling

    Setting out of work and dismantling SETTING OUT OF WORK AND DISMANTLING This chapter deals with the following topics: – Precautions before starting – Staff to set the plant out of work and dismantle it – Equipment and tools required –...
  • Page 98 Setting out of work and dismantling open the Control Unit main switch and lock it in open position disconnect the electric power at the distribution source and lock the switch in open position. disconnect the powering cable from the Control Unit; disconnect the power wires first and then the earth one disconnect the multipolar connectors by the Control Unit and Robot sides if installed, disconnect the pneumatic system from the distribution network and...

  • Page 99: Removing The Pile And Battery From The Control Unit

    The Control Unit features the following piles /batteries: • Button-shaped pile in the module AMS-APC820 (reference A) • Battery in the module C5G-UPS (reference B) • Battery in the WiTP Programming terminal (reference Operating procedure Button-shaped pile in the module...
  • Page 100 Setting out of work and dismantling Operating procedure (Continued) Battery in the module C5G-UPS (reference B) Remove the fuse before acting on module C5G-UPS. Remove the cover fastening screw. Remove the battery cover. Disconnect the cables from the battery terminals.
  • Page 101 Setting out of work and dismantling Operating procedure (Continued) Battery in the WiTP Programming terminal (reference C) Open the programming terminal removing the fastening screws. Remove the screws and items that lock the battery. Lift the battery and disconnect the side connector. Follow-up procedure Transfer piles and batteries to the suitable waste collecting sites.
  • Page 103 COMAU Robotics services Repair: repairs.robotics@comau.com Training: training.robotics@comau.com Spare parts: spares.robotics@comau.com Technical service: service.robotics@comau.com Original instructions comau.com/robotics...

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