Comau Robotics C5G Instruction Handbook Manual
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Comau Robotics C5G Instruction Handbook Manual

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Comau Robotics
Instruction Handbook
Control Unit
Standard version
Transport and installation
Information about the preparing activities and prearrangements required to install the C5G
Dimensions and weights, transport and lifting methods
Procedures to adapt the internal components and options for the powering network
Procedure to carry out the connections to the Robot and to the mains
Preliminary procedures to set the Control Unit at work
CR00757597_en-00/0411

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Summary of Contents for Comau Robotics C5G

  • Page 1 Control Unit Standard version Transport and installation Information about the preparing activities and prearrangements required to install the C5G Dimensions and weights, transport and lifting methods Procedures to adapt the internal components and options for the powering network Procedure to carry out the connections to the Robot and to the mains...
  • 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

    C5G featuring rising socket and Application Box ........
  • Page 4 Connection typologies depending on the Teach Pendant ......44 Terminal connection with cable (C5G-iTP) directly connected to the C5G ....44 SAFETY CIRCUITS: MINIMUM REQUIREMENTS FOR INTEGRATION .
  • Page 5 Selecting the 24 Vdc power supply source ........62 Digital I/O on SDM module .

  • Page 6: Preface

    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: Content Of The C5G Control Unit Manuals

    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

    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: Installation Instructions

    140 °F). Temperature up to 70° C (158 °F) are permissible for short periods (less than an hour). 2.3 Requirements for the installation area The working environment, where the C5G is to be installed, shall comply with the following requirements: The environment conditions (temperature, vibrations, etc.) shall fulfil the requirements specified in chapter “Technical Specifications”.

  • Page 20: Equipment And Tools Required

    The Control Units cannot be stacked. The possible installation of items over the Control Unit shall be limited to the allowed options. 2.4 Equipment and tools required To install the C5G the following equipment and tools are required: – Lifting equipment suitable for the installation area (crane or lift truck) –...

  • Page 21: Mounting Procedure: Dimensions, Space And Handling

    Weight and size including package – Overall dimensions and installation space required for the C5G (without conditioner) – Overall dimensions and installation space required for the C5G (with conditioner) – Lifting and handling procedures – Procedure to remove the crate, protection cloth and pallet –...

  • Page 22: Weight And Size Including Package

    – C5G standard version – C5G featuring rising socket – C5G featuring Application Box – C5G featuring rising socket and Application Box 3.4.1 C5G standard version Without conditioner (C) With conditioner (D) Supply On pallet In closed crate On pallet...

  • Page 23: C5G Featuring Rising Socket

    Mounting procedure: dimensions, space and handling 3.4.2 C5G featuring rising socket Without conditioner (C) With conditioner (D) Supply On pallet In closed crate On pallet In closed crate modality 157 kg 205 kg 192 kg 240 kg Weight 346 lb...

  • Page 24: C5G Featuring Application Box

    Mounting procedure: dimensions, space and handling 3.4.3 C5G featuring Application Box Without conditioner (C) With conditioner (D) Supply On pallet In closed crate On pallet In closed crate modality 180 kg 225 kg 215 kg 260 kg Weight *¹ 397 lb...

  • Page 25: C5G Featuring Rising Socket And Application Box

    Mounting procedure: dimensions, space and handling 3.4.4 C5G featuring rising socket and Application Box Without conditioner (C) With conditioner (D) Supply On pallet In closed crate On pallet In closed crate modality 195 kg 240 kg 230 kg 275 kg Weight *¹...

  • Page 26: Overall Dimensions And Installation Space Required For The C5G (Without Conditioner)

    Mounting procedure: dimensions, space and handling 3.5 Overall dimensions and installation space required for the C5G (without conditioner) B’’’ B’’ B’ C’ C’’ C5G Control Unit version (without conditioner) With rising socket Item Standard With rising socket With Application Box and Application Box 800 mm (31.49 in)
  • Page 27 Control Unit is free. – If necessary, it is possible to install wheels with the option C5G-WHK: wheel kit. The Wheel Option do not modify the cabinet total height but cannot be installed in case the version is supplied with Application Box.

  • Page 28: Overall Dimensions And Installation Space Required For The C5G (With Conditioner)

    Mounting procedure: dimensions, space and handling 3.6 Overall dimensions and installation space required for the C5G (with conditioner) B’’’ B’’ B’ C’ C’’ C5G Control Unit version (with conditioner) With rising socket Item Standard With rising socket With Application Box and Application Box 800 mm (31.49 in)

  • Page 29: Lifting And Handling Procedures

    3.7 Lifting and handling procedures The suitable procedure depend on the supply modality: – Lifting the C5G packaged in closed crate – Lifting the C5G on pallet without crate (Europallet 1200 x 800 mm) – Lifting the C5G without package. HS-RC-C5E-TIN_02.fm...

  • Page 30: Lifting The C5G Packaged In Closed Crate

    Mounting procedure: dimensions, space and handling 3.7.1 Lifting the C5G packaged in closed crate Lifting data Weight to be lifted *¹: 190 to 270 419 to 595 *¹The weight may differ depending on the version, in particular in case it deals with the one supplied with Application Box.

  • Page 31: Lifting The C5G On Pallet Without Crate (Europallet 1200 X 800 Mm)

    Mounting procedure: dimensions, space and handling 3.7.2 Lifting the C5G on pallet without crate (Europallet 1200 x 800 mm) Lifting data Weight to be lifted*¹: 145 to 260 >=60° 320 to573 *¹ The weight may differ depending on the version, in particular in case it deals with the one supplied with Application Box.

  • Page 32: Lifting The C5G Without Package

    Mounting procedure: dimensions, space and handling 3.7.3 Lifting the C5G without package Lifting data Weight to be lifted *¹: 120 to 240 265 to 529 *¹ The weight may differ depending on the version, in particular in case it deals with the one supplied with Application Box.

  • Page 33: Procedure To Remove The Crate, Protection Cloth And Pallet

    Mounting procedure: dimensions, space and handling 3.8 Procedure to remove the crate, protection cloth and pallet Status: – Not applicable Material: – Not necessary Equipment: – For crate removal: • iron lever (jemmy) – Gloves – 13-mm socket wrench The package removal is carried out in three steps: –...
  • Page 34 Remove the wooden boards that cross the base or the wooden items locking wheels (if applicable). Lift the C5G from the pallet by means of a crane / bridgecrane or lift truck as described in par. 3.7.3 Lifting without package on page 32 and move near the installation position.

  • Page 35: Placing In Position

    Make sure the minimum space requested around the C5G fulfil the requirements specified in par. 3.5 Overall dimensions and installation space required for the C5G...

  • Page 36: Powering Supply From The Mains: Features And Connection

    Powering supply from the mains: features and connection POWERING SUPPLY FROM THE MAINS: FEATURES AND CONNECTION This chapter deals with the following topics: – Precautions before starting – Equipment and tools required – Power supply features – Earth connection diagram –...

  • Page 37: Power Supply Features

    Component / function Description The fuse shall be gG type, with features similar to the ones of the Siemens Fuse up the C5G 3NAx-xxx series When a differential switch type B is requested (AC/DC sensitive according to norm IEC 60755), use a model featuring a fault current value >= 300 mA and Differential switch up the adjustable triggering time >...

  • Page 38: Earth Connection Diagram

    Powering supply from the mains: features and connection 4.4 Earth connection diagram HS-RC-C5E-TIN_03.fm 00/0211...

  • Page 39: Selecting The Powering Voltage

    Powering supply from the mains: features and connection 4.5 Selecting the powering voltage – Control Unit – C5G-ACO / C5G-ACBO: Conditioner (if installed) 4.5.1 Control Unit The Control Unit, powered with voltage from 400 Vac -15% to 500 Vac +10%, does not require any voltage selection. 4.5.2...

  • Page 40: Procedure To Install And Connect The Powering Cable (On Main Circuit Breaker)

    Powering supply from the mains: features and connection 4.6 Procedure to install and connect the powering cable (on Main Circuit breaker) Status: – Power source off Material: – Powering cable (not supplied) – Plate with cable gland (supplied) Equipment: – 5.5 x 1 blade screwdriver –...
  • Page 41 Powering supply from the mains: features and connection Operating procedure (Continua) Fit the cable end in the hole in the cabinet base. Push the cable in the hollow space and have it coming out from the upper hole. Connect the R-S-T phases on the terminal board (B) R, S and T terminals respectively.
  • Page 42 Powering supply from the mains: features and connection Follow-up procedure Do not turn on the main switch to power the Control Unit until the installation procedure is completed. If a different fitting point is required for the cable, the in-fitting hole shall not be left open.

  • Page 43: Teach Pendant: Connection

    Equipment and tools required – Connection typologies depending on the Teach Pendant • Terminal connection with cable (C5G-iTP) directly connected to the C5G 5.1 Precautions before starting Carry out all connection activities described in this chapter with main switch OFF (position 0).

  • Page 44: Connection Typologies Depending On The Teach Pendant

    Teach Pendant The Teach Pendant connection procedure varies depending on the terminal type and the options available: – Terminal connection with cable (C5G-iTP) directly connected to the C5G 5.3.1 Terminal connection with cable (C5G-iTP) directly connected to the C5G Status –...
  • Page 45 Teach Pendant: connection Operating procedure (Continua) Fit the movable connector (A) and tighten the ring nut firmly. Place the terminal on the supporting surface (B) on the door. Wind the cable tidily on the special support. carefully while closing the door to avoid damaging cable:...

  • Page 46: Safety Circuits: Minimum Requirements For Integration

    Safety circuits: minimum requirements for integration SAFETY CIRCUITS: MINIMUM REQUIREMENTS FOR INTEGRATION This chapter deals with the following topics: – Precautions before starting – Equipment and tools required – List of minimum activities required – List of suggested activities – Safety stop: checking the stop circuit timer –...

  • Page 47: List Of Minimum Activities Required

    Safety circuits: minimum requirements for integration 6.3 List of minimum activities required – Safety stop: checking the stop circuit timer – E-Stop circuits: inputs control procedure stop circuits mushroom-shaped push button on Teach Pendant. 6.4 List of suggested activities – Safe cut-off for 24 Vdc power supply: using the internal or external power supplies HS-RC-C5E-TIN_05.fm 00/1010...

  • Page 48: Safety Stop: Checking The Stop Circuit Timer

    Equipment: – Small flat blade screwdriver Preliminary procedures / notes C5G stop circuit category – The safety stop is accomplished according to the categories specified in norm EN 60204-1 par. 9.2.2. The Emergency Entries (E-Stop), Gate (Auto-Stop) and General Stop (Gen-Stop) are subjected to a safety stop time (refer also to par.
  • Page 49 Safety circuits: minimum requirements for integration Operating procedure If the time has to be adjusted: Disconnect the power from the mains. Determine the time required according data Tab. 6.1. Check or possibly set both rotating selector switches SW1 (A) and SW2 (B) on module SDM according to Tab.

  • Page 50: On Teach Pendant

    The emergency stop push button on the Teach Pendant is not controlled by the stop circuit inside the C5G. The integrator shall connect the above mentioned contacts to the machine emergency stop circuit by means of the connection available on the X30 connector.
  • Page 51 Safety circuits: minimum requirements for integration Operating procedure Depending on the intervention modalities and the machine requirements, identify the inputs to be connected (refer also to the par. 6.6.2 Further details about the stop circuit signals on page 52). Connect the signals as specified in par.

  • Page 52: Further Details About The Stop Circuit Signals

    Status: it is enabled in automatic operating mode only and triggers a stop according to category 1 (norm EN60204-1). By selecting the $SDI[47] Programming mode, the C5G will be controlled by the Enabling Channel 1 Device (on Teach Pendant) and the Auto-Stop input will be disabled.
  • Page 53 Safety circuits: minimum requirements for integration Tab. 6.3 - X30/CIP connector: safety signal definition (Continued) Signal Pin on X30 Definition and purpose Diagnosis Status:it is always enabled and triggers the stopping mode (norm EN60204-1) depending on the selected operating mode: •...

  • Page 54: X30/Cip Connector: Pins

    Safety circuits: minimum requirements for integration 6.6.3 X30/CIP connector: pins Fig. 6.1 - X30/CIP connector: pinouts External View Legend: – Not Used / Not Available – The 0V shown are connected together. The internal power supplies (0V INT, 0V EXT and 0V Field Bus) are connected to one another, to the 0V inside the Control Unit and to the earth.

  • Page 55: Safety Signals: Reference Wiring Diagram

    Stand-alone control reference diagram – Centralized control reference diagram The mushroom-shaped push button in the C5G shall be included in the emergency safety circuit. The wiring diagrams below are to be used only as guidelines to understand the connections. The integrator shall assess the cell/line safety requirements and carry out the connections accordingly.
  • Page 56 Safety circuits: minimum requirements for integration Fig. 6.3 - Centralized control reference diagram Line Operations Internal E-Stop External E-Stop Auto-Stop (Fence) General Stop iTP = Teach Pendant E-Stop The signals electric features are to be found in Tab. 6.3 - X30/CIP connector: safety signal definition on page HS-RC-C5E-TIN_05.fm 00/1010...

  • Page 57: Troubleshooting For Safety Signals Coming From Unsuitably Installed Safety Devices

    Safety circuits: minimum requirements for integration 6.6.5 Troubleshooting for safety signals coming from unsuitably installed safety devices In unusual cases, when the installation of safety devices (e.g. safety limit switch) is carried out on major or precarious doors, it may happen that the door closing causes irregular bounces on the contacts, that affect the electric signal.

  • Page 58: Safe Cut-Off For 24 Vdc Power Supply: Using The Internal Or External Power Supplies

    Status: – Electric energy off Material: – C5G-UCK: user connector kit, for SDM module Equipment: – Screwdriver set Operating procedure Carry out the circuit as shown in the outline wiring diagram in Fig.
  • Page 59 Safety circuits: minimum requirements for integration Fig. 6.4 - 24 Vdc power supply cutoff circuit on X106/SDM: outline diagram SDM MODULE SDM MODULE X102 24V INT. 24V INT. 24V INTP 24V INTP 24V EXT. 24V EXT. FIELD BUS FIELD BUS 24V EXT.
  • Page 60 Safety circuits: minimum requirements for integration Tab. 6.4 - X106/SDM: pin structure and features Features: – Voltage: 24 Vdc – Max current: 8 A, shared between (V24 I/O) and (V24 X 106 SAFE) – Corresponsing signals: V24 I/O, GND-V0, V24 SAFE Pin structure: X106/SDM Signal...

  • Page 61: Circuits For Minor Automation Routines: Minimum Requirements For Integration

    Ordinary electromechanical equipment – In case of Digital I/O on SDM module, movable connectors for the SDM module (purchase option C5G-UCK: user connector kit, for SDM module) – In case of RS232 / RS422 serial communication, female 9-pin tray-type movable connector, supplied with cap (to be purchased independently) HS-RC-C5E-TIN_06.fm...

  • Page 62: Selecting The 24 Vdc Power Supply Source

    Circuits for minor automation routines: minimum requirements for integration 7.3 Selecting the 24 Vdc power supply source Before starting this procedure, read the specific section in the manual “Technical Specifications”: Overview for 24 Vdc power supply in the Control Unit (see par. 6.1 on page 115).
  • Page 63 Circuits for minor automation routines: minimum requirements for integration Fig. 7.1 - Circuit to select the 24 Vdc source: power supply source selection reference diagram SDM MODULE SDM MODULE X102 24V INTP 24V INTP 24V EXT. 24V EXT. FIELD BUS FIELD BUS 24V EXT.

  • Page 64: Digital I/O On Sdm Module

    149). Preliminary procedures / notes To use digital I/O on the SDM module it is necessary to have the option C5G-UCK: user connector kit, for SDM module Operating procedure Carry out the circuit as shown in the reference wiring diagram in Fig.
  • Page 65 Circuits for minor automation routines: minimum requirements for integration Fig. 7.2 - Circuit required to use digital I/O on SDM module: electric connection reference diagrams Output Input Input For further details about the technical features and connectors, please refer to par.

  • Page 66: Rs232 / Rs422 Serial Communication

    Circuits for minor automation routines: minimum requirements for integration 7.5 RS232 / RS422 serial communication Preliminary procedures / notes – The user may use the COM2 port available on the AMS-APC820 module. – The COM2 provides the RS232 / RS422 serial connection. The RS232 and RS422 ports cannot be used contemporaneously.
  • Page 67 Circuits for minor automation routines: minimum requirements for integration Fig. 7.3 - Typical cable for RS232 serial connection between COM2 on AMS-APC820 and Personal Computer Features: AMS-APC820 Personal Computer – RS232C AMS-APC820 Personal Computer side side side side – Straight cable –...

  • Page 68: Start Up

    Start up START UP This chapter deals with the following topics: – Precautions to be taken before starting the machine up – Staring up the Control Unit – Errors caused by incorrect connections in the safety circuits or in the ystem inputs.

  • Page 69: Errors Caused By Incorrect Connections In The Safety Circuits Or In The Ystem Inputs

    To start properly, the Control Unit requires some safety circuits and system diagnostic inputs to be closed again. Find below the minimum requirements to be complied with. Tab. 8.1 - Circuits and signals to start the C5G Circuit Description Minimum requirements / Notes –...
  • Page 70 Start up Tab. 8.1 - Circuits and signals to start the C5G Circuit Description Minimum requirements / Notes – The two OVT POS + and OVT POS - inputs shall be closed again – Or, with C5G-OTK option installed, the 5 over-stroke...
  • Page 72 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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