Comau Robotics C5G Manuel

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

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.

Summary

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SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Manual content limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Staff for the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Storage requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Requirements for the installation area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. MOUNTING PROCEDURE: DIMENSIONS, SPACE AND HANDLING . . . . . . . . . . ...21

Precautions before starting the procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Packing list check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Weight and size including package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C5G standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C5G featuring rising socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C5G featuring Application Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

C5G featuring rising socket and Application Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Overall dimensions and installation space required for the C5G (without conditioner) . . . . . . . 26

Overall dimensions and installation space required for the C5G (with conditioner). . . . . . . . . . 28

Lifting and handling procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Lifting the C5G packaged in closed crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Lifting the C5G on pallet without crate (Europallet 1200 x 800 mm) . . . . . . . . . . . . . . . . . . . 31

Lifting the C5G without package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Summary

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Procedure to remove the crate, protection cloth and pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Placing in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. POWERING SUPPLY FROM THE MAINS: FEATURES AND CONNECTION . . . . . ..36

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Power supply features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Earth connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Selecting the powering voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

C5G-ACO / C5G-ACBO: Conditioner (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Procedure to install and connect the powering cable (on Main Circuit breaker) . . . . . . . . . . . . 40

5. TEACH PENDANT: CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connection typologies depending on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Terminal connection with cable (C5G-iTP) directly connected to the C5G . . . . . . . . . . . . . . 44

6. SAFETY CIRCUITS: MINIMUM REQUIREMENTS FOR INTEGRATION . . . . . . . . . ..46

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

List of minimum activities required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

List of suggested activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Safety stop: checking the stop circuit timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

E-Stop circuits: inputs and control procedure for stop circuits and mushroom-shaped push button

on Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

How to wire the X30 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Further details about the stop circuit signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X30/CIP connector: pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Safety signals: reference wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Troubleshooting for safety signals coming from unsuitably installed safety devices . . . . . . . 57

Safe cut-off for 24 Vdc power supply: using the internal or external power supplies. . . . . . . . . 58

Solution with power supply taken from the X106/SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7. CIRCUITS FOR MINOR AUTOMATION ROUTINES: MINIMUM REQUIREMENTS FOR

INTEGRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Selecting the 24 Vdc power supply source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Digital I/O on SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

RS232 / RS422 serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8. START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...68

Precautions to be taken before starting the machine up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Staring up the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Errors caused by incorrect connections in the safety circuits or in the ystem inputs . . . . . . . . . 69

Preface

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PREFACE

This chapter deals with the following topics:

–Reference documents

–Content of the C5G Control Unit manuals

–Document preservation

–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:

Those manuals are to be supplemented by the following documents:

Comau C5G Control Unit – Technical Specification

–Transport and installation

–Maintenance

– Control Unit use

Circuit Diagram – Circuit Diagram (ver. ACC1 and ACC3)

–Circuit Diagram (ver. ACC5)

–Circuit Diagram (ver. PAL)

Comau Robot – Technical Specifications *¹

– Transport and installation *¹

– Maintenance *¹

Programming – PDL2 Programming Language Manual

– VP2 - Visual PDL2

– Motion programming

Applications – According to the required application

type.

*¹ specific for the installed Robot type

The above mentioned manuals shall be preserved in good repair for the entire

Robot System operating life and shall always be available for the staff members

carrying out activities on the Robot System.

Preface

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Content of the C5G Control Unit manuals

Document preservation

All documents forwarded shall be preserved nearby the Robot System and be at the

disposal of all staff members, who carry out activities on the Robot System. Moreover

the documents shall be preserved in good repair for the entire Robot System operating

life.

Manual content limits

The images in the instruction manuals are aimed at representing the product and may

differ from the items actually installed on the Robot System.

Device Manuals Contents

C5G Control

Unit

–Technical

Specification

– Description and main features of the Control Unit

– Guide to Control Unit model selection

– General description about the expanding possibilities in

relation to I/O signals, communication networks and safety

devices

– Description and purchase codes for the Control Unit and its

optionals.

–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 perform the connection to the mains

– Preliminary procedure to set the Control Unit at work

–Maintenance – Help to problem-solving

– Preventive maintenance plan to guarantee the C5G

efficiency over time

– Preventive and special maintenance procedures

– Spare part list

– Wiring diagram

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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.

This symbol applies to operating procedures, technical information and

precautions that need necessarily to be highlighted.

This symbol concerns the material disposal procedures ruled by the RAEE

Directive.

This symbol reminds the user to avoid polluting the environment and stimulate a

sustainable attitude, i.e. disposing of the materials in the suitable waste collection

sites.

General Safety Precautions

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1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

–Responsibilities

–Safety Precautions.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robot System (Robot

and Control System) are installed and handled in accordance with the Safety

Standards in force in the country where the installation takes place. The application

and use of the protection and safety devices necessary, the issuing of declarations

of conformity and any 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 System), by

tampering with circuits, components or software, or the use of spare parts that are

not included in the spare parts list.

– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally

are to make sure that the Authorised Personnel is aware of and scrupulously follow

the precautions contained in this document as well as the Safety Standards in

addition to the Safety Standards in force in the country in which it is installed.

– The non-observance of the Safety Standards could cause injuries to the operators

and damage the Robot System (Robot and Control System).

It deals with a general specification that apply to the whole Robot System. Due to

ist significance, this document is referred to unreservedly in any system

instruction manual.

The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.

General Safety Precautions

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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.

Protected Area

The protected area is the zone confined by the safety barriers and to be used for the

installation and operation of the robot

Authorised Personnel

Authorised personnel defines the group of persons who have been trained and assigned

to carry out the activities listed in the Applicability section.

Assigned Personnel

The persons assigned to direct or supervise the activities of the workers referred to in

the paragraph above.

Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the

Robot and Control System in any environment that requires controlled movement of

robot axes, in compliance with the safety requirements of the country where the system

is installed.

Programming Mode

Operating mode under the control of the operator, that excludes automatic operation

and allows the following activities: manual handling of robot axes and programming of

work cycles at low speed, programmed cycle testing at low speed and, when allowed,

at the working speed.

Auto / Remote Automatic Mode

Operating mode in which the robot autonomously executes the programmed cycle at the

work speed, with the operators outside the protected area, with the safety barriers

closed and the safety circuit activated, with local (located outside the protected area) or

remote start/stop.

Maintenance and Repairs

Maintenance and repairs are activities that involve periodical checking and / or

replacement (mechanical, electrical, software) of Robot and Control System parts or

components, and trouble shooting, that terminates when the Robot and Control System

has been reset to its original project functional condition.

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