Comau Robotics C5G Operating instructions

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

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 © 2008-2011 by COMAU - Date of publication 04/2011

3
_
LB-RC-C5E-MAN_enTOC.fm
00/0000
SUMMARY
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. MAINTENANCE PRESCRIPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Precautions while carrying out maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Precautions at the end of the maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Equipment and tools necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. HELP IN TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Problem analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnosis messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Identification items and abbreviations for connectors, cables and modules . . . . . . . . . . . . . 25
Traceability for replacement purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing the components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Unit outline diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Comau Customer Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4. SWITCHING OFF THE POWER SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30
Precautions and risks associated to the power supply off-switching . . . . . . . . . . . . . . . . . . . . . 30
Switching off the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. HOW TO REACH THE MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...34
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Risks associated with the module reaching procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Module location and reaching methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4
_LB-RC-C5E-MAN_enTOC.fm
00/0000
Front door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Upper panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6. HOW TO MOVE THE ROBOT WHEN THE CONTROL UNIT IS DAMAGED . . . . . . ..39
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Risks associated with the Robot handling with Control Unit disconnected . . . . . . . . . . . . . . . . 39
How to use the Brake Release module C5G-OBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Preventive maintenance plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ACC: door closing and seal efficiency check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ACO: cleaning the condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ACO: emptying the condensate collectiong can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
E110: fan cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E111..E114: fan cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
UPS: replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..56
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Modules subject to special maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ACO: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AMS-APC820: module replacement and Compact Flash recovery . . . . . . . . . . . . . . . . . . . . . . 63
AMS-ASM32: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
AMS-IAM: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
AMS-PPS8: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
HMK: replacing the hour-counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SDM: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
UPS: replacing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..91
Precautions about the spare part usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Where to procure the spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5
_
LB-RC-C5E-MAN_enTOC.fm
00/0000
Spare part list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Spare parts for the C5G basic model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10. SETTING OUT OF WORK AND DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . ...97
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Staff to set the plant out of work and dismantle it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Setting out of work and dismantling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removing the pile and battery from the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Preface
6
HS-RC-C5E-0_01.fm
00/0211
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
7
HS-RC-C5E-0_01.fm
00/0211
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

8
HS-RC-C5E-0_01.fm
00/0211
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
9
ge-0-0-0_01.FM
00/0710
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
10
ge-0-0-0_01.FM
00/0710
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.

General Safety Precautions
11
ge-0-0-0_01.FM
00/0710
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.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.
Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.
1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
–Installation and Putting into Service;
–Programming Mode;
–Auto / Remote Automatic Mode;
–Robot axes release;
–Maintenance and Repairs;
–Putting Out of Service and Dismantling

General Safety Precautions
12
ge-0-0-0_01.FM
00/0710
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.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.

General Safety Precautions
13
ge-0-0-0_01.FM
00/0710
– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
–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. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.
In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.
Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.

General Safety Precautions
14
ge-0-0-0_01.FM
00/0710
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.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.

General Safety Precautions
15
ge-0-0-0_01.FM
00/0710
Auto / Remote Automatic Mode
– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robot System (Robot and Control System) integrated inside
an area with safety barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the safety barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked;
• that the safety devices (emergency stop, safety barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes release
– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
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.
First Aid. Contact with the eyes or the skin: wash the contaminated zones with
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.
Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.

General Safety Precautions
16
ge-0-0-0_01.FM
00/0710
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised
personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.
– Trouble-shooting and maintenance activities are to be executed, when possible,
outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– 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
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.

General Safety Precautions
17
ge-0-0-0_01.FM
00/0710
Putting Out of Service and Dismantling
– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– 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.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

General Safety Precautions
18
ge-0-0-0_01.FM
00/0710
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:
– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)
– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
Tab. 1.1 - Stop spaces in programming modality (T1)
Mode Expected
speed Case Stopping
time
Stopping
space
T1 250 mm/s Nominal 120 ms 30 mm
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming
modality (T1)
Mode Expected
speed Case Stopping
time
T1 250 mm/s
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
150 ms
For the stop stop and enabling device inputs
from the TP in wireless version, when the
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the
safety wire transmission is lost or interrupted.
350 ms

Maintenance prescriptions
19
HS-RC-C5E-MAN_01.fm
00/0309
2. 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.
2.1 Precautions before starting
– The majority of maintenance activities on the Control Unit are to be carried out wih
power off. In those cases the wording “Main switch open (OFF)” is specified in the
maintenance sheet.
When the main switch is OFF, the X120 terminal board and the related cable up
the main switch are energized. In that case, the procedure to cut the power off
completely requires the power disconnection from the mains.
– The maintenance activities to be carried out on the cabinet main powering section
shall be perfomed only after disconnecting the power from the mains. In those
cases the wording “Incoming voltage off” is specified in the maintenance sheet.
– Use orignal spare parts only. Spare parts are supplied by Comau. The bill of spare
parts is to be found in Chap.9. - Spare parts on page 91.
2.2 Precautions while carrying out maintenance
activities
– If the fault type allows the robot re-positioning, we recommed to move it in resting
position, before carrying out any maintenance activity.
–We remind you that in virtue of the Control Unit safety circuits inherent features, a
warranty reduction may be possible in case of multiple faults (refer to norm EN ISO
13849-1).
The maintenance activities that not are expressly specified in this manual are not
allowed. If necessary, turn to the manufacturer.
In case of maintenance and/or troubleshooting activities on the safety
circuits, do not stand nearby the Robot and carry out the motion in jog
mode keeping at suitable distance.

Maintenance prescriptions
20
HS-RC-C5E-MAN_01.fm
00/0309
2.3 Precautions at the end of the maintenance
activities
– After completing the maitenance activities, check whether the Control Unit and
matched Robot operate properly. Have the robot performing some working cycle
and check the safety device functionality before leaving the station.
2.4 Maintenance staff
The maintenance staff shall be suitably trained, in order to be able to use the lifting
means properly (in case the whole Control Unit is to be replaced).
Moreover, the staff shall be warned or trained (in electrics) and therefore aware of the
risks associated with electric energy and of the measures to be taken to safely reach the
Control Unit modules.
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:
–asforpreventive maintenance refer to par. 7.2 Equipment and tools required on
page 43.
–asforspecial maintenance refer to par. 8.2 Equipment and tools required on
page 56.
2.6 Torque wrench settings
While disassembling and re-assembling the components comply with the screw torque
wrench settings. If not otherwise specified, apply the torque corresponding to the screw
typology.
At the end of each maintenance session, the first machine start-up shall
be regarded as a test for the whole plant. During such phase the operator
shall stand outside the Robot range of action but in an position that
allows to check its movements. Moreover, he/she shall have the
Progrmaming Terminal at disposal nearby.
Do not overtight, as you may damage the thread and therefore the item position
in its seat.
Do not under tight, as it may cause the item falling and/or overheating (and
consequent breaking) due to an incorrect adherence to the dissipating frame.