Comau C3G Plus User manual

C3G Plus
OPERATIONS AND
MAINTENANCE MANUAL
3UM - C3G Plus 08/0702
00757045/GB
CELL CONTROLLER REL. 1.x e REL. 2.x

The information provided in this manual is the property of COMAU S.p.A.
Any form of reproduction, even partial, is forbidden without the prior written authorization of COMAU S.p.A.
COMAU reserves the right to modify the characteristics of the product described in this manual without prior
notice.
PRINTED IN ITALY -07/2002
Copyright © 1999 by COMAU

UPDATING LIST
In this issue of the manual, with respect to the previous one, changes to technical contents have been per-
formed due to the product updating. The modified sections are listed below.
TITLE: C3G Plus CELL CONTROLLER
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C3G Plus UPDATING LIST
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UPDATING CHAPT. SUBJECT PAG. No. ACTION
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C3G Plus PREFACE
05/1199 i
PREFACE
C3G Plus VERSIONS SDLP-SDMP-SDHP
C3G Plus VERSIONS DDMP-DDHP

This manual refers to the COMAU SYSTEMS robot system consisting of:
C3G Plus cell control unit Rel. 1.X Rel. 2.X
SDLP 3,8 KVA
7 KVA
16,5 KVA
Power installed SDMP
SDHP
Internal lighting l–
230 Vac 6 A, SCHUKO-type service socket l–
Emergency terminal function l–
RPT Resolver Position Tracker (on board robot) (1) (1)
System software version 5.2X / 5.3X / 5.4x / 5.5x / 5.6x
(1) RPT module is not available on robots identified by a release similar/higher to that indicated in the
following table:
Manufacture release is printed on robot identification plate.
Where necessary, this manual also gives information about RPT, as documentation concerning robots man-
ufactured in previous releases not specified in table or equipped with RPT module for special applications.
PREFACE C3G Plus
ii 08/0702
SMART RELEASE RPT
S2; S3; S4 3.0 -
S5 1.0 -
M4.0 -
H1/H2/H3/H5 4.0 -
H4 3.0 -
PREFACE

SYMBOLS USED IN THIS MANUAL
The symbols used to indicate: CAUTION,WARNING and NOTES are explained below:
Symbol used to identify operating procedures, technical information and precautions, which,
if not complied with and/or carried out correctly may cause injury to personnel.
Symbol used to identify operating procedures, technical information and precautions, which, if
not complied with and/or carried out correctly may cause damage to the equipment.
Symbol used to identify operating procedures, technical information and precautions to
which attention must be drawn.
The symbols below, which appear inside the operating procedures, mean that the operator should pay partic-
ular attention or carry out the instructions:
Dangerous electrical voltage
Components that are damaged by electrostatic charges
Earth connection point or pin.
TRAINING COURSES
·COMAU Robotics organises special training courses for robot system operating, programming and
maintenance personnel.
·Further courses can be organised to cater for any particular requirements and to provide the technical
and practical information required for independent operation of the COMAU robot system, depending on
the level of knowledge of the participants.
REFERENCE DOCUMENTS
For further information on the C3G Plus cell controller, consult the following documents:
·C3G Plus Technical Specifications (supplied with this manual);
·EZ Programming Environment;
·PDL2 Programming Language Manual;
·C3G Programming Guide;
·Manuals for the dedicated application programmes;
·Robot Operation and Maintenance Manuals.
·Manual for communication through field bus and Ethernet network.
C3G Plus PREFACE
08/0702 iii
PREFACE

SUMMARY
This manual contains:
Page
CHAPTER 1 - SAFETY REGULATIONS
Responsibility .............................................................................................................................................1-1
Safety regulations.......................................................................................................................................1-1
CHAPTER 2 - INSTALLATION
Installation summary table..........................................................................................................................2-i
Provisions for installation............................................................................................................................2-1
Check packing list.......................................................................................................................................2-1
Acquaintance with operator interface .........................................................................................................2-1
Connection to power mains........................................................................................................................2-2
C3G Plus - robot connections.....................................................................................................................2-5
Application Box connections.......................................................................................................................2-6
Connection of safety devices and cutting off commands leading from the transfer....................................2-7
Activation of C3G Plus ................................................................................................................................2-12
RPT buffer battery connection (when installed)..........................................................................................2-13
C3G Plus - robot off line functional check...................................................................................................2-14
Turn_Set operation.....................................................................................................................................2-17
Deactivating the C3G Plus..........................................................................................................................2-18
Robot system integration............................................................................................................................2-18
Functional check of the installed robot system...........................................................................................2-19
CHAPTER 3 - OPERATOR INTERFACE
Control panel and serial and parallel interfaces..........................................................................................3-1
Programming and emergency terminal (C3G-PTU4) .................................................................................3-3
C3G-PTU4 display......................................................................................................................................3-9
Provision for activating the emergency terminal.........................................................................................3-11
Emergency terminal active keys.................................................................................................................3-11
Emergency control C3G-EMC2..................................................................................................................3-12
Connector for enabling device additional button ........................................................................................3-14
C3G Plus interface on personal computer..................................................................................................3-15
Connection cable for COMP: - PC connectors......................................................................................3-15
Cable for connecting serial port connectors COM0: and COM1: ..........................................................3-15
Parallel port PAR: connection cable......................................................................................................3-15
SUMMARY C3G Plus
iv 08/0702
SUMMARY

Page
PCINT programme ................................................................................................................................3-15
C3G Plus video on PC...........................................................................................................................3-18
System commands.....................................................................................................................................3-21
Stand-By function .......................................................................................................................................3-68
Brake Release Device (C3G-BRD).............................................................................................................3-69
CHAPTER 4 - INTEGRATION GUIDE
Safety signals to remote.............................................................................................................................4-1
System inputs/outputs ................................................................................................................................4-4
Input signals from external logic (machine line) ....................................................................................4-6
Output signals towards external logic (machine line)............................................................................4-7
24 Vcc power supplies...........................................................................................................................4-8
Procedures for command activation with the controlloer in automatic remote status............................4-8
Examples of use of system signals dedicated to transfer interface............................................................4-11
Parallel inputs/outputs ................................................................................................................................4-14
Serial inputs/outputs...................................................................................................................................4-33
Programmes contained in floppy disk 3“ 1/2 C3G CONFIGURATION TOOL............................................4-33
CHAPTER 5 - MAIN OPERATIONS FOR SYSTEM USE
System operating modes............................................................................................................................5-1
System statuses .........................................................................................................................................5-1
System status in multimachine - multiarm configuration.............................................................................5-4
Robot movement in programming status....................................................................................................5-5
File management between PC and cell controller......................................................................................5-10
Use of the Floppy Disk ...............................................................................................................................5-11
Examples of the use of digital I/O’s and analogue outputs.........................................................................5-12
Calibration ..................................................................................................................................................5-13
Kinematic compensation algorithm.............................................................................................................5-19
CHAPTER 6 - EMERGENCY PROCEDURES
Cutting off alarms using the EXCL key on PTU4........................................................................................6-1
Use of the PTU4 as emergency terminal....................................................................................................6-1
Use of the BRAKE RELEASE DEVICE......................................................................................................6-3
C3G Plus SUMMARY
08/0702 v
SUMMARY

Page
CHAPTER 7 - MAINTENANCE
General rules for maintenance ...................................................................................................................7-i
Preventive maintenance.............................................................................................................................7-1
Extraordinary maintenance.........................................................................................................................7-3
Main C3G Plus versions SDLP - SDMP - SDHP connections...............................................................7-5
Main C3G Plus versions DDMP - DDHP connections...........................................................................7-14
Diagnostics............................................................................................................................................7-25
Troubleshooting indications...................................................................................................................7-38
Fuses and protections...........................................................................................................................7-39
Circuit diagrams.....................................................................................................................................7-41
Control Unit............................................................................................................................................7-43
C3G-DBU3 module................................................................................................................................7-49
C3G-BKM module .................................................................................................................................7-50
C3G-MPI module...................................................................................................................................7-51
C3G-RPT module (when installed)........................................................................................................7-52
Servo Amplifiers Unit SAU2...................................................................................................................7-54
System software loading .......................................................................................................................7-60
List of spare parts..................................................................................................................................7-68
SUMMARY C3G Plus
vi 08/0702
SUMMARY

SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Responsibility 1-1
Safety regulations 1-1
C3G Plus Operations and
Maintenance Manual
SAFETY REGULATIONS

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Operations and
Maintenance Manual C3G Plus

RESPONSIBILITY
·The “integrator” is responsible for incorporating the robot system in a manufacturing or re-
search environment, for issuing the declaration of conformity and applying the EC label to the
system in compliance with the safety principles of the Machine Directive.
·COMAU S.p.A. shall not be held responsible for injury or damage resulting from incorrect or im-
proper use of the robot system, use of unspecified spare parts and tampering with circuits, com-
ponents and system software.
·The foremen who manage / supervise the operations specified in point 3 are responsible for en-
suring that these safety rules are enforced. They must make sure that all authorized personnel
have been instructed as regards the rules contained in this document and the general safety
rules applicable to the robot system and that the aforesaid personnel comply with all these rules.
·Failure to comply with safety regulations may result in injury to personnel and damage to con-
troller components.
SAFETY REGULATIONS
1. PURPOSE
1.1 The purpose of these safety regulations is to define a series of behaviour rules and duties to be
observed when performing the activities listed in point 3, to ensure the safety of personnel, equip-
ment and the surrounding environment.
2. DEFINITIONS
2.1 Robot System
The term Robot System refers to the functional assembly consisting of: control unit, robot, porta-
ble programming and/or emergency terminal and any options.
2.2 Protected Area
Protected Area is the area that is enclosed by protective barriers, in which the robot is to be in-
stalled and operated.
2.3 Authorized Personnel
Authorised Personnel is the group of persons that have been appropriately trained and delegated
to perform the activities listed in point 3.
2.4 Foremen
Foremen are personnel who direct or supervise the activities assigned to subordinate workers as
defined in the previous paragraph.
2.5 Installation and Commissioning
The term installation refers to the integration of the robot system mechanics and electrics into a
manufacturing situation or research environment in accordance with the safety requirements laid
down in the Machines Directive.
The term commissioning refers to the operations involved in verifying system operation once the
system has been installed.
2.6 Operation during Programming
Operating mode under operator control. This mode excludes automatic operation and permits the
following activities: manual movement in the various different modes, programming of work cycles
at reduced speed, programmed cycle testing at reduced speed and when permitted, at working
speed.
2.7 Automatic Operation
Operating mode in which the robot performs the programmed cycle autonomously at working
speed inside the protected area, with protective barriers closed and interlocked with the emer-
gency stop circuit, and with local (situated outside the protected area)or remote start/stop.
2.8 Emergency Manual Operation
Operating mode that permits movement of the robot with downgraded safety system in the case
of a fault, under operator control and with protective barriers closed.
C3G Plus SAFETY REGULATIONS
02/1299 1-1
SAFETY REGULATIONS

DEFINITIONS - Continued
2.9 Maintenance and Repairs
Maintenance and repair operations refer to periodic checking and/or replacement of parts (me-
chanical, electrical, software) or of robot system components and tracing of the causes of any
faults and ends with resetting of the robot system to original operating conditions.
2.10 Removal from Service and Dismantling
Removal from Service refers to the removal of the robot system (mechanical and electrical) from
the manufacturing situation or research environment.Dismantling involves the demolition and dis-
posal of the components that make up the robot system.
2.11 Integrator
The integrator is the qualified person responsible for application of the robot system.
2.12 Incorrect Use
The integrator is the qualified person responsible for the application of the robot system.
2.13 Work Envelope
The robot work envelope is the area in which the robot, including fixtures, operates.
3. FIELD OF APPLICATION
3.1 These regulations must be complied with when performing the following activities:
·installation and commissioning;
·operation during programming;
·automatic operation;
·emergency manual operation;
·maintenance and repairs;
·removal from service and dismantling;
4. OPERATING MODES
4.1 Installation and Commissioning
4.1.1 Commissioning is allowed only when the robot system is incorporated in a manufacturing system
or in a research environment that guarantees the use of safety conditions.
4.1.2 Installation and commissioning of the system must be performed by authorized personnel only.
4.1.3 The system must only be installed and commissioned inside a protected area of a suitable size to
house the robot and its relative dressing, without any part of these being outside the safety
guards. Also, make sure that during normal robot movements this does not collide with other parts
inside the protected area (for instance, structural pillars, mains, etc.). If necessary, restrict the ro-
bot work area by means of mechanical stops.
4.1.4 The robot installation area must be kept free, as far as possible, from any materials that may ob-
struct or limit visibility.
4.1.5 During installation, handle the robot and control unit as specified in the Product User Manual; if
they must be lifted, check that the eyebolts are secured correctly and use only suitable slings and
equipment.
4.1.6 Secure the robot to the support with all the bolts provided.
4.1.7 Remove any anchoring brackets from the axes and check that the robot fixtures are secured cor-
rectly.
4.1.8 Check that the robot guards are fixed correctly and that there are no loose or loosened parts,
check also that the control unit components are in good condition.
SAFETY REGULATIONS C3G Plus
1-2 02/1299
SAFETY REGULATIONS

Installation and Commissioning - Continued
4.1.9 When required, connect the robot's pneumatic system to the air distribution network and check
carefully to make sure that the pressure is set correctly. If the pressure of the balancing system is
not correct it will affect the robot's movements.Also install filters to collect any condensate in the
system.
4.1.10 Install the control unit so that the control panel can only be operated from outside the protected
area.
4.1.11 Check that the pre-engineered voltage on the power supply transformers indicated on the specific
rating plate corresponds to the power mains voltage.
4.1.12 Before making the electrical connections to the control unit, make sure that the power mains cir-
cuit breaker is locked in the open position.
4.1.13 The connection between the control unit and the mains circuit breaker must be effected by means
of a shielded quadripole cable (3-phases + ground) of suitable dimensions for the control unit
power installed
4.1.14 The supply cable must enter the control unit through the appropriate raceway and locked cor-
rectly.
4.1.15 After connecting the ground conductor (PE), connect the power conductors of the power cable to
the main circuit breaker or to the terminals on the controller Assemble the protectiive cover on the
main circuit breaker or on the input terminals.
4.1.16 Connect the supply cable to the circuit breaker on the power mains after checking, with the use of
an appropriate instrument, that the circuit breaker terminals are disconnected.
4.1.17 The controller can be provided with an internal lighting circuit and service socket connected down-
stream of the main circuit breaker. Should it be necessary to power the circuits independently
from the main circuit breaker, it will be necessary to alter an internal connection by connecting a
shielded three-core cable (2 phases + ground) to the mains, scaled according to the protection
rating of the mains, in the same way and according to the same sequence of operations as speci-
fied for connection of the power supply.
4.1.18 Connect the earth wire and the signals and power cables between the control unit and the robot.
4.1.19 Check that the control unit door(s) is/are locked with the special key.
4.1.20 The components of the control unit may be permanently damaged if the connectors are con-
nected incorrectly.
4.1.21 The C3G Plus internally makes the main safety interlocks (gates, enable button, etc.). Should it be
necessary to connect to the signals provided to make additional external circuits, make sure that
these signals are used according to safety regulations. The safety of interlock signals leading from
the transfer line (emergency stop, gates safety, etc.), i.e. providing correct and safe circuits is the
task of the robot system integrator.
System safety cannot be guaranteed if these interlocks are missing, incomplete or incorrectly es-
tablished.
4.1.22 Stopping due to tripping of the protective barrier safety devices causes uncontrolled stopping of
the robot with possible loss of the trajectory programmed. To stop the robot with controlled
ramping down, it is advisable to connect the interlock signals so as to activate a Drive Off com-
mand before the emergency stop.
Example: opening of the protective barrier safety locks causes Remote Drive Off; opening of the
protective barriers causes an emergency stop..
4.1.23 If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and
AUTO REMOTE states, an emergency stop and/or opening of the safety gates causes controlled
stopping of the robot (EN 60204-1), category 1 stop). In this way, power is cut off (opening of the
power contactor) after 1 second. In PROGR. programming status, the power is cut off immediately
(EN 60204-1, category 0 stop). These times must be taken into account when installing the pro-
tective barriers in particular if light curtains are used.
4.1.24 Check that the environmental and operating conditions do not exceed the limits specified in the
product User Manual.
C3G Plus SAFETY REGULATIONS
02/1299 1-3
SAFETY REGULATIONS

Installation and Commissioning - Continued
4.1.25 Calibration operations must be carried out with extreme care as specified in the User Manual, and
must be completed by checking the correct machine position.
4.1.26 Only the original disks, supplied by COMAU S.p.A. with the robot, must be used to load or update
the system software (e.g. after replacing cards). After loading the software, always run a safety
test cycle from outside the protected area. When loading the system software, follow the proce-
dure described in the Product User Manual to the letter.
4.1.27 Make sure that the safety barrier around the protected area has been cerrectly fitted .
4.2 Operation during Programming
4.2.1 The robot must be programmed by authorized personnel only.
4.2.2 Before programming, the operator must check the robot system to ensure there are no potentially
dangerous anomalous conditions and (ensure) that there is nobody inside the protected area.
4.2.3 Whenever possible, programming must be carried out from outside the protected area.
4.2.4 Whenever work must be carried out inside the protected area, the operator outside the protected
area must make sure that all the necessary protections have been installed and are operational
and in particular that the portable programming unit functions correctly (reduced speed, enable
pushbutton, emergency stop, etc.).
4.2.5 The operator can enter the protected area during programming only if he has the programming
terminal.
4.2.6 During programming, only the operator with the programming terminal may remain within the pro-
tected area. If the presence of another operator is absolutely necessary, he must have a further
three-position safety device connected to the control system.
4.2.7 During programming, the operator must keep far enough away from the robot to be able to avoid
any unexpected movements from the robot, and in a position to avoid being caught between the
robot and parts of the surrounding structure( pillars, safety barrier, etc.), or between moving parts
of the robot.
4.2.8 During programming, the operator must not approach any parts of the robot that may drop or lift
due to the gravity.
4.2.9 The motors must always be activated (Drive On) from outside the robot's work envelope after
checking there is noone inside the area involved. The Drive On operation is concluded when the
relevant machine status message is displayed.
4.2.10 Programmed cycle testing at working speed (a function that is included only if specific request is
made), in situations which require close visual observation with the operator inside the protected
area, must only be carried out after a complete test cycle has been run at reduced speed. Testing
must be controlled from a safe distance.
4.2.11 Be extremely careful when programming from the portable programming terminal: the hardware
and software safety devices are in operation, but robot movement is under the operator's control.
4.2.12 The first time a new program is run, the robot may move along an unexpected path.The modifica-
tion of steps in the program (e.g. shifting one step from one part of the program to another, incor-
rect recording of a step, modification of the robot position outside the path that joins two steps in
the program), may give rise to movements that were not envisaged by the operator during pro-
gram testing.
In both cases, it is extremely important to proceed with caution, and remain outside the robot's
work envelope.
SAFETY REGULATIONS C3G Plus
1-4 02/1299
SAFETY REGULATIONS

4.3 Automatic Operation
4.3.1 The robot system can only be activated for automatic operation by authorised personnel when the
protective barriers are closed and electrically interlocked as specified in the safety standards.
4.3.2 Prior to activating automatic operation, the operator must check the robot system and the pro-
tected area to make sure there are no potentially dangerous anomalous conditions.
4.3.3 The operator can only activate automatic operation after checking that:
·the robot system is not being maintenanced or repaired;
·the protective barriers have been positioned correctly;
·there is noone inside the protected area;
·the control unit doors are locked by properly key.
·the safety devices (emergency stop, protective barrier safety devices) are working properly;
·the portable programming terminal has been placed in its housing (this condition is requested
by the controller in Auto-Remote status).
4.3.4 Special attention must be paid when selecting the automatic- remote status, in which the line PLC
may automatically switch on the motors and start the program.
4.4 Emergency Manual Operation
(In case the manual emergency operation state is provided for)
4.4.1 Emergency Manual Operation can be activated by authorized personnel only.
4.4.2 This operating mode must only be used when special robot system conditions will not allow the
use of manual movement during programming.
4.4.3 Emergency manual operation must be controlled from outside the protected area since the safety
system is downgraded.
4.4.4 If it is absolutely necessary to work inside the protected area, The robot system integrator must
realize an appropriate safety circuit that allows the operator to move the robot with the safety bar-
riers deactivated.
In that case, before performing manual emergency operations, the operator must check, while re-
maining outside the protected area, the correct functioning of the safety devices that are active in
this state and the teach pendant utilized as a portable emergency pushbutton panel..
4.4.5 Take great care during emergency manual operation remaining outside the work envelope of the
robot and its fixtures and pay particular attention to the axes that may drop due to the force of
gravity.
4.4.6 Braking release device of robot axes. With the driving force excluded, the robot can be moved
by the manual brake release device, directly connected to the robot or installed on it, which only
permits the deactivation of the brake of each axis individually .In this situation all the system
safety devices (including the emergency stop and enable buttons) are excluded. Any axes to be
handled (that could drop due to the force of gravity) should be put in slings.
C3G Plus SAFETY REGULATIONS
02/1299 1-5
SAFETY REGULATIONS

4.5 Removal from Service and Dismantling
4.5.1 Only authorised personnel may remove the robot system from service.
4.5.2 Position the robot ready for transport and fit anchoring brackets when required.
4.5.3 Prior to starting the removal from service procedure it is obligatory to disable the power grid circuit
breaker and lock it in the open position.
4.5.4 After using a specific instrument to check that the terminals are disconnected, disconnect the sup-
ply cable from the power mains circuit breaker by first disconnecting the power conductors and
then the ground connector. Disconnect the main circuit breaker supply cable on the control unit
and remove this.
4.5.5 Disconnect the cable that powers the internal lighting and the service socket (if these circuits are
powered from outside) on the controller after locking the corresponding circuit breaker on the
mains supply in the open position, and (after) checking that the system is not live disconnecting
first of all the phase conductors and then the ground conductor.
4.5.6 Disconnect the cables connecting the robot and the control unit, then disconnect the earth
4.5.7 Disconnect the robot pneumatic system from the air distribution network (if applicable).
4.5.8 Make sure that the robot is correctly balanced and, if necessary, harness it correctly and then dis-
assemble the robot anchor bolts from the support structure
4.5.9 Remove the robot and the controller from the work area complying with all the prescriptions given
in the manuals provided. If the equipment is to be lifted, check that the eyebolts are correctly se-
cured and use suitable rigging and equipment.
4.5.10 Before starting to dismantle the robot system components (disassembly, demolition and disposal),
contact COMAU, or one of its branches. Depending on the type of robot and control unit, they will
provide information regarding the operations to be carried out so as to comply with the current
safety regulations, and protect the environment.
4.5.11 Any waste must be disposed of in accordance with the current legislation of the country where the
robot system has been installed.
SAFETY REGULATIONS C3G Plus
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SAFETY REGULATIONS