C5G Tech Specs en

Comau Robotics
Instruction Handbook
Control Unit
Standard Version
Technical Specification (Quick Reference)
Description and general characteristics of the Control Unit
Guide to the choice of the Control Unit version
General description of the expandability to I/O signals,
communication networks, safety devices
Description and order codes for option
Quick Reference _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
Summary
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SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Manual content limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...18
Reliability and serviceability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calculation power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expandability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Compliance with the norms in force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Directives and norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Statement of incorporation of partly completed machinery . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Manufacturers details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety devices control procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety solutions installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27
Selecting the Control Unit version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Unit technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Teach Pendant operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Teach Pendant overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Teach Pendant technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Summary
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Teach Pendant with cable connection (C5G-iTP), selecting mode T1, AUTO and REMOTE 35
Teach Pendant with cable connection (C5G-iTP2), selecting mode T1 and REMOTE . . . . . 36
Teach Pendant with wireless connection (C5G-WiTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connection cables between C5G and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4. OVERVIEW OF THE CONNECTIONS TO THE C5G CONTROL UNIT. . . . . . . . . . . ..39
Overview of the C5G Control Unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Robot, positioning devices and auxiliary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
X10 connector (Robot signals). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
X60 connector (Robot Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
X10-EXT connector (Extension, Positioning device signals) . . . . . . . . . . . . . . . . . . . . . . . . . 44
X60-EXT connector (Extension, motors and brakes of the positioning device) . . . . . . . . . . . 45
X61..X64 connectors (Signals and power for auxiliary Axes). . . . . . . . . . . . . . . . . . . . . . . . . 46
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X30 connector (Safety items). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ETH2 connector on AMS-APC820 (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
COM2 connector on AMS-APC820 (RS422 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X90 cable gland connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X31..X32 connectors (Applications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X93..X94 connector (Master Field Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
COM2 connector on AMS-APC820 (RS232 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Programming and users interface on PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Summary of connectors and corresponding function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61
Information about the options installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Options Circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Opzions for the C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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 *
Transport and installation *
Maintenance *
Programming PDL2 Programming Language Manual
VP2 - Visual PDL2
Motion programming
Applications According to the required application
type.
* 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.
precautions that are to be complied with and/or properly performed to prevent
possible equipment damages.
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.
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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 Defi nitions
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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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;
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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.
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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.
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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 robots range of
action and test the cycle at slow speed.
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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.
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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.
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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.
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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
Introduction to the control unit: reliability and safety
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2. INTRODUCTION TO THE CONTROL
UNIT: RELIABILITY AND SAFETY
The C5G Control Unit is an industrial appliance created for user-friendly, efficient and
multi-purpose management of all SMART5 Comau Robot range.
The C5G Control Unit:
is powered directly from the factory mains with a voltage from 400 Vac -10% to 500
Vac +10% with no need of any adapting transformer.
with a total maximum power of 16 kVA, it can handle robot configured with up to
16 interpolated axes, supplied with brushless synchronous motors and
high-resolution Encoder-type position transducer with EnDat 2.2 interface.
can be interfaced through the most common communication interfaces (USB,
serial, Ethernet) as well as with the most common field Bus and communication
protocols (CanOpen, DeviceNet, Profibus-DP, EtherNet/IP, etc.). It can become an
Ethernet net node on the plant network to facilitate remote updating and
diagnostics.
can be programmed through a user-friendly software and controlled using a
chosen Teach Pendant featuring cable or wireless connection. The Teach Pendant
is supplied with a TFT 6.4 4096-colour graphic display, easy-to-understand user
interface, is lightweight and ergonomically structured with on-board USB interface.
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It is easily expandable through optional modules, to better adapt to the users
applications and make them easier.
The C5G Control Unit has been conceived to guarantee:
Reliability and serviceability
Calculation power
Expandability
Programming
Safety
Control modes.
The results obtained has enabled us to develop a Control Unit suitable to fulfil the
requirements of multiple applications featuring high-level sophisticated performances.
2.1 Reliability and serviceability
The C5G Control Unit has been conceived and developed applying care and precision
principles and using high-quality components, according to the following concepts:
minimum functional divisions, with specific high-potential modules
limited interconnections among modules, accomplished mainly through
communication networks
high MTBF: the system main items have been developed to guarantee a high
MTBF. The control unit internal wiring and interconnections have been carried out
such as not to impact on the main item MTBF.
reduced MTTR: the Control Unit main items assembly is such as to guarantee a
quick replacement of all control unit internal items.
sophisticated diagnostics in order to facilitate maintenance, with the possibility
of remote diagnostics as well as SMS and e-mail sending.
This Control Unit shall be matched to a SMART5 series Comau robot only.
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2.2 Calculation power
The C5G Control Unit features state-of-the-art processors to control the trajectory and
the periphery, the application software and the users interface, in order to ensure the
highest level of performance of both areas. The processors work through a real time
VxWorks operating system.
The processor controlling the movements carries out the following functions reliably and
accurately:
Servo-adaptive algorithms, with dynamic pattern calculated in real time based on
the load, position speed (Smart Move) and inertia conditions. The dynamic model
is applied to all 6 axes.
Acceleration/deceleration modulation for joint-like movements, to optimize the
robot motor performances in terms of speed.
Linear interpolation featuring fly-path total programmability and constant speed.
Circular interpolation featuring different orientation evolution possibilities (even 2
angles in relation to the trajectory).
Possibility to control up to 16 axes:
Synchronized movements - Sync Move (function provided for)
Integrated Arms the control arm chains (1 arm carries a second one that
performs the process) (function provided for)
is open to Cooperative Motion, to control two cooperating arms (1 arm
position the item, 1 arm carries out the process).
Conveyor tracking, to carry out the process of items moving on conveyor lines or
rotating plates that are not controlled by the robot.
Weaving, for more sophisticated arc welding processes (Cartesian weaving and
high frequency joints).
Sensor Tracking, guaranteeing the highest tracking precision and the possibility to
interfacing with different sensor typologies: 3D laser telecameras, arc parameter
sensors, power sensors, others (function provided for).
Reference systems: base, tool, users, to reuse programmes on different cells.
Collision detection: it allows to detect collision situation between the robot and the
surrounding environment.
Load self-determination: a software tool is available that allows to correctly define
the load parameters that will influence the robot movements, to optimize the
performances and protect the components.
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2.3 Expandability
The expandability is based on the usage of standard protocols and connections, usually
available in industrial environments.
The C5G Control Unit is supplied with 6 base axes that can be expanded up to 11 inside
the same cabinet.
Modules are available on the Ethernet POWERLINK network for the interfacing with field
and application control Bus and parallel I/O signals.
The safety circuit basic prearrangement, that can be easily integrated on the line, can
be expanded using modules for the safe control on Safety Bus and axes safe shutting.
Moreover, several options allow to adapt and customize the C5G Control Unit such as
to fulfil the different installation requirements.
2.4 Programming
The programming features:
on-line and off-line programming facilities through a graphic Teach Pendant,
Personal computer and dedicated CAD (e.g. RobCad)
PDL2 easy language combined with the potential to guarantee the robot integration
in the most demanding applications
possibility to run simultaneously more PDL2 programmes
possibility to customize application programmes through J ava graphics and
language.
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2.5 Safety
Compliance with the norms in force
Directives and norms
Statement of incorporation of partly completed machinery
Manufacturers details
Safety devices control procedures
Safety solutions installed.
2.5.1 Compliance with the norms in force
The C5G Control Unit consists of a functional area specifically designed to fulfil the
safety requirements provided for by the norms in force:
Compliance with norm EN ISO 10218-1: the Robot Control Unit to be used with
the Comau robots has been developed to fulfil the norm requirements and facilitate
the controller integration
Safe stopping circuits: the emergency stop control, that is available also as
connection outside the Control Unit, ensures a safe stop of the corresponding
Comau robot, also under the most demanding conditions that are to be expected
(full load at high speed)
Safe movement control circuits: the motion is triggered and controlled by the
Control Unit, which ensures the correct motion accomplishing. All trajectories are
constantly checked and monitored and any possible deviation due to external
causes is immediately detected and corrected. If the trajectory is compromised, the
immediate stop will be triggered in good time.
Safety circuit category: all safety circuits inside on Robot Control Unit standard
models are in compliance with category 3 according to standard EN ISO 13849-1
(PL =d, DC
awg
=95%, MTTF
d
>100, CCF =75). Also all internal circuits, external
interconnection circuits and expansion modules, which allow to increase the
number of contacts for the application interfacing, comply with the same category.
Compliance with the European Directives: Machine Directive,
Electromagnetic Compatibility Directive (EMC), Low Voltage Directive and
Directives pertaning the environmental protection. The Control Unit matched
to a Comau robot is an partly completed machinery (according to the definition in
the Machinery Directive 2006/42/CE, item 2 paragraph g). The terms of
compliance with the directives are described in details in par. 2.5.3 Statement of
incorporation of partly completed machinery on page 24.
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2.5.2 Directives and norms
The C5G Control Unit has been designed and manufactured in compliance with the
directives and norms listed in Tab. 2.1.
Tab. 2.1 - Applicable Directives and norms
Directive / Norm Description and applicability
2006/42/CE DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast) (for the sake of brevity referred to as Machine directive)
COUNCIL of 12 December 2006 on the harmonisation of the laws of Member
States relating to electrical equipment designed for use within certain voltage
limits (for the sake of brevity referred to as Low voltage directive)
COUNCIL of 15 December 2004 on the approximation of the laws of the Member
States relating to electromagnetic compatibility and repealing Directive
89/336/EEC (for the sake of brevity referred to as EMC Directive)
COUNCIL of 27 J anuary 2003 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment (for the sake of brevity referred
to as RoHS Directive) and later amendments (2008/385/EC)
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 13732-1 Ergonomics of the thermal environment - Methods for the assessment of human
responses to contact with surfaces - Part 1: Hot surfaces
EN ISO 10218-1 Robots for industrial environments - Safety requirements - Part 1: Robot
EN ISO 13849-1 Safety of machinery - Safety related parts of control systems - General principles
for design
EN 60068-2-6 Basic environmental testing procedures - part 2: Vibration (sinusoidal)
EN 60068-2-31 Basic environmental testing procedures - part 2: Drop and topple, primarily for
equipment type specimens
EN 60068-2-64
Environmental testing - Test methods - Test FH: vibration, broad band random
(Digital Control) and guidance
EN 60204-1 Safety of Machinery - Electrical equipment of machines - Part 1: General
requirements
EN 60529 Degrees of protection provided by enclosures (IP code)
EN 61000-6-2 Electromagnetic Compatibility - Generic immunity standard - Part 6-2: Industrial
environment
EN 61000-6-4 Electromagnetic Compatibility - Generic emission standard - Part 6-4: Industrial
environment
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2.5.3 Statement of incorporation of partl y completed machinery
The group consisting of the C5G Control Unit and the SMART5 series robot is supplied
with statement of incorporation of partly completed machinery, as provided for in
the Annex II b. of directive 2006/42/EC.
The Statement of incorporation of partly completed machinery is supplied in
original together with the group consisting of the C5G Control Unit and SMART5 serie
Robot.
The C5G Control Unit identification plate is posted on the electric cabinet front side.
Fig. 2.1 - C5G Control Unit Identification Plate (facsimile for
version C5G-ACC3)
2.5.4 Manufacturers detail s
The manufacturer, as defined in the Machinery Directive, is:
COMAU S.p.A.
Robotics Business Line
Via Rivalta, 30
10095 Grugliasco (TO) - ITALY
it is forbidden to set the group consisting of the C5G Control Unit and the
SMART5 series Robot at work before the machinery in which it is to be installed
is declared to be in compliance with the provisions in directive 2006/42/EC.
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2.5.5 Safety devi ces control procedures
To facilitate the safety devices control procedures, the controlling circuits and basic
interlocks, that are necessary to control a cell, have been integrated inside the C5G
Robot Control Unit.
This solution represents a noticeable advantage for the installation, as it will no longer
be necessary to provide for the outside interlocks controlling the safety gates or other
operator protecting devices and it will simply be sufficient to connect to the dedicated
connector located by the cabinet base to make use of all available safety functions.
This flexibility do not damage the reverse situation, i.e. the safety signals controlling by
the external circuits. In that case all C5G Robot Control Unit safety and status signals
are available on the same dedicated connector.
If the number of contacts related to the safety and status signals available in the Control
Unit are not sufficient to control one or more applications, it is possible to use the
available expansion cards to increase the contact number without altering the safety
circuit category.
(In compliance with norm EN 60204-1) the stopping procedure is accomplished
according to category 0 (zero) in Programming (T1) mode and to category 1 in Local
automatic (AUTO) and Remote automatic (REMOTE) mode
2.5.6 Safety soluti ons i nstal led
The safety circuit and the connections for the external devices allow the compliance in
according to norm EN ISO 13849-1.
Find below the solutions installed to guarantee the operators safety:
Emergency stop push button
The red mushroom-shaped push button triggering the emergency stop is installed
on the Teach Pendant.The potential-free push button contacts are available on the
interface connector and are not connected to the internal emergency stop circuit.
Emergency stop control
The cell emergency contacts (mushroom-shaped push buttons) can be connected
to the internal safety circuit to trigger the robot stopping. In automatic mode, the
robot stopping is accomplished through controlled decelation ramp, in compliance
with category 1, according to norm EN 60204-1.
Enabling Device pushbutton
The Teach Pendant hosts the three-position Enabling Device with hardware
control. By pressing the enabling device power is delivered to the actuating devices
and the robot movements are enabled in programming operating mode. The
enabling device is active in programming mode only and disabled in the other
machine modes.
Cell access gates control
The contacts of the limit switches installed on the cell access gates can be
connected to the safety circuit to control the robot stopping in automatic mode. In
programming mode, those contacts are cut off to allow the robot motion with open
gates.
Safe power cut-off
The 24V I/O power supply to the dedicated interface connectors depends on the
following items:
emergency stop
safety gate opening in automatic mode
enabling device releasing in programming mode
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motor-off command (Drive Off).
2.6 Control modes
The group consisting of the C5G Control Unit and SMART5 series Robot features 3
control modes. The control modes can be selected using the key selector switch
located on the Teach Pendant.
Programming (T1)
Used for low speed motion, to programme the robot operating trajectory.
The operator may remain inside the cell. The robot movements are accomplished
at reduced speed, reaching maximum 250 mm/s by the flange centre. The robot is
directly controlled by the operator. Movements and program running at reduced
speed are allowed.
Local automatic (AUTO)
Used to run working programmes, in automatic mode with gates closed and at set
speed, that are triggered from the Teach Pendant.
This mode may be unavailable for some Teach Pendant versions.
Remote automatic (REMOTE)
Used to run programmes, in automatic mode with gates closed and at set speed,
that are triggered from external devices (PLC, others).
Versions and Technical features
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3. VERSIONS AND TECHNICAL FEATURES
Selecting the Control Unit version:
C5G Control Unit
Teach Pendant
Connection cables between C5G and Robot
3.1 Selecting the Control Unit version
To choose the most suitable C5G Control Unit version it is necessary to take into
account first of all the Robot family and the related required electric power. This manual
does not deal with the selection of the Robot version, please refer to the Robot specific
Technical Specifications manuals.
The C5G Control Unit configuration has to be chosen accomplishing the following steps:
C5G Control Unit, depending on the Robot family it will be matched to
Teach Pendant, depending on the type of connection required between Control
Unit and Teach Pendant
Connection cables between C5G and Robot, depending on the Robot family and
the installation distance.
Customizing adding optional functions (refer to Chap.5. - Options on page 61).
Fig. 3.1 - C5G Control Unit: overall view
A: C5G Control Unit
B: Teach Pendant
-: Connection cables between C5G
and Robot
-: Options
B
A
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3.2 C5G Control Unit
Different configurations are available for the C5G Control Unit. The main feature that
distinguishes the configuration is the available electric power and therefore the Robot
family it can be matched to.
The Control Unit includes all modules necessary to control the Robot (powering from the
mains, actuating devices, signal distribution module and safety devices control). The
basic version does not include the Teach Pendant and the optional modules. Also the
Connection cables between C5G and Robot are to be chosen separately.
* As for the information related to the Robot features and available versions, please
refer to the Robot specific Technical Specifications manuals
*
The power value does not vary with the powering voltage fluctuations, as the system
works at constant power.
*
Besides the 8 kVA installed the option C5G-AFK: Auxiliary Fan Kit is required.
*4
Refer to section Additional axes.
Tab. 3.1 - C5G: available basic versions
Robot family*
(SMART5 series)
Matching C5G
Control Unit
/ Comau Code
Power *
No. of
controllable
robots
No. of axes
avalable /
max
controllable
*4
Total installed /
average current
at 400 Vac
peak
(<=2s)
SMART5
SiX
NS
C5G-ACC1
CR17930181
3 kVA / 4,5 A 9 kVA 1 6
12 kVA* / 18,5 A 36 kVA 1 6 / 11
SMART5
NM
NJ <180
C5G-ACC3
CR17930381
8 kVA / 14 A 24 kVA 1 6
12 kVA* / 18,5 A 36 kVA 1
6 / 9 SMART5
NJ >175 <400
NJ 450 - 2.7
12 kVA* / 18,5 A 36 kVA 1
SMART5
PAL
C5G-ACC3P
CR17930681
12 kVA / 18,5 A 36 kVA 1 4
SMART5
NJ 420 - 3.0
NJ 500 - 2.7
C5G-ACC5
CR17930581
12 kVA / 18,5 A 36 kVA 1 6
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Fig. 3.2 - C5G Control Unit: front and rear view
This picture shows the C5G Control Unit already supplied with iTP Teach Pendant.
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3.2.1 Control Unit techni cal features
In Tab. 3.2 are listed the technical features of the product basic version.
Tab. 3.2 - General technical feature
C5G-ACC1 C5G-ACC3 C5G-ACC5
Size
Height x width x depth (basics version, no options)
1110 x 800 x 510 mm
43.31 x 31.50 x 20.08 in
Height with wheel option no difference
Height with rising socket option 100 mm +100 mm (+3.94 in)
Height with Application Box option +540 mm (+21.26 in)
Powering details
Powering voltage
(according to norm EN 60204-1 4.3.3, voltage breaking not exceeding
20 ms)
from 400 Vac -10%
to 500 Vac +10%
(optional from 400 Vac -10% to 575 Vac +10%)*
Frequency
(according to norm EN 60204-1 4.3.3)
50 at 60 Hz (2 Hz)
Main switch breaking power 6 kA @ 500 Vac
Installed power from 3 to 12 kVA (see Tab. 3.1)
Auxiliary circuit voltage 24 Vdc
Axis controlling capability
Total for the system up to 16 axes
Control Unit without expansion cabinets up to 11 axes
Environmental conditions
Cabinet protection (non including rear space)
(according to norm EN 60529)
IP 54 / NEMA 12
Rear space protection
(according to norm EN 60529)
IP 2x
Room temperature without cooling systems
(test conditions according to norm EN 60068-2-14)
from +5 C to +45 C *
from +41 F to 113 F
Room temperature with cooling systems
(test conditions according to norm EN 60068-2-14)
from +5 C to +55 C *
to +41 F a 131 F
Storage room temperature
(according to norm EN 60204-1 4.5)
from -25 C to +55 C
from -13 F to 131 F
+70 C / 158 F fro short periods, less than a hour.
Maximum thermal gradient
1,5 C/minute
2.7 F/minute
Relative humidity
(according to norm EN 60204-1 4.4.4, test conditions HD 323.2.3. S2)
from 5% to 95% without condensate
Installation area altitude
(according to norm EN 60204-1 4.4.5)
from 0 to 1.000 m / 0 to 3280 ft
above sea level
Cooling
Standard booth Natural convection
Booth with cooling options Conditioner
Actuation Forced air recirculation
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* It is possible to widen the voltage range with the transformer option and voltage switch
on terminal board.
* With restrictions (refer to par. 4.13 Internal ventilation system on page 84).
Weight
Control Unit (basic version)
The weight specified may change depending on the configuration, in
particular when it deals with the version featuring Application Box. Always
refer to the plate posted on the Control Unit
125 kg / 275 lb without package
Conditioner (optional) 31 kg / 68 lb
Vibrations and impacts
Sinusoidal vibrations
(according to norm EN 60068-2-64)
Frequency 10 - 250 Hz
acceleration 0,6 g rms axis Z
acceleration 0,2 g rms axes X-Y
Colour
Cabinet body, painted items RAL 7024
Tab. 3.2 - General technical feature (Continued)
C5G-ACC1 C5G-ACC3 C5G-ACC5
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3.3 Teach Pendant
The Control Unit basic version shall be completed with the Teach Pendant that is
available in models that differ depending on the type of connection required between
Control Unit and Teach Pendant.
Fig. 3.3 - Teach Pendant: overall view
3.3.1 Teach Pendant operati ng principle
The Teach Pendant communicate with the C5G Control Unit through the Ethernet
protocol. The connection starts on the dedicated Ethernet ETH1 port of the
AMS-APC820 module and, depending on the terminal type, ends directly on the
C5G-iTP terminal or connects to the access point on the docking station for the
C5G-WiTP terminal.
The Programming (T1), Local automatic (AUTO) and Remote automatic (REMOTE)
control mode selection may be performed acting on the slector switch installed on the
Teach Pendant (C5G-iTP) or through the docking station (C5G-WiTP).
Through the color user interface it is possible to easily access all parameters and
perform the Robot movements as well as run the working programmes. Using suitable
application softwares (that can be developed also by the user), the interface can be
customized to fulfil the requirements of specific production environments and
processes.
More details about the control modes are to be found in the par. 2.6 Control
modes on page 26.
The Teach Pendant functions are complex and are dealt with in details in the
usage manual.
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3.3.2 Teach Pendant overview
There are following possible solutions:
Teach Pendant with cable connection (C5G-iTP), selecting mode T1, AUTO and
REMOTE
Teach Pendant with cable connection (C5G-iTP2), selecting mode T1 and
REMOTE
Teach Pendant with wireless connection (C5G-WiTP).
The technical differences are to be found in par. 3.3.3 Teach Pendant technical features
on page 34.
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3.3.3 Teach Pendant technical features
* Modality unavailable for model C5G-iTP2
* Each independent communication channel can be used to send and receive data from
different Wi-Fi sources at the same time.
* Implementing the Pairing / Un-Pairing procedure (Comau Patented) it is possible to
use an only one terminal for 2 or more Control Units
NA: Not Applicable
Tab. 3.3 - Teach Pendant: versions available
Feature
C5G-iTP / C5G-iTP2
Terminal
C5G-WiTP
Terminal
Modal selector switch (Mode T1, AUTO *,
REMOTE)
Installed on terminal
Installed on the docking
station
Display
lit-up LCD
4096-colour TFT 6.4
resolution 640 x 480
Sizes 360 x 210 x 80 mm
Weight 1090 g 1470 g
Port USB 1.1 available on terminal 1
Connection typology Cable Wireless
Reachable distance between Control Unit and Teach
Pendant
up to 60 m guaranteed up to 40 m
Need to combine the terminal with one only Control
Unit
Yes No*
Colour Grey Blue
Processor Intel
PXA 270 Intel
PXA 270
Operating system Microsoft
Windows
CE Microsoft
Windows
CE
Internal memory 128 Mbyte 128 Mbyte
Communication protocol / method
TCP-IP
through cable
TCP-IP
IEEE802.11a
Independent communication channels * (as per
standard 802.11 a)
NA 19 EU / 24 USA
Connection safety wired
Pairing / Un-Pairing * -
Comau Patented
Safety according to standar EN ISO 13849-1 PL =d
PL =d, DC
awg
=95%,
MTTF
d
>100, CCF =75
Usage endurance illimited 5 hours (typical)
Battery charging time NA 2 hours (typical)
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3.3.4 Teach Pendant with cable connection (C5G-iTP), selecting
mode T1, AUTO and REMOTE
At the time of purchase it is necessary to choose a Station, including Teach Pendant
and medium.
The medium can be installed on the door or be delivered separately to allow the
customized installation by the line/cell control station (installation to be carried out by the
user). At the time of purchase the user shall specify if it shall be pre assembled on the
Unit Control door.
The Programming (T1), Local automatic (AUTO) and Remote automatic (REMOTE)
control mode selection may beperformed acting on the key selector switch available
on the terminal.
When only the Teach Pendant with cable is needed, it is possible to choose among the
versions listed below.
Moreover it is possible to install an additional extension, to be chosen among the models
specified below.
Tab. 3.4 - Teach Pendant with cable, selector switch for 3 modes,
supplied with medium: available station versions
Description Cable length Abbreviation Comau Code
Station C5G-iRT10 10 m (33 ft) C5G-iRT10 CR17431980
It includes: C5G-iTP Teach Pendant with inside-cabinet cable and connectors, C5G-iBK2 medium.
Tab. 3.5 - Teach Pendant with cable (no medium): available
versions
C5G-iTP Teach Pendant with cable
10 m (33 ft) C5G-iTP10 CR17910381
20 m (66 ft) C5G-iTP20 CR17910382
30 m (98 ft) C5G-iTP30 CR17910383
It includes: C5G-iTP Teach Pendant with cable.
Tab. 3.6 - Extension cable for Teach Pendant with cable:
available models
C5G-iTP cable extension iTP 10 m 10 m (33 ft) -- CR17241260
It includes: Cable extension with end male and female connectors
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3.3.5 Teach Pendant with cable connection (C5G-iTP2),
selecting mode T1 and REMOTE
At the time of purchase it is necessary to choose a Station, including Teach Pendant
and medium.
The medium can be installed on the door or be delivered separately to allow the
customized installation by the line/cell control station (installation to be carried out by the
user). At the time of purchase the user shall specify if it shall be pre assembled on the
Unit Control door.
The Programming (T1) and Remote automatico remoto (REMOTE) control mode
selection can be performed acting on the lever selector switch available on the
terminal.
When only the Programing terminal with cable is needed, it is possible to choose among
the versions listed below.
Moreover it is possible to install an additional extension, to be chosen among the models
specified below.
Tab. 3.7 - Teach Pendants with cable, selector switch for 2
modes, supplied with medium: available station
versions
It includes: C5G-iTP2 Teach Pendant with inside-cabinet cables and connectors, medium C5G-i BK2.
Tab. 3.8 - Teach Pendants with cables (no medium): available
models
Terminal C5G-iTP2 con cavo
10 m (33 ft) C5G-iTP210 CR17910581
20 m (66 ft) C5G-iTP220 CR17910582
30 m (98 ft) C5G-iTP230 CR17910583
It includes: C5G-iTP Teach Pendant with cableo.
Tab. 3.9 - Extension cable for Teach Pendant with cable:
available models
It includes: Cable extension with end male and female connectors
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3.3.6 Teach Pendant with wirel ess connecti on (C5G-WiTP)
At the time of purchase it is necessary to choose a C5G-WiWS Station, including Teach
Pendant and docking station.
The key selector switch is located on the docking station and it si possible to select
the Programming control (T1) mode, Local automatic (AUTO) and Remote automatic
(REMOTE).
When components are to be purchased separately (e.g. Teach Pendant) the user may
choose among the ones listed in the table below.
Tab. 3.10 - Teach Pendant without cable (wireless), equipped with
docking station: available station versions
Description Abbreviation Comau Code
Station C5G-WiWS C5G-WiWS CR17432280
It includes : C5G-WiTP wireless Teach Pendant, inside-cabinet cables and connectors, medium and docking
station C5G-WiDK5 on cabinet door, antenna
Tab. 3.11 - Single components: available versions
Description Abbreviation Comau Code
Wireless C5G-WiTP Teach Pendant C5G-WiTP CR17911380
C5G-WiDK5 Docking station for C5G-WiTP Teach
Pendant
C5G-WiDK5 CR17432180
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3.4 Connection cables between C5G and Robot
The connection cables between the C5G Control Unit and the Robot are connected from
one end by the cabinet base to another end by the Robot base, on the corresponding
connector panels respectively.
The cable supply kit includes the service, motor and earth cables. The cables are
fixed-laying-type and can be chosen depending on the installation required length and
the Robot family:
service cable, X10 connector by cabinet base, X1 by Robot base
motor cable, X60 connector by cabinet base, X2 by Robot base
earth cable, supplied with eyelet lug by the ends.
Tab. 3.12 - Cable kit to connect C5G and Robot: available
versions
Comau Code Description
For all Robot versions
CR18945880
Kit consisting of service, motor and earth cables.
Cable length 5 m (16 ft)
CR18945881
CR18945882
CR18945883
CR18945884
CR18945885
Overview of the connections to the C5G Control Unit
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4. OVERVIEW OF THE CONNECTIONS TO
THE C5G CONTROL UNIT
Overview of the C5G Control Unit connections
Summary of the Robot, positioning devices and auxiliary axes connections
Summary of the Line connections
Summary of the Application connections
Summary of the Programming and users interface on PC connections
To help the user to identify the functions of the main connectors:
Summary of connectors and corresponding function.
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4.1 Overview of the C5G Control Unit
connections
The C5G Control Unit connects and interface with:
Robot, positioning devices and auxiliary axes (A). Those connections allow to
control the Robot and the auxiliary axes.
Line (B). Through this connection, the Control Unit connects with the production
plant where the robot system is integrated.
Application (C). It allows to control the application connected with the Robot and
the related equipment or other items required by the integrator.
Programming and users interface on PC (D). It allows to program, control and
diagnose the robot system through the Teach Pendant and related software
supplied with it.

A - Robot, positioning
devices and auxiliary
axes
B - Line
C - Application
D - Programming and
users interface on
PC
The picture shows the main connections between the Control Unit and the peripherals
A
(Robots)
D
(Programming)
B
(Line)
Ethernet
Field Bus
from
X30
from
X10
X60
....
from
X93
....
C
(Applications)
Safety
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4.2 Robot, positioning devices and auxiliary
axes
The connection with the Robot, positioning devices and auxiliary axes is accomplished
through suitable connectors installed on the Connector Interface Panel (CIP) by the
C5G Control Unit base.
The typical configurations feature the following solutions:
C5G peripheral
Involved
connector
Description
Robot
X10
X60
the main Robot is connected through the Connection cables between
C5G and Robot with the X10 connector (Robot signals) and the X60
connector (Robot Power)
Positioning device
X10-EXT
X60-EXT
the positioning device (e.g. series SMART5 PTDV, PTDORB, other
ones) is connected through the Connection cables between C5G and
Robot (uses the same Robot cables exploiting only the necessary wires,
depending on the no. of available axes) with the X10-EXT connector
(Extension, Positioning device signals) and the X60-EXT connector
(Extension, motors and brakes of the positioning device)
Auxiliary axes
X61
X62
X63
X64
the single auxiliary axes (e.g. saddle on axis 7, electric gripper for spot
welding on axis 8, other ones) are connected through the Connection
cables between C5G and Robot, each one with only one connector that
includes both the power and the control signal, with the X61..X64
connectors (Signals and power for auxiliary Axes)
The X10, X60, X10-EXT, X60-EXT, X61..X63 connector pin structure is available in
the wiring diagram of the C5G Control Unit.
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4.2.1 X10 connector (Robot signals)
The X10 is a multipole connector that collects all Robot position control signals
(Encoders with EnDat 2.2 interface), for configurations featuring up to 6 axes.
The X10 is installed on the Connector Interface Panel (CIP) and connects to the X1
connector by the Robot base through the Connection cables between C5G and Robot.
Some I/O signal that can be used freely by the user are available on the Safety
Distribution Module (SDM) and through suitable options can be made available by the
Robot border area (on corresponding connectors on axis 3 or Robot wrist, depending on
the version). For further details refer to par. 9.3 Digital Inputs / Outputs, by the Robot
border area on page 157.
The High Speed Input (HSI) signals are available on the CPU, power supplies and
power modules and are at disposal by the Robot border area only after the installation
of the option C5G-HSK5: High Speed Input Kit (see par. 13.2.1 on page 248). As for the
pin structure and the connections by the Robot border area, refer to the Robot specific
manuals.
Fig. 4.1 - X10 connector: structure
A: Connector Interface Panel (CIP)
X10: Signal connector for the Robot
A
X10
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4.2.2 X60 connector (Robot Power)
The X60 is a multipole connector that collects all power signals of the Robot axes
(motor) and brakes, for configurations featuring up to 6 axes.
The X60 is installed on the Connector Interface Panel (CIP) and connects to the X2
connector by the Robot base through the Connection cables between C5G and Robot.
X60: Power connector for the Robot
A
X60
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4.2.3 X10-EXT connector (Extension, Positioning device
signals)
The X10-EXT is a multipole connector that collects all positioning device position control
signals (Encoders with EnDat 2.2 interface), with the possibility to connect 5 additional
axes in the most extended configuration. This connector and the corresponding
connection cable are available only if optional auxiliary axes are installed in the
configuration for the positioning device and is matched to the X60-EXT connector
(Extension, motors and brakes of the positioning device).
The X10-EXT is installed on a plate fastened on the Connector Interface Panel (CIP)
and connects to the X1 connector by the positioning device base through the
Connection cables between C5G and Robot.
In case of need, the plate features an area for the installation of an additional auxiliary
axis (refer to par. 4.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 46).
Fig. 4.3 - X10-EXT connector: structure
A: Area intended for the installation of the
plate with the auxiliary axes connectors
X10E: Control signal connector (Encoders)
X60E: X60-EXT connector (Extension, motors
and brakes of the positioning device) (see
par. 4.2.4 on page 45)
X61:Additional auxiliary axis installed
A
X60E X10E
X61
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4.2.4 X60-EXT connector (Extension, motors and brakes of the
positioning device)
The X60-EXT is a multipole connector that collects all power signals of the axes of the
positioning device (motors) and brakes, with the possibility to connect additional 5 axes
in the most extended configuration. This connector and the corresponding connection
cable are available only if optional auxiliary axes are installed in the configuration for the
positioning device and is matched to the X10-EXT connector (Extension, Positioning
device signals).
The X60-EXT connector is installed on the Connector Interface Panel (CIP) and
connects to the X2 connector by the positioning device base through the Connection
cables between C5G and Robot.
In case of need, the plate features an area for the installation of an additional auxiliary
axis (refer to par. 4.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 46).
Fig. 4.4 - X60-EXT connector: structure
plate with the auxiliary axes connectors
X60E: Motor and brake connector
X10E: X10-EXT connector (Extension,
Positioning device signals) (see par. 4.2.3 on
page 44)
X61: Additional auxiliary axis installed
A
X60E X10E
X61
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4.2.5 X61..X64 connectors (Signals and power for auxi liary
Axes)
The X61, X62, X63 or X64 are multipole connectors that collect the power, brake and
the position control signals (Encoders with EnDat 2.2 interface) of the auxiliary axes.
Those connectors and the corresponding cable are available only if optional auxiliary
axes are installed.
Each auxiliary axis is matched to a specific connector and the latter is polarized such as
to prevent connection errors; the axes and matching connectors are listed in the table
below:
The X61, X62, X63 or X64 connectors are installed on one or more plates fastened on
the Connector Interface Panel (CIP) and connect to the connector on the motor
switching case through the corresponding cables. Each plate can take up to 3
connectors.
Fin below some typical match examples:
X61..X63 connector in a solution featuring up to 3 axes: structure
X61 connector in a solution featuring 1 axis matched to X60-EXT and X10-EXT
already available: structure
Fig. 4.5 - X61..X63 connector in a solution featuring up to 3 axes:
structure
Tab. 4.1 - Axis-connector match
Auxiliary axis Matching connector
Axis 7
(usually saddle)
X61
Axis 8
(usually electric gripper)
X62
Axis 9 X63
Axis 10 X64
plate hosting the auxiliary axes connectors
X61:First auxiliary axis installed
X62: Second auxiliary axis installed
X63:Third auxiliary axis installed
Note: the picture shows an example featuring
3 connectors with consecutive abbreviation.
A
X61 X62
X63
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Fig. 4.6 - Polarization of connectors X61..X64
Fig. 4.7 - X61 connector in a solution featuring 1 axis matched to
X60-EXT and X10-EXT already available: structure
A: Area inteded for the installation of the plate
hosting the auxiliary axes connectors
X61..X64: connector possible configurations
plate hosting the auxiliary axes connectors
X61: First auxiliary axis installed
X60E: X60-EXT connector (Extension, motors
and brakes of the positioning device) (see
par. 4.2.4 on page 45)
X10E: X10-EXT connector (Extension,
Positioning device signals) (see par. 4.2.3 on
page 44)
The cables, connector polarization, the connections between X61..X64 and the
motors are dealt with in details in the instruction manuals of the auxiliary axes.
A X61 X62
X63
X61 X62 X63 X64
Axis 7 Axis 8 Axis 9 Axis 10
Pin
No
Pin
A
X60E X10E
X61
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4.3 Line
The connection with the line is accomplished through special connectors installed on the
Connector Interface Panel (CIP) by the C5G Control Unit base.
The typical configurations include the solutions described below.
Peripheral
connected to the
C5G
Involved
connector
Descripti on
Safety item X30
the safety signals (e.g. emergency stop, cell access door limit switch,
other ones) are available on the X30 connector (Safety items)
Host system --
the communication with the Host systems (e.g. line PLC) can be
controlled through field Bus (see Field Bus Modules on the X20
interface: principles (see par. 9.4.5 on page 167)).
Host system for
monitoring
(Ethernet)
ETH2 /
APC820
the communication with the Host systems (e.g. line PLC, factory
production control PC, analysis devices, other ones) can be controlled
through Ethernet connections (see ETH2 connector on AMS-APC820
(Ethernet) (see par. 4.3.2 on page 50))
Host system for
monitoring
(Serial)
COM2 /
APC820
the communication with the Host systems (e.g. line PLC, factory
production control PC, analysis devices, other ones) can be controlled
through the RS422 serial connection (see COM2 connector on
AMS-APC820 (RS422 serial) (see par. 4.3.3 on page 50)).
Also the RS232 serial connection is available.
Other connections
(e.g. net or serial
communication
cables output)
X90
The cables that do not features a specific optional connector by the
cabinet base and exit the Control Unit to reach the device on the line,
use the way provided by the I X90 cable gland connector.
X30
ETH2
COM2
X90
X20 modules
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4.3.1 X30 connector (Safety items)
The X30 is a multipole connector that collects all safety signals to and from the C5G
Control Unit. It is installed on the Connector Interface Panel (CIP).
To interface with the Control Unit, a movable connector equipped with cap and pins for
crimping connection is supplied as standard.
The safety signal are connected internally with the Safety Distribution Module (SDM)
and using special options it is possible to increase the no. and type of available signals.
The auxiliary signals will be available on other connectors (being defines).
X30: X30 connector
More details about the safety signals connection are to be found in par. 7.1 Safety
circuits: particulars about the E-Stop, Auto-Stop (Fence) and General Stop
signals on page 126.
A
X30
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4.3.2 ETH2 connector on AMS-APC820 (Ethernet)
The ETH2 is a RJ 45 connector that allows to connect the Ethernet network to a host
system. It is available on AMS-APC820 module.
Fig. 4.9 - ETH2 connector: structure
4.3.3 COM2 connector on AMS-APC820 (RS422 serial)
The COM2 is a tray-type 9-pin connector that allows the RS422 serial connection. It is
available on AMS-APC820 module.
On the same connector also the RS232 serial connection is available (refer to COM2
connector on AMS-APC820 (RS232 serial)).
Fig. 4.10 - COM2 connector: structure
A: ETH2 connector on AMS-APC820
Further details about the connection with the Ethernet network are available in
Chap. Ethernet network communication on page 221.
A: COM2 connector on AMS-APC820
Further details about the serial connection are available in par. 10.3 RS232 serial
connection cable to PC on page 219.
XD2
COM2 COM1
XD3
XD4
X3A
ETH1
ETH2 XD5
A
XD2
COM2 COM1
XD3
XD4
X3A
ETH1
ETH2 XD5
A
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4.3.4 X90 cable gland connector
The X90 is a multiple-way cable gland that represents the crossing point of the cables
of the Field Bus and/or Ethernet network/ serial connection or other cables that connect
directly on the internal connectors located on the specific modules. It is installed on the
Connector Interface Panel (CIP). The X90 connector is supplied as standard with the
Control Unit.
A movable connector with cap and rubber cable glands is supplied to allow the cable
passage while preserving the IP 54 protection category of the Control Unit.
X90: X90 connector
Further details about the Field Bus are available in par. 9.4.5 Field Bus Modules
on the X20 interface: principles on page 167.
The connections with Ethernet network are described in par. 4.3.2 ETH2
connector on AMS-APC820 (Ethernet) on page 50.
The connection with serial protocols are described in par. 4.3.3 COM2 connector
on AMS-APC820 (RS422 serial) on page 50.
A
X90
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4.4 Application
Under application we understand a set consisting of one or more tool or machine parts
connected to the Robot and/or used in the production process associated to the Robot,
typically integrated to obtain a homogeneous solution.
The typical configurations include the solutions described below.
Peripheral
connected to the
C5G
Involved
connector
Descripti on
I/O and safety
signal, on
connectors
X31
X32
the I/O, safety and powering signals directly available on the optional
X31..X32 connectors (Applications)
digital I/O for small
applications
X310/SDM
X311/SDM
X312/SDM
the I/O signals are available as standard on the Safety Distribution
Module (SDM) and described in par. 9.2 Internal Digital Inputs / Output,
on the SDM module on page 151
remote I/O
(C5G with
master role)
X93
X94
the communication with the systems (e.g. measurement devices,
remote I/O, other ones) can be controlled through Field Bus protocols
with X93..X94 connector (Master Field Bus) with X20 interface modules
COM2
X31..X32 X93..X94 X90
X20 modules
X310/SDM
X311/SDM
X312/SDM
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Analysis,
measurement
systems
(serial)
COM2 /
APC820
the communication with the systems (e.g. measurement systems, other
ones) can be controlled through the serial RS232 on COM2 connector
on AMS-APC820 (RS232 serial).
The serial connection RS422 is also available.
Other connections
(e.g. net or serial
communication
cables output)
X90
The cables that do not features a specific optional connector by the
cabinet base and exit the Control Unit to reach the device on the line,
use the way provided by the I X90 cable gland connector.
Other connections
(e.g. output for
electrode dresser
powering cables)
--
The powering cables can exit from the box base through the cable
glands (that are not part of the supply volume), which are to be fastened
to the 25,5 mm dinking holes (M25 cable glands) located on the central
panel.
Peripheral
connected to the
C5G
Involved
connector
Description
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4.4.1 X31..X32 connectors (Applications)
The X31..X32 is a multipolar connector that collects one or more solutions with digital
I/O, power supplies and safety signals. It is installed on the Connector Interface Panel
(CIP).
To interface with the Control Unit, a movable connector equipped with cap and pins for
crimping connection is supplied as standard.
The I/O signals are internally connected with the Ethernet POWERLINK bus and using
special options it is possible to increase the no. and type of available signals.
Fig. 4.12 - X31..X32 connector: structure
plate with the application connectors
X31: First application installed
X32: Second application installed
The options for the signal expansion are described in par. 9.4.9.4 Overview of
prearranged solutions related to the digital and analog I/O on page 197 (solutions
with connection on connector and terminal board)
A
X31 X32
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4.4.2 X93..X94 connector (Master Field Bus)
The connector for the Master Field Bus allows to connect the Field Bus between the
master module inside the Control Unit and the slave modules available on the tooling
and/or Robot border area.
The connector, matched to its specific cable, is a solution called Multibus, i.e. both the
field bus signal (Device Net or Profibus-DP) and the 24 Vdc power supply for the remote
slave modules are trasmitted through the same multipolar cable.
The connector is installed by the Control Unit base on the Connector Interface Panel
(CIP).
The X93 connector is matched to the first Master field Bus module while the X94 to the
second master module, if available.
Fig. 4.13 - X93..X94 connector: structure
X93: Multibus connector for the first Master
field Bus module
X94: Multibus for the second Master field Bus
module
Further details on the Field Bus are available in par. 9.4.5 Field Bus Modules on
the X20 interface: principles on page 167.
The usage, connector pin structure and connection cables examples are to be
found in the manuals of the corresponding application.
A
X93
X94
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4.4.3 COM2 connector on AMS-APC820 (RS232 serial)
The COM2 is a tray-type 9-pin connector that allow the RS232 serial connection. It is
available on AMS-APC820 module.
Also the RS422 serial connection is available (see COM2 connector on AMS-APC820
(RS422 serial)).
Fig. 4.14 - COM2 connector: structure
A: COM2 connector on AMS-APC820
Further details about the serial connection are available in par. 10.3 RS232 serial
connection cable to PC on page 219.
XD2
COM2 COM1
XD3
XD4
X3A
ETH1
ETH2 XD5
A
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4.5 Programming and users interface on PC
Programming and motion can be performed by means of theTeach Pendant (see par.
3.3 on page 32).
Program WinC5G offers a convenient interface to the Control Unit, to facilitate the
diagnostic, setting and other activities. WinC5G runs on Personal Computer (PC)
supporting Microsoft
Windows
operating system.

A - Teach Pendant
B - Personal
Computer
The usage modalities for the Teach Pendant and program WinC5G are described
in details in the Usage Manual of the Control Unit or in chapter Program WinC5G
Interface to the C5G on Personal Computer .
A B
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Die typical connections feature the solutions below.
Peripheral device
connected to the
C5G
Involved
connectors
Descripti on
PC via Ethernet
ETH2
Ethernet net connection for automation applications with Host systems.
Available as standard on Modulo AMS-APC820 (see par. 4.4 on
page 49) or Ethernet connector C5G-ETHK: Kit Ethernet (see par. 11.4
on page 220) as optional.
ETH
additional
Optional Ethernet net connection for programming.
Available with the option C5G-U2E: Adattatore USB to Ethernet (see
par. 11.5 on page 221).
USB storage
media
USB
XD:
XD2:
XD3:
Connection for USB storage media (e.g. C5G-FDU: Flash Disk USB
(see par. 14.2 on page 256).
Available as standard:
XD: on Modulo AMS-APC820 (see par. 4.4 on page 49)
XD2: on Operator Panel Devices (OPD).
Available with options:
XD3: on Operator Panel Devices (OPD) with option C5G-USBK: Kit
USB.
XD:
USB
ETH
ETH2
XD2:
XD3:
ETH
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4.6 Summary of connectors and corresponding
function
To facilitate the identification of the functions of the main Control Unit connectors, find
below the list in alphabetical order and the corresponding paragraph.
Tab. 4.2 - Summary of connectors
Connector /
Position
Typical function Description
COM2 /
APC820
Analysis,
measurement
systems
(via RS232 serial)
The communication with the systems (e.g. measurement systems, other
ones) can be controlled through the RS232 serial connection on COM2
connector on AMS-APC820 (RS232 serial).
COM2 /
APC820
Host systems for
monitoring
(via RS422 serial)
The communication with the Host systems (e.g. line PLC, factory
production controlling PC, analysis devices, other ones) can be
controlled through the RS422 serial connection (see COM2 connector
on AMS-APC820 (RS422 serial) (see par. 4.3.3 on page 50)).
ETH2 /
APC820
Host systems for
monitoring
(via Ethernet)
The communication with the Host systems (e.g. line PLC, factory
production controlling PC, analysis devices, other ones) can be
controlled through Ethernet connections (see ETH2 connector on
AMS-APC820 (Ethernet) (see par. 4.3.2 on page 50))
X10/CIP Robot
The main Robot is connected through the Connection cables between
C5G and Robot con I X10 connector (Robot signals)
X10-EXT/CIP Positioning device
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
Robot (it uses the same Robot cables, exploiting only the necessary
wires depending on the no. of axes available) with the X10-EXT
connector (Extension, Positioning device signals)
X30/CIP Safety items
The safety signals (e.g. emergency stop, cell access door limit switches,
other ones) are available on the X30 connector (Safety items)
X31/CIP
X32/CIP
wired I/O, on
connector
The I/O, safety and power supply signals are directly available on the
optional X31..X32 connectors (Applications)
wired I/O, on
module and terminal
board
The I/O signals are directly available on the optional X31..X32
connectors (Applications)
X60/CIP Robot
The main Robot is connected through the Connection cables between
C5G and Robot with the X60 connector (Robot Power)
X60-EXT/CIP Positioning device
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
Robot (it uses the same Robot cables, exploiting only the necessary
wires depending on the no. of axes available) with the X60-EXT
connector (Extension, motors and brakes of the positioning device)
X61/CIP
X62/CIP
X63/CIP
X64/CIP
Auxiliary axes
The single auxiliary axis (e.g. saddle on axis 7, electric gripper for spot
welding, other ones) are connected through the Connection cables
between C5G and Robot, each one with an only one connector that
includes both the power and the control signals, with the X61..X64
connectors (Signals and power for auxiliary Axes)
X90/CIP
Multiple cable
input/output
The cables can be connected inside the Control Unit through the X90
cable gland connector with no interruption
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X93/CIP
X94/CIP
Remote I/O
(C5G with master
role)
The communication with the systems (e.g. measurement systems,
remote I/O, other ones) can be controlled through Field Bus protocols
with X93..X94 connector (Master Field Bus)
X106/SDM
24 Vdc power
supply for users
applications
The 24Vdc powering is available according to the modalities specified in
par. 6.2 How to use the 24 Vdc in the users applications on page 120
X124/SDM
X126/SDM
X128/SDM
24Vdc power
supply and
emergency stop
signal
Dedicated connectors. They are used with the Control Unit options to
deliver 24Vdc powering and enable the emergency stop control.
X310/SDM
X311/SDM
X312/SDM
digital I/O for minor
applications
The I/O signals are available as standard on the Safety Distribution
Module (SDM) and decribed in par. 9.2 Internal Digital Inputs / Output,
on the SDM module on page 151
XD:
XD2:
XD3:
/ APC820 or
OPD
USB
Connection for USB storage systems (e.g. C5G-FDU: Flash Disk USB
(see par. 14.2 on page 256).
Available as standard:
XD: on Modulo AMS-APC820 (see par. 4.4 on page 49)
XD2: on Operator Panel Devices (OPD).
Available with options:
XD3: on Operator Panel Devices (OPD) with option C5G-USBK: Kit
USB.
Tab. 4.2 - Summary of connectors (Continued)
Connector /
Position
Typical function Description
Options
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5. OPTIONS
Information about the options installation
Options Circuit diagram
Opzions for the C5G Control Unit
5.1 Information about the options installation
The options purchased together with the C5G Control Unit are supplied already
installed.
If the options are purchased later, the installation instruction are to be found in the single
option installation manual.
5.2 Options Circuit diagram
The options circuit diagrams (available only for those ones where electric connections
are to be performed) are to be found in the Control Unit complete circuit diagram.
Due to the complexity of some options, some circuit diagrams may be supplied in a
separate document.
The option listed here can be installed and used solely for the C5G Contrl Unit.
All circuit diagrams are available in the CD-ROM supplied together with the C5G
Control Uni t. Refere al so to par. Reference documents a pag. 5.
Options
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5.3 Opzions for the C5G Control Unit
The C5G basic model can be integrated with additional options to better suit the
installation requirements. If not otherwise specified, such options can be choosen
among the available ones. Possible limits related to incompatibility or maximum
installable no. are clearly specified.
To facilitate the search, the options below are grouped according to the topic and
application field, while the details are to be found in the corresponsing chapters.
Available optioni
Field Bus
DeviceNet
Bus Coupler PFG-BCO module on X20 interface
C5G-DNM-DNMI: DeviceNet Master Interface
C5G-DNM-DNSI: DeviceNet Slave Interface
C5G-DNPC: movable connector for Devicenet modules
C5G-DMI: Multibus cable interface for Devicenet module
Profibus-DP
C5G-PFM-PDPM: Profibus-DP Master Interface
C5G-PFM-PDPS: Profibus-DP Slave Interface
C5G-PFPC: movable connector for Profibus-DP modules
C5G-PMI: Multibus cable interface for Profibus-DP module
Profinet
C5G-PNC: Profinet I/O Controller interface
C5G-PND: Profinet I/O Device interface
Profinet (protocol solution only)
Profinet I/O Device (software protocol)
I/O modules
optional movable connectors
C5G-UCK: user connector kit, for SDM module
on X20 interface
C5G-D12 - C5G-D24: Digital I/O options (12 I / 12 O or 24 I / 24 O)
C5G-AI2 - C5G-AO2, Analog I/O options (2 I or 2 O)
on multipole connector
C5G-EDI: Digital I/O external interface (24 I / 12 O)
Safety
C5G-PSB: PILZ safety Bus
Communication
C5G-ETHK: Ethernet kit
Options
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Installation customization
Structural items
C5G-AEB: Empty Box for application
C5G-APK1 kit Auxiliary Plate 1
C5G-HFK kit fastening hangers
C5G-OPK: Option Panel kit
C5G-RSK100: 100-mm rising socket kit
Services
C5G-ACO / C5G-ACBO: Conditioner
C5G-AFK: Auxiliary Fan Kit
C5G-ETHK: Ethernet kit
C5G-HMK: Hour-meter kit
C5G-MCK: Powering connector kit
C5G-USBK: USB kit
Special applications
C5G-HSK5: High Speed Input Kit
C5G-OTK: Axis Over Travel kit
C5G-SMK: Signal Machine Kit
C5G-TDC400: 400V Tip Dresser Command kit
C5G-TDC400-2: 400V Double Tip Dresser Command kit
C5G-TDS400: 400V Tip Dresser Supply kit
Fittings
C5G-FDU: Flash Disk USB
Software
The software options are listed in the Control Unit Usage Modalities manual.
Available optioni
Original instructions
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
comau.com/robotics

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