R1C-4 Control

Unit
Rel. 0

Technical Specifications,
Transport and Installation,
Maintenance

Description and general features

Guide to the model selection
Description of the expandability towards the I/O
signals,
the communication networks, the safeties
Description and order part numbers of the options
Indications and procedures for the installation and
the first power up

CR00757975-en_00/2016.06

Instruction handbook
The contents of this handbook are the property of COMAU S.p.A.

Any reproduction, even partial, is prohibited without prior written authorization from COMAU S.p.A.

COMAU reserves the right to modify, without notice, the features of the product presented in this handbook.

Copyright © 2008-2016 by COMAU - Published on 07/2016

 Comau Robotics Product Instruction

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contents of the Control Unit handbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Fundamental Requirements Applied and Respected . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. CONTROL UNIT TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Introduction to the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
In Compliance with the standards in force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Declaration of incorporation of partly completed machinery. . . . . . . . . . . . . . . . . . . . . . . . .24
Name and address of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Safeties management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety solutions adopted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Robotic system configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Unit technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connections available on the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
IEC C20 Connector (electrical power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
X10 Connector (Robot signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
X60 Connector (Robot power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
X30 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Further details about the stop circuit signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
X55 Connector (Robot Input / Output ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
I/O mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
I/O connection on X55 Connector principle wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . .42
X124 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ETH Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3
Comau Robotics Product Instruction

SUMMARY

Motor cables and encoder between Control Unit and Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Services cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
R1C-UIO (R1C User Input Output). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
I/O mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Options for communication on ProfiNet / EthernetIP Field Bus . . . . . . . . . . . . . . . . . . . . . . . 58
R1C-EFB: Ethernet Field Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Bus Coupler PFG-BCO module on X20 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Bus Coupler Module Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Bus Coupler module address for the X20 interface modules . . . . . . . . . . . . . . . . . . . . . .62
Minimum requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Technical features and purchase Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Configuration of the Bus Coupler module in the System . . . . . . . . . . . . . . . . . . . . . . . . .64
Technical Features of the Power Supply Unit X20 PS9400 . . . . . . . . . . . . . . . . . . . . . . .64
C5G-PND: Profinet I/O device interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
C5G-EtherNetIP adapter Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Options for communication on Profibus Field Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R1C-PFB: Profibus Field Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
C5G-PFM-PDPS: Profibus-DP Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
C5G-PFPC: ProFibus Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Options for communication on CAN-bus or Devicenet Field Bus. . . . . . . . . . . . . . . . . . . . . . 75
R1C-CFB: Can Field Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
C5G-DNM-DNSI: DeviceNet Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
X20-CANopen slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
R1C-DNPC: DeviceNet Mate Connector Master or Slave . . . . . . . . . . . . . . . . . . . . . . . . . .81
R1C-CTKH: Conveyor Tracking Kit Hiperface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
C5G-FDU: Flash Disk USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
C5G-TP5 Teach Pendant with specific adapter for connecting to R1C-4 Control Unit . . . . . 87
C5G-TP5: technical features of the Teach Pendants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
R1C-4 TP5 - Connection adapter cable (CR17233255). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
C5G-TP5Exx: Extension Cable for Teach Pendant C5G-TP5 . . . . . . . . . . . . . . . . . . . . . . . . 90
C5G-FPB: Free Position Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3. TRANSPORT AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..92

Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Staff in charge of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Storage environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Control Unit transporting and carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Control Unit dimensions and weights (with packaging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Control Unit installation dimensions, weights and spaces (without packaging) . . . . . . . . . . . 96
Lifting and carrying methodologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Packaging removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Control Unit installation and connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Control Unit positioning inside the RACK cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Mains electrical power supply: features and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Precautions before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

4
 Comau Robotics Product Instruction

SUMMARY

Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Power supply plug wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Safety circuits: minimum principles for integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Precautions before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
X30 Connector wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Safety signals: principle electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Troubleshooting for safety signals caused by inadequate mechanical installations of safety
devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Teach Pendant connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Suggestions for completion of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
The first power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...111
General requirements for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Precautions during the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Precautions at the end of the maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Tightening torques of the screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Assistance for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Problem analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Diagnostic messages and alarm reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Comau service center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
How to disconnect the electrical power supply on the Control Unit . . . . . . . . . . . . . . . . . . . . . 116
Precautions and risks associated with the electrical power supply disconnection . . . . . . . . 116
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
How to access the modules inside the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Maintenance structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Summary diagram of the maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Preventive maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
E110: fan cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Special maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Connection of the PC to the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Identification of the IP address of the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Connection of the PC via Ethernet cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Access to Web pages in the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Components subject to special maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
APC: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
System configuration with TP5 Teach pendant, with CFast recovery . . . . . . . . . . . . . . . .135
System configuration with TP5 Teach pendant, with new CFast . . . . . . . . . . . . . . . . . . . .140

5
Comau Robotics Product Instruction

SUMMARY

CFast: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

System Configuration with the TP5 Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Line filter: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
OPS: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Braking resistor: replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
X20 Input / Output: module replacement (or power supply). . . . . . . . . . . . . . . . . . . . . . . . . 158
X20 Input / Output Safe: module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Safe-key: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
X20 SLU: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Teach Pendant: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Control Unit: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Precautions regarding the spare parts usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Where to find the spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Staff in Charge of decommissioning and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Procedure for disassembly, decommissioning and dismantling the Robotic system . . . . . . 181

6
 Comau Robotics Product Instruction

PREFACE

PREFACE
This chapter deals with the following topics:
– Reference documentation
– Contents of the Control Unit handbooks
– Documents storage
– Limits on the handbook contents
– Symbols used in the handbook
– Modification History.

Reference documentation
This document refers to the R1C-4 Control Unit.
The complete set of R1C-4 handbooks consists of:

Comau R1C-4 Control Unit – Technical Specifications, Transport and

Installation, Maintenance
– Use of R1C-4 Control Unit

Electrical circuit – R1C-4 electrical circuit diagram

diagram

These handbooks must be integrated with the following documents:

Comau Robot matched*¹ – Technical Specifications, Transport and

Installation
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion programming
Applications – Depending on the type of application
required.

*¹ depending on the model of Robot matched with the Control Unit.

The handbooks mentioned above shall be maintained intact for as long as the Robotic
System is installed and operational, and must always be available to the personnel
working on the Robotic System.

7
Comau Robotics Product Instruction

PREFACE

Contents of the Control Unit handbooks

Device Handbook Contents
R1C-4 Control – Technical – Description and general characteristics of the Control Unit
Unit Specifications, – Guide to choice the Control Unit model
Transport and – General description of the expandability towards the I/O
Installation, signals, communication networks, safeties
Maintenance – Description and purchase part numbers of the Control Unit
and options.
– Information on preparations and prearrangements needed for
the Control Unit installation.
– Dimensions and weights, transport and lifting methods
– Procedures for internal components and options adjustment
to the power supply network
– Procedure for connection to the electric power supply
– Preliminary procedures for the Control Unit startup
– Electrical circuit diagram

Documents storage
All the provided documents shall be placed nearby the Robotic System, kept available
for all the persons that work on it and shall be maintained intact for the entire operating
life of the Robotic System.

Limits on the handbook contents

Figures inserted in the instructions handbook have the purpose to represent the product
and can differ from what actually visible on the Robotic System.

8
 Comau Robotics Product Instruction

PREFACE

Symbols used in the handbook

Here are the symbols that represent: WARNINGS, CAUTION and NOTES and their
meaning

This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the staff.

This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause equipment damage.

The symbol indicates operating procedures, technical information and precautions that
must be underlined.

The symbol draws the attention to materials disposal that is regulated by the WEEE
Directive.

The symbol points out to avoid environmental contamination and to properly dismiss the
materials in the appropriate collection sites.

9
Comau Robotics Product Instruction

MODIFICATION HISTORY

Modification History
The following table shows the history of the Handbook release, with related changes /
improvements made.

Edition of the
Date Contents
Handbook

10
 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.

This chapter deals with the following topics:

– Responsibilities
– Safety Requirements.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robotic System (Robot
and Control Unit) is 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 necessary protection and safety devices, the issuing of declaration of
conformity and any EC marking of the system are the responsibility of the
Integrator.

– COMAU refuses any responsibility for accidents caused by incorrect or improper

use of the Robotic System (Robot and Control Unit), by tampering with circuits,
components, software and with the use of spare parts that are not included in the
spare parts list.
– The application of these Safety Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic System (Robot and Control Unit)
in force in the Country where the system is installed.
– The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic System (Robot and
Control Unit).

The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.

11
Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1.1.1 Safety Fundamental Requirements Applied and

Respected
The robotic system is composed of Control Unit and Robot series SMART 5 considers
as applied and respected the following Safety Fundamental Requirements, Annex 1 of
Directive on Machinery 2006/42/CE: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 – 1.2.5
– 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 – 1.5.10 –
1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
In case it is provided only the Robot series SMART 5 are to be considered as applied
the following requirements: 1.1.3 – 1.1.5 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4
– 1.5.6 – 1.5.8 – 1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2
– 1.7.4.

1.2 Safety Requirements

1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.

1.2.2 Definitions
Robotic System (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.

Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.

Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.

Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.

Installation and Startup

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.

Functioning in Programming Mode

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual movement of Robot axes and programming
of work cycles at low speed, programmed cycle testing at low speed and, when allowed,

12
 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

at working speed.

Functioning in Auto / Remote Mode

Operating mode in which the Robot autonomously executes the programmed cycle at
work speed, with the operators outside the protected area, with the protection barriers
closed and included in the safety circuit, with local (located outside the protected area)
or remote start/stop.

Maintenance and Repair

Maintenance and repair are activities that involve periodical checking and / or
replacement of Robot and Control System (mechanical, electrical, software) parts or
components, and trouble shooting, that ends when the Robot and Control System has
been reset to its original project functional conditions.

Decommissioning and Dismantling

Decommissioning 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 Robot and Control System
installation and startup.

Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.

Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.

1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup
– Functioning in Programming Mode
– Functioning in Auto / Remote Mode
– Robot Axes Brake Release (if present)
– Maintenance and Repair
– Decommissioning and Dismantling.

13
Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1.2.4 Operating Modes

Installation and Startup
– The startup is only possible when the Robot and Control System has been correctly
and completely installed.
– The system installation and startup is exclusively the task of the authorised
personnel.
– The system installation and startup is only permitted exclusively inside a protected
area of an adequate size to house the Robot and the equipment it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that in
normal Robot movement conditions there is no collision with parts inside the
protected area ( e.g structural columns, power supply lines, etc.) or with the
barriers. If necessary, limit the Robot work area using mechanical hard stop (see
optional units).
– Any fixed Robot control stations must be located outside the protected area and in
a point such as to permit a full view of the Robot movements.
– The Robot installation area must be as free as possible from materials that could
impede or limit the visibility.
– During installation the Robot and the Control Unit must 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.
– Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torque indicated in the product Technical Documentation.
– If present, remove the fixing brackets of the axes and verify the proper fixing of the
equipment the Robot is outfitted with.
– Check that the Robot guards are correctly fixed and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit should not be
used as part of the fencing.
– Check that the voltage value of the power mains is consistent with that indicated
on the nameplate of the Control Unit.
– Before electrically connect the Control Unit, check that the circuit breaker on the
power mains is locked in open position.
– Connection between the Control Unit and the supply mains at the works, is to be
with a cable dimensioned appropriately for the power installed on the Control Unit
(for further details see the Control Unit “Transport and Installation” manual).
– Connect the ground cable (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the ground cable to the circuit
breaker on the power mains line, after checking with a tester that the circuit breaker
terminals are not powered. It is recommended to connect the cable armouring to
the earth.
– Connect the signals and power cables between the Control Unit and the Robot.

14
 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– Connect the Robot to earth through the Control Unit or by means of specific ground
terminal blocks, depending on the predispositions available on the Robot and/or on
the Control Unit.
– If present, check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors may cause permanent damage to the
Control Unit components.
– The Control Unit manages internally the main safety interlocks (gates, enabling
pushbuttons, etc.). Connect the 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 (emergency stop, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.

In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed in case of interlocks erroneous,

incomplete or missing execution.
– 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 mode; in Programming mode the power is disabled
immediately.
– When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.

If present, on the Control Unit, make sure that the setting of the stop circuit timer
is consistent with the type of Robot connected (for further details see the Control Unit
“Transport and Installation” manual)

– Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
– The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.

15
Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– To load or update the system software (for example after boards replacing), use
only the original software handed over by COMAU. Scrupulously follow the system
software loading procedure described in the Technical Documentation supplied
with the specific product. After loading, always make some Robot moving tests at
low speed remaining outside the protected area.
– Check that the barriers of the protected area are correctly positioned.

Functioning in Programming Mode

– The programming of the Robot is exclusively the task of the authorized personnel.
– Before starting to program, the operator must check the Robotic System (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
– The programming should be controlled from outside the protected area whenever
possible.
– 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 Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
– During the programming phases, only the operator with the Teach Pendant 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) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
– When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
– When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on a inclined 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 low speed has been carried out. The
test must be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: 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.

16
 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.

Functioning in Auto / Remote Mode

– The activation of the automatic operation (AUTO and REMOTE states) is permitted
only with the Robotic System (Robot and Control Unit) integrated inside an area
with protection barriers properly interlocked, as required by the Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator must check the Robot and Control
System and the protected area to make sure there are no potentially dangerous
irregular conditions.
– The operator can activate automatic operation only after having checked:
• that the Robot and Control System is not in maintenance or repair status;
• that the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the appropriate key;
• that the safety devices (emergency stop, protection barrier safety devices)
are functioning;
– Special attention is to be paid when selecting the remote mode, in which the line
PLC can perform automatic operations of motors power up and program starting.

Robot Axes Brake Release (if present)

– In the absence of motive power, the Robot axes repositioning is possible by means
of optional brake release devices and suitable lifting devices. Such devices only
allow the brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enabling push-button) are disabled; also the
Robot axes can move upwards or downwards because of the forces generated by
the balancing system or by the gravity force.

Before using the manual brake release devices, it is recommended to sling the Robot,
or hook it to an overhead travelling crane.

– The use of brake releasing device may cause the axes falling due to gravity, as well
as possible impacts due to an incorrect reset, 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
handbooks.

17
Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– When after the interruption of an unfinished MOVE the motion is enabled again, the
typical function of trajectory recuperation may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next restart of the
automatic cycle. Avoid moving the Robot in positions that are distant from the ones
required for the motion restarting; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repair

– When assembled in COMAU the Robot is supplied with lubricants that do not
contain any harmful to health substances, however, in some cases, repeated and
prolonged exposure to the product may cause skin irritation, or if swallowed,
sickness.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
– Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
– When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
– Maintenance and components or Control Unit replacement operations must 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 deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Defective components must be replaced with others having the same Part
Number, or equivalent components defined by COMAU.

If present, the safety components, in case of replacement, must be configured using the
same parameters of the components just removed.

– Trouble-shooting and maintenance activities must be carried out, whenever

possible, outside the protected area.
– Trouble-shooting executed on the control is to be carried out, whenever 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 must be observed
when operating in presence of dangerous voltages.
– Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).

18
 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– Maintenance, repair and trouble-shooting operations must be concluded with the

check of the correct functioning of the Robotic System (Robot and Control Unit)
and all the safety devices, executed from outside the protected area.
– During the software loading phases (for example after replacement of electronic
boards) use only the original software handed over by COMAU. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
– Disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in any direction: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
– If present, always restore the protective covering where previously installed.

Decommissioning and Dismantling

– The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
– Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
– Before decommissioning initiation, the mains voltage at the Control Unit inlet must
be powered off (switch off the circuit breaker on the power mains 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 power mains,
first disconnecting the power conductors, then the earth one. 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 ground cable.
– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
– Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU, 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 environment
safeguarding.

Disposal operations must be carried out in accordance with the legislation of the country
where the Robot System is installed; dispose the batteries, oils and other chemical
liquids respecting the environment and in accordance with the legislative standarts in
force, transfering them to the appropriate waste collection sites.

– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

19
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2. CONTROL UNIT TECHNICAL

SPECIFICATIONS
This chapter deals with following topics:
– Introduction to the Control Unit
– Robotic system configuration
– Control Unit technical features
– Connections available on the Control Unit
– Motor cables and encoder between Control Unit and Robot
– Options

20
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.1 Introduction to the Control Unit

R1C-4 Control Unit is an industrial equipment designed for simplified, efficient and
multifunctional management of the low payload Comau Robot.

R1C-4 Control Unit

– It has been designed and manufactured in order to allow the installation inside a
RACK cabinet.
– Is powered directly from the plant mains with voltage of 230 Vac ±10%
single-phase.
– It can manage up to 4 interpolated axis, equipped with brushless synchronous
motors and high resolution position transducer of Encoder type with EnDat 2.2
interface.
– Can be interfaced through the most common communication interfaces as well as
with the most common Field Bus and communication protocols (DeviceNet,
Profibus-DP, EtherNet/IP, etc.). It can become an Ethernet network node on the
plant network to facilitate remote updates and diagnostics.
– Options are available to allow the customization of the Control Unit (see par. 2.6
Options on page 53)

21
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.1.1 Safety
– In Compliance with the standards in force
– Directives and standards
– Declaration of incorporation of partly completed machinery
– Name and address of the manufacturer
– Safeties management
– Safety solutions adopted.

2.1.1.1 In Compliance with the standards in force

The R1C-4 Control Unit consists of a functional area specifically designed to fulfill the
safety requirements demanded by the legislation in force:
– In compliance with EN ISO 10218-1 standard: the Robot Control Unit to be used
with the Comau Robots has been developed to fulfil the standards requirements
and facilitate the controller integration.
– Safe stopping circuits: the emergency stop command, also available as a
connection outside the Control Unit, ensures a safe stop of the Comau Robot
matched with it.
– Safe motion control circuits: the motion is issued and controlled by the Control
Unit, that ensures its correct execution and accomplishment. 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,
immediate stop shall act promptly.
– Safety circuits category: all safety circuits inside the Control Unit are in
compliance withthe EN ISO 13849-1 standard (PL = d, DCawg = 95%,
MTTFd > 100, CCF = 75), assimilable to the category 3.
– In compliance with the European Directives: Machine Directive,
Electromagnetic Compatibility Directive (EMC), Low Voltage Directive and
Directives for the environmental protection. The Control Unit matched to a
Comau Robot is a “partly completed machinery” (according to the definition in the
Machinery Directive 2006/42/EC, item 2 paragraph g). The Compliances with the
directives are described in details in par. 2.1.1.3 Declaration of incorporation of
partly completed machinery on page 24.

22
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.1.1.2 Directives and standards

The R1C-4 Control Unit was designed and developed in accordance with the directives
and standards listed in the Tab. 2.1.

Tab. 2.1 - Applied directives and standards

Directive / Standard Description and Applicability

2006/42/EC DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THECOUNCIL
of 17 May 2006 on machinery and amending directive 95/16/EC (recast) (for the sake of
brevity referred to as Machine Directive)
2006/95/EC DIRECTIVE 2006/95/EC OF THE EUROPEAN PARLIAMENT AND OF THECOUNCIL
of 12 December 2006 on the harmonisation of the laws of MemberStates relating to
electrical equipment designed for use within certain voltagelimits (for the sake of brevity
referred to as Low voltage Directive)
2004/108/EC DIRECTIVE 2004/108/EC OF THE EUROPEAN PARLIAMENT AND OF THECOUNCIL
of 15 December 2004 on the harmonisation 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)
2002/95/EC DIRECTIVE 2002/95/EC OF THE EUROPEAN PARLIAMENT AND OF THECOUNCIL
of 27 January 2003 on the restriction of the use of certain dangerous 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

23
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.1.1.3 Declaration of incorporation of partly completed machinery

The assembly consisting of the R1C-4 Control Unit and the matched Comau Robot is
supplied with the declaration of incorporation of partly completed machinery, as set
out in Annex II b. of Directive 2006/42/EC.

It is forbidden to startup the assembly consisting of the Control Unit and the matched
Comau Robot before the machinery in which it will be incorporated has been declared
in compliance with the provisions stated in the 2006/42/EC Machinery Directive.

The Declaration of incorporation of partly completed machinery is supplied in

original copy with the assembly consisting of the R1C-4 Control Unit and Comau Robot
matched with it.
The Control Unit identification plate is installed on the side of the electrical cabinet.

Fig. 2.1 - The identification plate of the Control Unit (facsimile)

COMAU S.p.A.
Via Rivalta 30
10095 Grugliasco (TO), Italy

A xxxx xx
B xxxxxxxx
C

D xx xx
E xxx
xx xx

– A: Machine name and release

– B: Product Part No.
– C: The date of issue and the serial number
– D: Weight
– E: Electrical power supply features

2.1.1.4 Name and address of the manufacturer

As defined by the Machinery Directive, the manufacturer is:

COMAU S.p.A.
Via Rivalta, 30
10095 Grugliasco (TO) - ITALY

24
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.1.2 Safeties management

The R1C-4 Control Unit integrates the management circuits and base interlockings
required to manage a cell.
This solution represents a simplification for the integrator since the Control Unit has a
dedicated connector usable for the bidirectional connection of safety signals from and
towards the cell (E-stop, gates, etc.).
The stopping category (in compliance with standard EN 60204-1) is 0 (zero) in
Programming (T1) mode and 1 in Local automatic (AUTO) mode and Remote automatic
(REMOTE) mode

2.1.2.1 Safety solutions adopted

The safety circuit and the connections for the external devices allow the compliance with
the standard EN ISO 13849-1 (see par. 2.1.1.1).
Below are given the adopted solutions to guarantee the operators’ safety:
– Emergency stop push-button
The red mushroom-shaped push-button for the emergency stop 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 deceleration ramp, conform to
category 1, in compliance with the standard EN 60204-1.
– Enabling Device Push-button
On the Teach Pendant there is a three-positions Enabling Device with hardware
control. By pressing the enabling device, power is delivered to the motor drivers
and the Robot movements are enabled in programming operating mode. The
enabling device is active only in programming mode and disabled in other machine
modes.
– Managing of the cell access gates
The contacts of the limit switches installed on the cell access gates can be
connected to the safety circuit in order to control the Robot stopping in automatic
operating mode. In programming mode, these contacts are cut off to allow the
Robot motion with open gates.

2.1.3 Control modes

The assembly consisting of the R1C-4 Control Unit and the Comau Robot matched with
it, features 3 control modes. The control modes can be selected using the key selector
switch located on the Teach Pendant.
– Programming (T1)
Used for moving the Robot at low speed.
The operator may remain inside the cell. The Robot movements are accomplished
at reduced speed, reaching maximum 250 mm/s at the flange centre. The Robot is
directly controlled by the operator. Movements and program running at reduced
speed are allowed.

25
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

– Local automatic (AUTO)

Used to run working programmes in automatic mode with gates closed and at set
speed, triggered by the Teach Pendant.
– Remote automatic (REMOTE)
Used to run programs in automatic mode with gates closed and at set speed,
triggered by external devices commands (PLC, others).

26
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.2 Robotic system configuration

The R1C-4 Control Unit shall be matched with COMAU Robot Rebel-S series only.

The Robotic System is mainly composed of:

– R1C-4 Control Unit (installed inside the RACK cabinet, the responsibility of the
User)
– COMAU Robot
– TP5 Teach Pendant (optional)
– Interface on Personal Computer

In order to ensure the proper functioning of the robotic system, are required at least the
electrical power supply connections to the Control Unit, motor cables and encoder
connection between the Control Unit and Robot, safety signals connection from and
towards the line.
The R1C-4 Control Unit to manually move the Robot, create, modify and run programs,
change stepping movements, provide control and system monitoring functions, it
involves the use of the Teach Pendant (TP5) or Virtual TP5 interface on Personal
Computer.

If there is no a Teach Pendant, it must be inserted on the x124 connector of the R1C-4
Control Unit, the mating connector with cap functions for closing six emergency signals.

27
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Fig. 2.2 - Main connections of the Robotic system

230 Vac

D
A TP5
(optional)
C

Interface
Safety Virtual TP5
R1C-4 B

Robot Rebel

Robot motor and encoder cable

Typical Robot representative image

Ref. Description
A R1C-4 Control Unit
B Comau Robot matched
C Bypass circuit X124 connector
TP5 Teach Pendant (optional) with specific adapter for
D
connecting to R1C-4 Control Unit
E Teach Pendant Interface (virtual TP5) on Personal Computer

28
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.3 Control Unit technical features

In the following Tab. 2.2 are given the main technical features of the R1C-4 Control Unit.

Tab. 2.2 - General technical features

R1C-4 Control Unit CR17931882

Dimensions
266 x 427 x 498 mm
Height x Width x Depth (basic version without options)
10.47 x 16.81 x 19.60 in
Weight
Control Unit (standard version)
The weight indicated may differ minimally depending on the 19 kg / 42 lb without packaging
configuration. Always refer to the nameplate posted on the Control Unit
Power Supply Data
Power supply voltage
(according to EN 60204-1 § 4.3.3 standard, voltage interruption not 230 Vac ± 10%
exceeding 20 ms)
Frequency
50 to 60 Hz (±2 Hz)
(according to EN 60204-1 § 4.3.3 standard)
Main switch rated current 16 A to 250 Vac
Note: the supply disconnecting device is a switch-disconnector
Power installed 3 KW
Auxiliary circuits voltage 24 Vdc
Environmental conditions
Cabinet protection
IP 2x
(according to EN 60529 standard)

Environment temperature without cooling systems from +5 °C to +45 °C

Test conditions according to EN 60068-2-14 standard) from +41 °F to 113 °F
from -25 °C to +55 °C
Environment storage temperature
from -13 °F to 131 °F
(according to EN 60204-1 § 4.5 standard)
+70 °C / 158 °F for periods shorter than one hour.
1,5 °C/minute
Maximum temperature gradient
2,7 °F/minute
Relative humidity from 5% to 95% without condensate
(according to EN 60204-1 § 4.4.4, test conditions HD 323.2.3. S2)

Altitude of the installation site from 0 to 1.000 m / 0 to 3280 ft

(according to EN 60204-1 § 4.4.5 standard) above sea level
Controllable axes
Total of the system up to 4 axes
Cooling
Cabin Forced air recirculation (with exhaust fan)
Drive command Forced air recirculation
Vibrations and shocks during transportation
Frequency 10 - 250 Hz
Sinusoidal vibration
0.6 g rms axis Z acceleration
(according to EN 60068-2-64 standard)
0.2 g rms axes X-Y acceleration

29
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Tab. 2.2 - General technical features (Continued)

R1C-4 Control Unit CR17931882

Colour
Cabinet body, varnished parts RAL 7024
Installation requirements
Installation position Inside the RACK cabinet
Internal minimum dimensions of the RACK cabinet 483 x 600 x 265.9 mm
(width x depth x height) 19 x 23.62 x 10.47 in
Space occupied on RACK cabinet 6 Units
Number of RACK Units to be placed between 2 Control
Units in case of simultaneous installation in the same Minimum 1 Unit
cabinet

30
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4 Connections available on the Control Unit

The Control Unit is equipped with front connectors panel, in order to allow an easy and
manageable connection of the cables, even with the Control Unit already installed inside
the RACK cabinet.
In the following Fig. 2.3 and Tab. 2.3 is illustrated the connectors panel of the Control
Unit, with a brief description of the connectors functionality.

Fig. 2.3 - Connectors panel: overview

Tab. 2.3 - Connectors description

Connector Description For details see
Connectors available as standard
IEC C20 Connector for electrical power supply connection par. 2.4.1
X10 Multipolar connector for Robot position control signals par. 2.4.2
X60 Multipolar connector for power signals of the Robot axes (motors) par. 2.4.3
X30 Interface connector of safety signals par. 2.4.4
X55 Multipolar connector for Robot I/O par. 2.4.5
Multipolar connector for connection to TP5 Teach Pendant (optional) via par. 2.4.6
X124
specific adapter.
The RJ45 connector that allows the Ethernet network connection to a host par. 2.4.7
ETH
system
USB type-A connector for USB supports connection (e.g. C5G-FDU: Flash par. 2.4.8
USB
Disk USB)
J5 Glass fuse 6.3x32 UL 250V 5A
X89 Not used ---
X94 Precut for M23 circular connector ---
AP Reserved connector ---

31
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Tab. 2.3 - Connectors description (Continued)

Connector Description For details see
Optional connectors
Connector for additional I/O (available only after installing the option R1C-UIO par. 2.6.3
X31
(R1C User Input Output))
X69 Connectors for Conveyor Tracking (available only after installing the option par. 2.6.7
X70 R1C-CTKH: Conveyor Tracking Kit Hiperface)
X93 Connectors for ProfiNet / EthernetIP Field Bus (available only after installing par. 2.6.4.1
X95 the option R1C-EFB: Ethernet Field Bus)
Connector for Profibus Field Bus (available only after installing the option par. 2.6.5.1
X96
R1C-PFB: Profibus Field Bus)
Connector for Can Bus and Devicenet Field Bus (available only after installing par. 2.6.6.1
X97*¹
the option R1C-CFB: Can Field Bus)
*¹ Connector adhesive code, included in the option R1C-CFB: Can Field Bus and present only in case of
installation of the option.

32
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.1 IEC C20 Connector (electrical power supply)

IEC C20 male connector installed on the Control Unit allows the quick and immediate
connection to the power supply coming from the plant.
IEC C19 female connector (Part No. CR19190080) to be matched, is included in the
supply and must be wired by the User at the time of Control Unit installation.

Fig. 2.4 - Electrical power supply connection: overview

A: IEC C20 male connector (installed as

standard on the Control Unit)
A B: IEC C19 female connector (supplied with
the Control Unit, to be wired by the User)

33
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.2 X10 Connector (Robot signals)

The X10 connector is a D-Sub 37 pins multipolar female connector that collects all the
Robot position control signals.
The connection of the control signals must be carried out directly on the Robot's motors
entering with the encoder cable through the X1 cable gland connector on Robot base.

Fig. 2.5 - X10 Connector: overview

A: X10 connector (Robot signals)

A

Tab. 2.4 - X10 Connector: pinout

Connector Pinout
Axis 1 Axis 3
– PIN 20: Up – PIN 13: Up
– PIN 21: 0 V – PIN 14: 0 V
– PIN 22: CLK+ – PIN 15: CLK+
– PIN 23: CLK- – PIN 16: CLK-
– PIN 24: Data+ – PIN 17: Data+
– PIN 25: Data- – PIN 18: Data-

Axis 2 Axis 4
– PIN 26: Up – PIN 1: Up
– PIN 27: 0 V – PIN 2: 0 V
– PIN 28: CLK+ – PIN 3: CLK+
– PIN 29: CLK- – PIN 4: CLK-
– PIN 30: Data+ – PIN 5: Data+
X10 Connector: front view – PIN 31: Data- – PIN 6: Data-
– PIN 19: GND

34
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.3 X60 Connector (Robot power)

The X60 connector is a 24 pins multipolar female connector that collects all the power
signals of the Robot axes (motors) and brakes.
The connection of the power signals and brakes must be carried out directly on the
Robot's motors entering with the motor cable through the X2 cable gland connector on
Robot base.

Fig. 2.6 - X60 Connector: overview

A: X60 Connector (Robot Power)

Tab. 2.5 - X60 Connector: pinout

Connector Pinout
– PIN 1: M4 - U – PIN 13: M1 - U
– PIN 2: M4 - V – PIN 14: M1 - V
– PIN 3: M4 - W – PIN 15: M1 - W
– PIN 4: BK + – PIN 16: +24V DC
– PIN 5: – PIN 17: M2 - U
– PIN 6: – PIN 18: M2 - V
– PIN 7: BK - – PIN 19: M2 - W
– PIN 8: LAMP - – PIN 20: GND ax. 1-2
– PIN 9: M3 - U – PIN 24: GND ax. 3-4
– PIN 10: M3 - V
– PIN 11: M3 - W
– PIN 12: LAMP +

X60 Connector: front view

35
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.4 X30 Connector

The X30 is a D-Sub 15 pins multipolar female connector that collects all the safety
signals from and towards the Control Unit in order to interface with the line.
For the connection is available as standard the mating connector with cap and crimp pin
(User charge).

Fig. 2.7 - X30 Connector: overview

A: X30 Connector
A

Tab. 2.6 - X30 Connector: pinout

Connector Pinout
– PIN 1: PULSE 3
– PIN 2: PULSE 4
8 – PIN 3: NOT USED
15 – PIN 4: NOT USED
– PIN 5: E-STOP PB CH1A
– PIN 6: E-STOP PB CH1B
– PIN 7: AUTO STOP LINEA CH1
9 1 – PIN 8: AUTO STOP LINEA CH2
– PIN 9: PULSE 3
– PIN 10: PULSE 4
– PIN 11: NOT USED
– PIN 12: E-STOP PB CH2A
– PIN 13: E-STOP PB CH2B
– PIN 14: E-STOP LINEA CH1
X30 Connector: front view – PIN 15: E-STOP LINEA CH2

36
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.4.1 Further details about the stop circuit signals

The following table provides a brief description of safety signals available on X30
Connector.

Tab. 2.7 - X30 Connector: safety signals definition

Signal Pin Definition and Use Diagnostics

Status: is always active and generates a type of stop (EN60204-1
standard) depending on the selected operating mode:
• in category 1 in automatic mode
• in category 0 in programming mode
Signal: input used for the emergency stopfunction; connect a pair
of dry contacts of a safety device coming from the line.

Input R1C-4 X30

1, 2
E-Stop Pulse 3 1
14, 15
Line Pulse 4 2
15
External 14
E-Stop

Electrical features:
– voltage 24 Vdc

Status: is enabled only in automatic operating mode and

generates a stop according to category 1 (standard EN60204-1).
Selecting the Programming mode, sets the Control Unit under the
control of the Enabling Device (on Teach Pendant) and excludes
the Auto-Stop input.
Signal: input used for the emergency stopfunction; connect a pair
of dry contacts of a safety device coming from the line.

Input R1C-4
7, 8 X30
Auto-Stop
9, 10 Pulse 4 10
Line 9
Pulse 3
7
Auto-Stop 8
(Fence)

Electrical features:
– voltage 24 Vdc

37
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Tab. 2.7 - X30 Connector: safety signals definition (Continued)

Signal Pin Definition and Use Diagnostics

Status: is always enabled.
Signal: output for (dry) contacts of the emergency stop
push-button on the Teach Pendant (optional).
The emergency push-button on the Teach Pendant is not directly
connected to the Control Unit emergency stop circuit.
The integrator task is to:
–suitably interlock the push-button contacts with the machine
(cell/system) emergency stop circuit
– remember to include also the E-Stop push-button of the Teach Pendant
in the procedure for the periodic inspection of the machine emergency
devices.
Output 5, 6
E-Stop PB 12, 13
R1C-4 X30

TP5
5
12
Internal 13
E-Stop 6

Internal contacts electrical features:

– max current 1 A
– typical voltage 24 Vdc, max 50 V
Note: install 1 A quick-fit protection fuse on the 24 Vdc power supply input (to be
carried out by the integrator)

38
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.5 X55 Connector (Robot Input / Output )

The X55 connector makes available 6 inputs 24 Vdc, 6 outputs 24 Vdc and 24 Vdc I/O
power supply on Robot, to be Used by the user for small applications.
As an option, it can be made available instead of 2 Digital Inputs (Input 5 and Input 6) 1
alarm input*¹ 24 Vdc to be used as “Robot alarm” or “Air input” and 1 fast input*¹
(typically used to acquire a precise technological position, such as the welding wire
control). For the signals connection, see Fig. 2.10.

I/O signals are made available on the X50 connector on Robot base, through the
appropriate Services cable.

*¹ To be used only after software enabling

Fig. 2.8 - X55 Connector: overview

A: X55 Connector (Robot I/O)

A

Tab. 2.8 - I/O signals features

Feature Description
Input signals electric features – 6 inputs
– Voltage: 24 Vdc (-15% / +20%)
(“1 logic” > 15 Vdc. “0 logic” < 5Vdc)
– Typical current: 2.68 mA @ 24 Vdc
Output signals electric features – 6 outputs
– Voltage: 24 Vdc (-15% / +20%)
– Max current per output: 0.5 A

39
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Tab. 2.9 - X55 Connector: pinout

Connector Pinout
– PIN 1: Input 6 / optionally HSI*¹*³
– PIN 2: Input 5 / optionally Robot Alarm / Air input*¹*²
– PIN 3: Input 1
– PIN 4: Input 2
– PIN 5: Input 3
– PIN 6: +24 Vdc I/O
– PIN 7: Input 4
– PIN 8: Output 1
– PIN 9: Output 2
– PIN 10: Output 3
– PIN 11: Output 4
– PIN 12: 0V (24 Vdc) OUT
– PIN 13: Output 5
– PIN 14: Output 6
X55 Connector: front view – PIN 15: Not used
– PIN 16: Not used
– PIN 17: Not used
– PIN 18: Not used
– PIN 19: 0V (24 Vdc)

*¹ Not enabled as standard.

*² Is possible to enable the input at software level. The input is of active low type (0V)
*³ The input activates in case of switchover from 0V to 24V (o vice versa). It is possible
to choose at software level to enable the input on the rising edge (switchover 0V - 24V)
or on the falling edge (24V - 0V)

40
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.5.1 I/O mapping

I/O signals are associated with variables $DIN and $DOUT as indicated in the following
Tab. 2.10.
Some signals of the I/O may not be available to the User as a result of matching the
Control Unit with one of the Robots indicated in Tab. 2.10.

Tab. 2.10 - Association between I/O and related variables

PIN on X55 Associated variable Signal

1 $DIN[6] Digital Input 6
2 $DIN[5] Digital Input 5
3 $DIN[1] Digital Input 1
4 $DIN[2] Digital Input 2
5 $DIN[3] Digital Input 3
7 $DIN[4] Digital Input 4
8 $DOUT[1] Digital Output 1
9 $DOUT[2] Digital Output 2
10 $DOUT[3] Digital Output 3
11 $DOUT[4] Digital Output 4
13 $DOUT[5] Digital Output 5
14 $DOUT[6] Digital Output 6

41
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.5.2 I/O connection on X55 Connector principle wiring diagram

In the following figures are shown, respectively, the principle diagram of I/O connection
with Robot connected to the Control Unit Fig. 2.9 and connection diagram of “Robot
Alarm” and “HSI input” optional signals Fig. 2.10.
Depending on the Robot matched, some signals of the I/O may not be available to the
User. For details see Tab. 2.10.

Fig. 2.9 - Principle connection diagram, matched with a Robot

R1C-4
Terminal
Block X55/CAB
6
+24Vp
+24Vp

0V 19

0V 12

0V

X20 PS2100
25
+24V
26
0V

IM16
11 3
INP 1

21 4
INP 2

12 5
INP 3

22 7
INP 4

13 2
INP 5

23 1
INP 6

OM16

11 8
OUT 1

21 9
OUT 2

12 10
OUT 3

22 11
OUT 4

13 13
OUT 5

23 14
OUT 6

42
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

Fig. 2.10 - Connection diagram of Robot Alarm / Air input and HSI
(optional) signals

R1C-4
Terminal
Block
0V

X55/CAB
P31 X8
1
ROBOT ALARM 1

2 2

HSI 3

43
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.6 X124 Connector

The X124 connector is a 25 pins multipolar female connector, used for connection of the
Teach Pendant, or if no, the mating connector with cap functions for closing six
emergency signals.

Fig. 2.11 - X124 Connector: overview

A: X124 Connector

Tab. 2.11 - X124 Connector: pinout

Connector Pinout
– PIN 1: PROG – PIN 11: PULSE1
– PIN 2: ES-PTU-1A – PIN 12: MONITOR E-STOP
1 14 – PIN 3: ES-PTU-1B – PIN 13: TX+
– PIN 4: ES-PTU-2A – PIN 14: TZ-
– PIN 5: ES-PTU-2B – PIN 15: RX+
– PIN 6: 24V INT – PIN 16: RX-
– PIN 7: PULSE1 – PIN 17: AUTO REMONTE
– PIN 8: ENDV-CH1B – PIN 18: AUTO LOCAL
– PIN 9: PULSE2 – PIN 19: 0V
– PIN 10: ENDV-CH2B

13 25

X124 Connector: front view

44
 Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.7 ETH Connector

The ETH connector allows the communication on Ethernet network from and towards
the Control Unit.
The Ethernet port available on the connectors panel is internally connected to the main
computing unit (industrial Personal Computer) of system management.

Fig. 2.12 - ETH Connector: overview

A: ETH Connector
A

Tab. 2.12 - ETH Connector: technical features

Feature Description
Electrical features – Ethernet RJ45 Port, 10/100/1000 Mbit/s
– Protection degree IP2x

45
Comau Robotics Product Instruction

CONTROL UNIT TECHNICAL SPECIFICATIONS

2.4.8 USB Connector

The USB type-A connector allows an easy connection of compatible storage devices,
such as C5G-FDU: Flash Disk USB.
The USB port available on the connectors panel is internally connected to the main
computing unit (industrial Personal Computer) of system management.

Fig. 2.13 - USB Connector: overview

A: USB connector

Tab. 2.13 - USB Connector: technical features

Feature Description
Electrical features – USB port type-A
– Protection degree IP2x
Usage limitations – The Hub USB connection is not allowed.

46
 Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

2.5 Motor cables and encoder between Control Unit

and Robot
The supply cables kit includes the signal cable and the motors cable. Cables are static
installation type and can be chosen depending on the lengths required by the
installation:
– signals cable, X10 connector on Control Unit, X1 cable gland connector on Robot
base
– motors cable, X60 connector on Control Unit, X2 cable gland connector on Robot
base

The connectors on Robot side are connected pin-to-pin to the corresponding connectors
on Control Unit side (X10 and X60).
Unless otherwise noted, the cables and connectors are assembled in order to obtain the
protection degree equal to IP54 Robot side (according to the EN 60529 standard).
The same cables kits are to be considered as spare parts.
The cable kit is available in different lengths, as indicated in the following Tab. 2.14.

Fig. 2.14 - Motor and encoder cables between Control Unit and Robot:
overview

Motor cable

Encoder cable

47
Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

Tab. 2.14 - Motor and encoder cables between Control Unit and Robot:
available models

Comau Part No. Description

Robot Rebel
Kit consisting of encoder signals cable and motors cable.
CR18947589
Cables length 3 m (6.5 ft)
Kit consisting of encoder signals cable and motors cable.
CR18947580
Cables length 5 m (16 ft)
Kit consisting of encoder signals cable and motors cable.
CR18947581
Cables length 10 m (33 ft)

48
 Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

Fig. 2.15 - Encoder signals cable principle diagram

49
Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

Tab. 2.15 - X10/CAB Connector: pinout

Connector Pinout
Axis 1 Axis 3
– PIN 1: Up – PIN 20: Up
– PIN 2: 0 V – PIN 21: 0 V
– PIN 3: CLK+ – PIN 22: CLK+
– PIN 4: CLK- – PIN 23: CLK-
– PIN 5: Data+ – PIN 24: Data+
– PIN 6: Data- – PIN 25: Data-
Axis 2 Axis 4
– PIN 7: Up – PIN 26: Up
– PIN 8: 0 V – PIN 27: 0 V
– PIN 9: CLK+ – PIN 28: CLK+
– PIN 10: CLK- – PIN 29: CLK-
– PIN 11: Data+ – PIN 30: Data+
– PIN 12: Data- – PIN 31: Data-

Tab. 2.16 - X1/DS Connector: pinout

Connector Pinout
Axis 1 encoder Axis 2 encoder
– PIN 1: Up – PIN 20: Up
Pin 1 Pin 8 – PIN 2: 0 V (Up) – PIN 21: 0 V (Up)
– PIN 3: CLK+ – PIN 22: CLK+
– PIN 4: CLK- – PIN 23: CLK-
– PIN 5: Data+ – PIN 24: Data+
– PIN 6: Data- – PIN 25: Data-

Pin 7 Pin 14

Axis 3 encoder Axis 4 encoder

– PIN 1: Up – PIN 20: Up
Pin 1 Pin 9
– PIN 2: 0 V (Up) – PIN 21: 0 V (Up)
– PIN 3: CLK+ – PIN 22: CLK+
– PIN 4: CLK- – PIN 23: CLK-
– PIN 5: Data+ – PIN 24: Data+
– PIN 6: Data- – PIN 25: Data-

Pin 8 Pin 16

50
 Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

Fig. 2.16 - Motors cable principle diagram

51
Comau Robotics Product Instruction

MOTOR CABLES AND ENCODER BETWEEN CONTROL UNIT AND ROBOT

Tab. 2.17 - X60/CAB Connector: pinout

Connector Pinout
– PIN 1: M3 - U – PIN 13: M1 - U
– PIN 2: M3 - V – PIN 14: M1 - V
– PIN 3: M3 - W – PIN 15: M1 - W
1 – PIN 4: BK+ – PIN 16: +24V
– PIN 7: BK- – PIN 17: M2 - U
– PIN 8: LAMP- – PIN 18: M2 - V
– PIN 9: M3 - U – PIN 19: M2 - W
– PIN 10: M3 - V – PIN 20: GND ax. 1-2
– PIN 11: M3 - W – PIN 24: GND ax. 3-4
– PIN 12: LAMP+

Tab. 2.18 - X2/DS Connector: pinout

Pinout
Connector
Axis 1 - 2 Motors
– PIN 1: M1 - U
– PIN 2: M1 - V
Pin 1 Pin 7 – PIN 3: M1 - W
– PIN 4: GND
– PIN 5: M2 - U
– PIN 6: M2 - V
– PIN 7: M2 - W
– PIN 8: GND
– PIN 9: LAMP+
– PIN 10: LAMP-
– PIN 11: + 24V DC
Pin 6 Pin 12

Axis 3 - 4 Motors
– PIN 1: M1 - U
Pin 1
– PIN 2: M1 - V
Pin 8
– PIN 3: M1 - W
– PIN 4: F1+, F2+, F3+
– PIN 5: M2 - U
– PIN 6: M2 - V
– PIN 7: M2 - W
– PIN 8: F1-, F2-, F3-
– PIN 9: M3 - U
– PIN 10: M3 - V
– PIN 11: M3 - W

Pin 7 Pin 14

52
 Comau Robotics Product Instruction

OPTIONS

2.6 Options
In this paragraph are listed and described the available options for the Control Unit,
organized below by topics and application purpose.
Available options
Optional Connection Cables
– Services cable
– Power supply cable
Additional I/O
– R1C-UIO (R1C User Input Output)

Communication on Field Bus

Profinet / EtherNet/IP
– Bus Coupler PFG-BCO module on X20 interface
– R1C-EFB: Ethernet Field Bus
– C5G-PND: Profinet I/O device interface
– C5G-EtherNetIP adapter Slave
Profibus-DP
– Bus Coupler PFG-BCO module on X20 interface
– R1C-PFB: Profibus Field Bus (only slave)
– C5G-PFM-PDPS: Profibus-DP Slave Interface
– C5G-PFPC: ProFibus Plug Connector
Can Bus / DeviceNet
– Bus Coupler PFG-BCO module on X20 interface
– R1C-CFB: Can Field Bus (only slave)
– C5G-DNM-DNSI: DeviceNet Slave Interface
– X20-CANopen slave Interface
– R1C-DNPC: DeviceNet Mate Connector Master or Slave
Special Applications
– R1C-CTKH: Conveyor Tracking Kit Hiperface

Accessories
– C5G-FDU: Flash Disk USB
– C5G-TP5 Teach Pendant with specific adapter for connecting to R1C-4 Control Unit
– R1C-4 TP5 - Connection adapter cable (CR17233255)
– C5G-TP5Exx: Extension Cable for Teach Pendant C5G-TP5
– C5G-FPB: Free Position Bracket
Software
– The software options are listed in the Control Unit Use handbook.

53
Comau Robotics Product Instruction

OPTIONS

2.6.1 Services cable

The Services Cable is an optional multipolar cable that collects all the I/O signals
available on the X55 connector (Robot Input / Output), and makes them available on the
X50 connector on Robot base.
The option is composed of a multipolar cable already equipped at the ends with M23 19
pins connectors. The Control Unit side end (labeled with the code X55/DS) is equipped
with male connector, while the Robot side end (labeled with the code X50/DS) is
equipped with female connector.
You can choose between models of different length, which should be consistent with the
length of the Motor and encoder cables between the Control Unit and Robot.

Fig. 2.17 - Services cable: overview

A: Services Cable

Typical Robot representative image

Tab. 2.19 - Services cable: technical features

Feature Description
Comau Part No. – CR18947589: cable length 3 m (9,8 ft)
– CR18947580: cable length 5 m (16 ft)
– CR18947581: cable length 10 m (33 ft)
Connectors features – Connector Control Unit side (X55/DS):
• 19 pins male M23
• Hummel Part No. 7.206.500.000
– Connector Robot side (X50/DS):
• DSUB 15 pins female

54
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.19 - Services cable: technical features (Continued)

Feature Description
Cable principle diagram

Usage limitations – Usable only matched with Robot equipped with X50 connector on
the base.

2.6.2 Power supply cable

The option makes available a pre-wired power supply cable for the Control Unit. The
cable is equipped with IEC C19 connector (on Control Unit side end) and Schuko plug
on the other end.
The cable is available in several lengths, as indicated in Tab. 2.20.

Tab. 2.20 - Power Supply Cable: Ordering Part No.

Feature Description
Comau Part No. – CR19743099 Power supply cable length 2 m (6.56 ft)

55
Comau Robotics Product Instruction

OPTIONS

2.6.3 R1C-UIO (R1C User Input Output)

The option R1C-UIO (User Input Output), makes available 12 inputs 24 Vdc, 10
outputs 24 Vdc and the power supply 24 Vdc I/O on X31 connector installed on the front
panel of the cabinet.
The option is composed of a D-Sub 25 pins multipolar female connector to be installed
on the appropriate precut present on the front side of the Control Unit, and of the internal
cables for connection on I/O modules installed inside the Control Unit.
The I/Os available on the X31 connector, are mapped by default as indicated in
Tab. 2.23 (see par. 2.6.3.1).

Fig. 2.18 - R1C-UIO: overview

A: X31 connector
A

Tab. 2.21 - R1C-UIO: technical features

Feature Description
Comau Part No. – CR17233065
Input signals electric features – 12 inputs
– Voltage: 24 Vdc (-15% / +20%)
(“1 logic” > 15 Vdc. “0 logic” < 5Vdc)
– Typical current: 2.68 mA @ 24 Vdc
Output signals electric features – 10 outputs
– Voltage: 24 Vdc (-15% / +20%)
– Max current per output: 0.5 A

56
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.22 - X31 Connector: pinout

Connector Pinout
– PIN 1: Input 5 (optional) – PIN 14: Output 7
– PIN 2: Input 6 (optional) – PIN 15: Output 8
– PIN 3: Input 7 – PIN 16: Output 9
– PIN 4: Input 8 – PIN 17: Output 10
– PIN 5: Input 9 – PIN 18: Output 11
– PIN 6: Input 10 – PIN 19: Output 12
– PIN 7: Input 11 – PIN 20: Output 13
– PIN 8: Input 12 – PIN 21: Output 14
– PIN 9: Input 13 – PIN 22: Output 15
– PIN 10: Input 14 – PIN 23: Output 16
– PIN 11: Input 15 – PIN 24: 24 V Drive ON
– PIN 12: Input 16 – PIN 25: +24 Vdc I/O
– PIN 13: 0V (24 Vdc)

X31 connector: front view

2.6.3.1 I/O mapping

Tab. 2.23 - Association between I/O and related variables

PIN on X31 Associated variable Signal

1 $DIN[5] Digital input 5 (optional)
2 $DIN[6] Digital input 6 (optional)
3 $DIN[7] Digital Input 7
4 $DIN[8] Digital Input 8
5 $DIN[9] Digital Input 9
6 $DIN[10] Digital Input 10
7 $DIN[11] Digital Input 11
8 $DIN[12] Digital Input 12
9 $DIN[13] Digital Input 13
10 $DIN[14] Digital Input 14
11 $DIN[15] Digital Input 15
12 $DIN[16] Digital Input 16
14 $DOUT[7] Digital Output 7
15 $DOUT[8] Digital Output 8
16 $DOUT[9] Digital Output 9
17 $DOUT[10] Digital Output 10
18 $DOUT[11] Digital Output 11
19 $DOUT[12] Digital Output 12
20 $DOUT[13] Digital Output 13
21 $DOUT[14] Digital Output 14
22 $DOUT[15] Digital Output 15
23 $DOUT[16] Digital Output 16

57
Comau Robotics Product Instruction

OPTIONS

2.6.4 Options for communication on ProfiNet / EthernetIP Field

Bus
In the following paragraphs are described the available options, in order to make
possible the communication on ProfiNet / EthernetIP Field Bus from and towards the
Control Unit:
– R1C-EFB: Ethernet Field Bus
– C5G-PND: Profinet I/O device interface
– C5G-EtherNetIP adapter Slave

58
 Comau Robotics Product Instruction

OPTIONS

2.6.4.1 R1C-EFB: Ethernet Field Bus

The option R1C-EFB (Ethernet Field Bus) makes available a connector in order to allow
the communication on ProfiNet / EthernetIP Fieldbus, from and towards the Control Unit.
The option consists of a M12 D-coded 4 pins female connector and of cables and
connector for the connection on the Field Bus modules (Slave) inside the Control Unit.
The Field Bus modules must be ordered separately and are not included in the
R1C-EFB option. The connector is installed on appropriate precut on the connectors
panel of the Control Unit.
It is possible to install up to 2 options. In this case, the connector of the first option is
named X93, while the connector of the second option is named X95.

Fig. 2.19 - R1C-EFB: overview

A: X93 connector (first option installed)

B: X95 connector (second option installed)
A

Tab. 2.24 - R1C-EFB: Technical features

Feature Description
Comau Part No. – CR17240761
X93 / X95 Connectors pinout – PIN 1: TX+
– PIN 2: RX+
– PIN 3: TX-
– PIN 4: RX-

X93 / X95 connector: front view

Usage limitations – It is possible to install a maximum of 2 options

59
Comau Robotics Product Instruction

OPTIONS

2.6.4.2 Bus Coupler PFG-BCO module on X20 interface

– General principles
– Bus Coupler Module Connection Diagram
– Bus Coupler module address for the X20 interface modules
– Minimum requirements
– Technical features and purchase Part No.
– Configuration of the Bus Coupler module in the System
– Technical Features of the Power Supply Unit X20 PS9400

2.6.4.2.1 General principles

The optional Bus Coupler C5G-PFG-BCO (Bus COupler) module is the essential node
and shall always be available to allow the interconnection between the Ethernet
POWERLINK network inside the Control Unit and the Field Bus modules on X20
interface, digital and analog I/O modules on X20 interface.
The Bus Coupler module is supplied as single unit and consists of:
– one base for fixing to DIN rail (A), with 2 free slots for the Field Bus modules on
X20 interface
– one interface for the connection with the Ethernet POWERLINK net (B)
– a DC/DC (C) powering device, identification label*¹ X20 PS9400. The module
provides power supply both to the Bus Coupler and the X2X internal bus.
– arrangement for adding digital and analog I/O Modules on the X20 interface.

Fig. 2.20 - Bus Coupler PFG-BCO Module

A: Base and bus of the X20 interface module

system, with 2 free slots for Field Bus
modules
B: Interface for the connection with the
POWERLINK network
C: DC/DC 24 Vdc powering device,
DC identification label*¹ X20 PS94000
/
DC
Interface

Slot Slot
2 1

A B C
*¹ Identification tag indicated on the front of the component

60
 Comau Robotics Product Instruction

OPTIONS

2.6.4.2.2 Bus Coupler Module Connection Diagram

Each Bus Coupler module is connected as additional node on the Ethernet
POWERLINK network (see Fig. 2.21) and configured with an univocal address (see
par. 2.6.4.2.3 Bus Coupler module address for the X20 interface modules on page 62).
The connection between the modules and the network is accomplished using 1,5-m (4.9
ft) Ethernet POWERLINK cables (supplied separately).
It is possible to install up to 2 Bus Coupler modules. With each Bus Coupler module it is
possible to couple:
– Up to 2 Field Bus modules on X20 interface, installed directly on the 2 slots
available on the left
– a solution with Digital and analog I/O modules on X20 interface, installed on the
right side of the Bus Coupler.

Fig. 2.21 - General principles of connection of the Bus Coupler PFG-BCO

module

From last Ethernet POWERLINK internal module

Ethernet POWERLINK Cable Ethernet POWERLINK Cable

Bus Coupler Bus Coupler

#1 #2

&H81 &H82

61
Comau Robotics Product Instruction

OPTIONS

2.6.4.2.3 Bus Coupler module address for the X20 interface modules
The module address on the Ethernet POWERLINK network is configured through 2
rotating sector switches, X1 and X16 (Fig. 2.22), according to the instructions in
Tab. 2.25.
Inside the same Control Unit, the address of a module on the Ethernet POWERLINK
network shall be univocal.

Fig. 2.22 - X1 and X16 selector switches for Bus Coupler module for X20
interface modules

Tab. 2.25 - Ethernet POWERLINK network addresses configurations on

Bus Coupler of the X20 interface modules

Rotary selector
switches
Function of Bus Coupler module setting Notes about the addresses configuration
(Address)

X16 X1

First module installed 8 1 Address of the first module installed: 129 (0x81)

Second module installed 8 2 Address of the second module installed: 130 (0x82)

62
 Comau Robotics Product Instruction

OPTIONS

2.6.4.2.4 Minimum requirements

The Bus Coupler option may be installed only if the following optional items are already
in place:
– Ethernet POWERLINK 1,5 m long cable (CR17231863)
– 24 Vdc powering cable (CR17240260) to power the Bus Coupler. The power is
taken from module SDM, connector X103.

2.6.4.2.5 Technical features and purchase Part No.

Fig. 2.23 - C5G-PFG-BCO: overview

A: C5G-PFG-BCO

Tab. 2.26 - C5G-PFG-BCO: technical features

Feature Description
Comau Part No. – CR10146383
Electrical features – Power supply: 24 Vdc (-15% a +20%)
– Available slots: 2, only for the following field bus modules:
• C5G-DNM-DNMI: DeviceNet Master Interface
• C5G-DNM-DNSI: DeviceNet Slave Interface
• C5G-PFM-PDPM: Profibus-DP Master Interface
• C5G-PFM-PDPS: Profibus-DP Slave Interface
Installation position – Inside the R1C4 Control Unit, on DIN rail.
Usage limitations – It is possible to install maximum 2 options.
Ethernet POWERLINK 1,5 m (4.9 ft) – CR17231863 (ACC ETH POWERLINK 1,5 m)
cable, Comau part no.
24 Vdc Power supply cable – CR17240260 (PFG supply cable)
Comau Part No.

63
Comau Robotics Product Instruction

OPTIONS

2.6.4.2.6 Configuration of the Bus Coupler module in the System

The Bus Coupler module can be used in the system only after being suitably configured.
The Bus Coupler module configuration shall be carried out using the special IO_CNFG
(configuration of the module in the system) routine supplied together with the Control
Unit. After carrying out the configuration, the system shall be restarted acting on the
Restart Cold control.

The usage instructions for the IO_CNFG routine are to be found in the “Control Unit
Usage” manual, chapter “Programmes for the I/O configuration”.

2.6.4.2.7 Technical Features of the Power Supply Unit X20 PS9400

Tab. 2.27 - X20 PS9400: technical features

Feature Description
Identification label *¹ – X20 PS9400
Electrical features – 24 Vdc power supply input provided by Safety Distribution Module
(SDM), X103A connector, 24V INT
– used to supply both the module Bus Coupler and the internal bus
X2X
Installation position – Insidethe Control Unit, near the Bus Coupler, on Din rail.
Dimension – 1 module (12,5 mm)
Pinout
– +24 V Bus Coupler and internal bus X2X, power supply input,
terminal 14
– +24 V Bus Coupler and internal bus X2X, power supply input,
terminal 15
– GND, power supply input, terminal 16
– +24 VI/O, power supply input, terminal 24
– +24 VI/O, power supply input, terminal 25
– GND, power supply input, terminal 26

64
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.27 - X20 PS9400: technical features (Continued)

Feature Description
Status LED
– r (green):
• [OFF]: input power off from Module SDM or power off on
internal bus X2X
• [Single blinking]: reset mode
• [Blinking]: Preoperational mode
• [ON]: Run mode
– e (red):
• [OFF]: input power off from Module SDM or power off on
internal bus X2X or everything ok
• [Double blinking]: insufficient I/O power supply or insufficient
power supply on internal bus X2X or power supply overload on
internal bus X2X.
– e + r:
• [Steady red, Single green blinking]: incorrect firmware
– l:
• [OFF]: power supply on X2X internal bus is in a good range
• [ON]: power supply overload on internal busX2X:
*¹ Identification tag indicated on the front of the component

65
Comau Robotics Product Instruction

OPTIONS

2.6.4.3 C5G-PND: Profinet I/O device interface

The C5G-PND (ProfiNet I/O Device) option makes available one Profinet Slave interface
module inside the Control Unit, with Profinet RT Controller (Slave) function.
The module must be installed on PFG-BCO Bus Coupler module on X20 interface. It is
supplied with an integrated Ethernet switch to allow an efficient connection of two RJ45
connectors.

Fig. 2.24 - C5G-PND: overview

A: C5G-PND

Tab. 2.28 - C5G-PND: technical features

Feature Description
Comau Part No. – CR10145183
Identification label *¹ – X20 IF10E3-1
Electrical features – qty 2 for RJ45 Ethernet Port, 100 Mbit/s
Pinout

66
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.28 - C5G-PND: technical features (Continued)

Feature Description
Status LED
– READY/RUN (green / red):
• [OFF]: lack of power supply on X2X internal bus
• [Red Blinking]: Boot Error
• [ON Red]: Communication on the PCI bus has not yet been
started
• [ON Green]: Communication on the PCI bus is operating
– SF (red):
• [OFF]: no error
• [Blinking *²]: DCP signal service triggered via bus
• [ON]: System error
– BF (red):
• [OFF]: no error
• [Blinking]: No data exchange
• [ON]: No configuration or physical connection error
– L/A IF1/IF2 (error):
• [OFF]: No link to peer station
• [Flickering]: A link to the remote station has been established.
The LED flickers when Ethernet activity is present on the bus.
• [ON]: A link to the remote station has been established
Installation position – Inside Control Unit, on PFG-BCO Bus Coupler module on X20
interface.
Usage limitations – Up to 2 modules
*¹ Identification tag indicated on the front of the component
*²Cyclic blinking at 2 Hz, duration 3 s.

67
Comau Robotics Product Instruction

OPTIONS

2.6.4.4 C5G-EtherNetIP adapter Slave

The C5G-EtherNet/IP adapter Slave option makes available an EtherNet/IP Slave
interface module inside the Control Unit, with EtherNet/IP adapter (Slave) function.
The module must be installed on PFG-BCO Bus Coupler module on X20 interface. It is
supplied with an integrated Ethernet switch to allow an efficient connection of two RJ45
connectors.

Fig. 2.25 - C5G-EtherNet/IP adapter Slave

A: C5G-EtherNet/IP adapter Slave

Tab. 2.29 - C5G-EtherNet/IP adapter Slave: technical features

Feature Description
Comau Part No. – CR10144083
Identification label *¹ – X20 IF10D3-1
Electrical features – qty 2 for RJ45 Ethernet Port, 100 Mbit/s
Pinout

ETHERNET/IP

68
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.29 - C5G-EtherNet/IP adapter Slave: technical features

Feature Description
Status LED
– READY/RUN (green / red):
• [OFF]: lack of power supply on X2X internal bus
• [Red Blinking]: Boot Error
• [ON Red]: Communication on the PCI bus has not yet been
started
• [ON Green]: PCI bus communication in progress
– Mod Status (green / red):
• [OFF]: lack of power supply on X2X internal bus
• [Green/Red Blinking]: Startup / Auto-test
• [Red Blinking]: Recoverable hardware error
• [Green Blinking]: Interface module not yet configured
• [ON Red]: Irrecoverable hardware error
• [ON Green]: Adapter (Slave) is operational
– Net Status (green / red):
• [OFF]: No IP address assigned or module not supplied
• [Green/Red Blinking]: Startup / Auto-test
• [Red Blinking]: Timeout occurred on at least one connection
• [Green Blinking]: No active connection
• [ON Red]: An IP address has been used repeatedly
• [ON Green]: Indicates at least one active connection
– L/A IF1/IF2 (green):
• [OFF]: No link to remote station
• [Flickering]: A link to the remote station has been established.
The LED flickers when Ethernet activity is present on the bus.
• [ON]: A link to the remote station has been established
Installation position – Inside Control Unit, on PFG-BCO Bus Coupler module on X20
interface.
Usage limitations – Up to 2 modules
*¹ Identification tag indicated on the front of the component

69
Comau Robotics Product Instruction

OPTIONS

2.6.5 Options for communication on Profibus Field Bus

In the following paragraphs are described the available options, in order to make
possible the communication on Profibus Field Bus from and towards the Control Unit:
– R1C-PFB: Profibus Field Bus
– C5G-PFM-PDPS: Profibus-DP Slave Interface
– C5G-PFPC: ProFibus Plug Connector

70
 Comau Robotics Product Instruction

OPTIONS

2.6.5.1 R1C-PFB: Profibus Field Bus

The R1C-PFB (Profibus Field Bus) option makes available a connector (named X96) in
order to allow the communication on Profibus Field Bus, from and towards the Control
Unit.
The option is composed of a D-Sub 9 pins female connector and of cables and
connector for connection on the Field Bus modules (only slave) inside the Control Unit.
The Field Bus modules must be ordered separately and are not included in the
R1C-PFB option. The connector is installed on appropriate precut on the connectors
panel of the Control Unit.

Fig. 2.26 - R1C-PFB: overview

A: X96 connector

Tab. 2.30 - R1C-PFB: Technical features

Feature Description
Comau Part No. – CR17240861
X96 Connector pinout – PIN 1: Reserved
– PIN 2: Reserved
– PIN 3: RxD/TxD-P
– PIN 4: CNTR-P
– PIN 5: DGND
– PIN 6: VP
– PIN 7: Reserved
– PIN 8: RxD/TxD-N
– PIN 9: CNTR-N

X96 Connector: front view

Usage limitations – It is possible to install maximum 1 option

71
Comau Robotics Product Instruction

OPTIONS

2.6.5.2 C5G-PFM-PDPS: Profibus-DP Slave Interface

The C5G-PFM-PDPS (ProFibus Module - Profibus-DP Slave) option makes available a
Profibus-DP interface module inside the Control Unit.
The module must be installed on PFG-BCO Bus Coupler module on X20 interface.

Fig. 2.27 - C5G-PFM-PDPS: overview

A: C5G-PFM-PDPS

Tab. 2.31 - C5G-PFM-PDPS: technical features

Feature Description
Comau Part No. – CR10145583
Identification label *¹ – X20 IF1063-1
Electrical features – Requires the optional connector C5G-PFPC: ProFibus Plug
Connector
Pinout

72
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.31 - C5G-PFM-PDPS: technical features (Continued)

Feature Description
Terminating resistor – Integrated in the C5G-PFPC: ProFibus Plug Connector (lever
switch A)

Status LED
– READY/RUN (green / red):
• [OFF]: lack of power supply on X2X internal bus
• [Blinking]: Boot error
• [ON Red]: Communication on the PCI bus has not yet been
started
• [ON Green]: Communication on the PCI bus is operating
– STATUS DP (green / red):
• [Cyclic flash Red]: STOP, no communication, connection
error
• [Acyclic flash Red]: Slave not configured
• [ON Green]: RUN, cyclic communication
– RxD (yellow):
• [On]: The module receives data via the Profibus DP slave
interface
– TxD (yellow):
• [On]:The module sends data via the Profibus DP slave
interface
Installation position – Inside Control Unit, on PFG-BCO Bus Coupler module on X20
interface.
Usage limitations – Up to 2 modules
*¹ Identification tag indicated on the front of the component

73
Comau Robotics Product Instruction

OPTIONS

2.6.5.3 C5G-PFPC: ProFibus Plug Connector

The option C5G-PFPC (ProFibus Plug Connector) makes available a mating connector
suitable for the connection of the Profibus cable on X96 connector of the Control Unit
(present only in case of the option installation R1C-PFB: Profibus Field Bus).
The connector is equipped with integrated lever switch, to allow the insertion /
disinsertion of the terminating resistor.

Fig. 2.28 - R1C-PFPC: overview

A: C5G-PFPC connector
B: Switch to insert the terminating resistor
C A B C: X96 connector on Control Unit

Tab. 2.32 - R1C-PFPC: Technical features

Feature Description
Comau Part No. – CR17131980
Usage limitations – It is possible to install maximum 1 option
– The connector is usable only if the option is already present
R1C-PFB: Profibus Field Bus.

74
 Comau Robotics Product Instruction

OPTIONS

2.6.6 Options for communication on CAN-bus or Devicenet

Field Bus
In the following paragraphs are described the available options, in order to make
possible the communication on CAN-bus or Devicenet Field Bus from and towards the
Control Unit:
– R1C-CFB: Can Field Bus
– C5G-DNM-DNSI: DeviceNet Slave Interface
– X20-CANopen slave Interface
– R1C-DNPC: DeviceNet Mate Connector Master or Slave

75
Comau Robotics Product Instruction

OPTIONS

2.6.6.1 R1C-CFB: Can Field Bus

The option R1C-CFB (Can Field Bus) makes available a connector (named X97) in
order to allow the communication on CAN-bus or Devicenet Field Bus, from and towards
the Control Unit.
The option is composed of a 5 pins male connector and of cables and connector for
connection on the Field Bus modules (only slave) inside the Control Unit. The Field
Bus modules must be ordered separately and are not included in the R1C-CFB
option. The connector must be installed on a suitable plate (comes with the option),
between the X10 connector and the X124 connector.
The nameplate of the X97 connector is not screen printed on the front panel of the
Control Unit but is of adhesive type and is included in the option.

Fig. 2.29 - R1C-CFB: overview

A: X97 Connector

Tab. 2.33 - R1C-CFB: Technical features

Feature Description
Comau Part No. – CR17240661
X97 Connector pinout – PIN 1: V-
– PIN 2: CAN_L
– PIN 3: Shield
– PIN 4: CAN_H
– PIN 5: V+

X97 Connector: wires insertion side view

Usage limitations – It is possible to install maximum 1 option

76
 Comau Robotics Product Instruction

OPTIONS

2.6.6.2 C5G-DNM-DNSI: DeviceNet Slave Interface

The C5G-DNM-DNSI (DeviceNet Module - DeviceNet Slave Interface) option makes
available a DeviceNet Slave interface module inside the Control Unit.
The module must be installed on PFG-BCO Bus Coupler module on X20 interface.

Fig. 2.30 - C5G-DNM-DNSI: overview

A: C5G-DNM-DNSI

Tab. 2.34 - C5G-DNM-DNSI: technical features

Feature Description
Comau Part No. – CR10145883
Identification label *¹ – X20 IF1053-1
Pinout

77
Comau Robotics Product Instruction

OPTIONS

Tab. 2.34 - C5G-DNM-DNSI: technical features (Continued)

Feature Description
Terminating resistor – Integrated in the module
– Terminating signalling inserted on module front side (LED A)

Bottom view Front view

Status LED
– READY/RUN (green / red):
• [OFF]: lack of power supply on X2X internal bus
• [ON Red]: Communication on the PCI bus has not yet been
started
• [ON Green]: Communication on the PCI bus is operating
– MOD/NET (green / red):
• [OFF]: lack of power supply on X2X internal bus or module is
not online
• [Green Blinking]: Module is online but the I/O connection is
not active
• [ON Green]: Module is online and the I/O connection is active
("operating")
• [Red Blinking]: The red LED blinks if at least one of the
following errors has occurred:
– Minor fault (recoverable fault)
– Connection error
– No DeviceNet supply voltage
• [ON Red]: Critical fault or critical connection error (double MAC
ID, bus failure or module defect)
– TxD (yellow):
• [Flickering or on]: The module is sending data via the
DeviceNet interface
– Term (yellow):
• [On]: The terminating resistor integrated in the module is
turned on
Installation position – Inside Control Unit, on PFG-BCO Bus Coupler module on X20
interface.
Usage limitations – Up to 2 modules
*¹ Identification tag indicated on the front of the component

78
 Comau Robotics Product Instruction

OPTIONS

2.6.6.3 X20-CANopen slave Interface

The option X20-CANopen slave interface makes available a CANopen Slave interface
module inside the Control Unit.
The module must be installed on PFG-BCO Bus Coupler module on X20 interface.

Fig. 2.31 - X20-CANopen slave interface: overview

A: X20-CANopen slave interface

Tab. 2.35 - X20-CANopen slave interface: technical features

Feature Description
Comau Part No. – CR10144283
Identification label *¹ – X20 IF1043-1
Pinout

CAN bus

NC

79
Comau Robotics Product Instruction

OPTIONS

Tab. 2.35 - X20-CANopen slave interface: technical features (Continued)

Feature Description
Terminating resistor – Integrated in the module
– Terminating signalling inserted on module front side (LED A)

Bottom view Front view

Status LED
– READY/RUN (green / red):
• [OFF]: lack of power supply
• [ON Red]: Communication on the PCI bus has not yet been
started
• [Red Blinking]: error when booting
• [ON Green]: PCI bus communication in progress
– ERR/RUN (green / red):
• [OFF]: Module executes a reset
• [Green Blinking double pulse; Red Blinking double pulse]:
CANopen communication disrupted. This may be due to one
of the following reasons:
• The CAN bus cable is broken or the
CAN bus controller is in "Bus off"
mode
• The module is in
PREOPERATIONAL mode
• CANopen communication was
stopped (the module is in STOPPED
mode)
• [Green Blinking; Red Blinking double pulse]: CANopen
communication was stopped by the master
• [ON Green]: Communication is ready
• [Green Blinking]: Communication is being started (module is
being initialized)
– TxD (yellow):
• [Flickering or on]: The module is sending data via the
CANopen interface
– Term (yellow):
• [On]: The terminating resistor integrated in the module is
turned on
Installation position – Inside Control Unit, on PFG-BCO Bus Coupler module on X20
interface.
Usage limitations – Up to 2 modules

80
 Comau Robotics Product Instruction

OPTIONS

2.6.6.4 R1C-DNPC: DeviceNet Mate Connector Master or Slave

The R1C-DNPC option makes available a mating connector suitable for the connection
of the CAN-Bus or Devicenet cable on X97 connector of the Control Unit (present only
in case of option installation R1C-CFB: Can Field Bus).

The connector terminals are of screw type.

The connector is also provided with screws to allow stable fixing and to avoid accidental
disconnections.
In the option is also included the terminating resistor of 120 Ohm. The terminating
resistor must be installed on User charge at the ends of the CAN-Bus junctions, as
indicated in Tab. 2.36.

Fig. 2.32 - R1C-DNPC: overview

A: Mating connector for R1C-CFB

B: Terminating resistor 120 Ohm
A

81
Comau Robotics Product Instruction

OPTIONS

Tab. 2.36 - R1C-DNPC: Technical features

Feature Description
Comau Part No. – CR17132082
Connector pinout – PIN 1: V-
– PIN 2: CAN_L
– PIN 3: Drain
– PIN 4: CAN_H
– PIN 5: V+

Mating connector: wires insertion side view

82
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.36 - R1C-DNPC: Technical features (Continued)

Feature Description
Terminating resistor wiring diagram

GND
CAN L
120 Ohm
5%, 1/4 W

CAN H

Usage limitations – It is possible to install maximum 1 option

– The connector is usable only if the option is already present
R1C-CFB: Can Field Bus.

83
Comau Robotics Product Instruction

OPTIONS

2.6.7 R1C-CTKH: Conveyor Tracking Kit Hiperface

The R1C-CTKH (Conveyor Tracking Kit Hiperface) option makes available a connector,
named X69 (or X70 in case of second option installed) on which signals for the control
and the reading of an encoder, installed externally to the Control Unit, are passing.
The option consists of:
– 1 encoder interface module to be installed within the Control Unit
– 1 X69 (or X70) 12 pins circular female connector including cables and connectors
for connection on the encoder interface module
– 1 ground terminal block to be installed on DIN rail within the Control Unit
– 1 encoder to be installed, on User charge, on the motor which needs to be
controlled
– 1 connection cable between X69 (or X70) connector on Control Unit and external
encoder.

The option is typically used for performing the working of moving parts on conveyor lines
or rotary tables not controlled by the Control Unit. In this case, the encoder of the option
R1C-CTKH must be installed on the conveyor / rotary table motor, in order to know the
accurate position. Consequently the Control Unit will be able to determine the
trajectories of the Robot necessary for the proper execution of the working process.

Fig. 2.33 - R1C-CTKH: overview

A: X69 connector (first option installed)

B: X70 connector (second option installed)
C: External encoder
D: Connection cable between Control Unit
and encoder

B
C D

84
 Comau Robotics Product Instruction

OPTIONS

Tab. 2.37 - R1C-CTKH: Technical features

Feature Description
Comau Part No. – CR17132281
X69 / X70 Connector pinout – PIN 1: COS-
– PIN 2: DATA+
– PIN 3: Reserve
– PIN 4: Reserve
– PIN 5: SIN+
– PIN 6: SIN-
– PIN 7: DATA-
– PIN 8: COS+
– PIN 9: N/A
– PIN 10: 0V
– PIN 11: N/A
– PIN 12: US

X69 / X70 connector: front view

Installation requirements – Requires free space on DIN rail within the Control Unit, for encoder
interface module and ground terminal block installation
– In order to allow the software recognition of the Conveyor Tracking
(CTKH) modules, these modules must be installed in the first free
slot on the right of the 16 Digital Output module, as shown in the
figure below:

SAFE I/O + PS2100

+ 16 DI + 16 DO CTKH

GND

Usage limitations – It is possible to install a maximum of 2 options

85
Comau Robotics Product Instruction

OPTIONS

2.6.8 C5G-FDU: Flash Disk USB

The C5G-FDU (Flash Disk USB) option is a portable storage device to be used as
external storage device for the backup or to enhance the system storage capacity.
The storage capacity of the Flash Disk is 4 GB or higher.
The Flash Disk is supplied already formatted in FAT32 and besides the Control Unit and
Teach Pendant USB connections is also compatible with Personal Computers that use
operating systems supporting the FAT32 File System.

Fig. 2.34 - C5G-FDU: overview

A: C5G-FDU

Tab. 2.38 - C5G-FDU: technical features

Feature Description
Comau Part No. – CR10145283
Electrical features – Storage capacity 4 GB or higher
– Max connection speed: USB 2.0 (Universal Serial Bus)
– Formatting: FAT32 (Note: other File Systems are not supported by
the system)
– Operating temperature: from 5 to 45 °C (from 41 to 113 °F)
Installation position – On ETH Connector

86
 Comau Robotics Product Instruction

OPTIONS

2.6.9 C5G-TP5 Teach Pendant with specific adapter for

connecting to R1C-4 Control Unit
The Teach Pendants communicate with Control Unit mainly through the TCP/IP
protocol on Ethernet network. The connection with the Control Unit is foreseen through
adapter connection on X124 25 pins connector. The network, power supply and modal
selection signals are passing on the connector, with enabling push buttons.
The Programming (T1), Local automatic (AUTO) and Remote automatic (REMOTE)
control mode selection may be performed using the selector switch installed on the
Teach Pendant. The selector switch is connected to hardware circuits, with 24-Vdc
signals.
Motion stopping and enabling (Enabling device) are connected to hardware circuits
on Teach pendant.
Through the colour user interface it is possible to easily access all the parameters,
perform the Robot movement and run the working programs. Using suitable application
software (that can be developed also by the user), the interface can be customized for
specific environments and processes.

More details about the control modes are to be found in the par. 2.1.3 Control modes on
page 25.
The Teach Pendant functions are complex and are dealt with in details in the usage
handbook.

Fig. 2.35 - C5G-TP5 Teach Pendant : overview

C5G-TP5 (wired)
3 key positions

87
Comau Robotics Product Instruction

OPTIONS

2.6.9.1 C5G-TP5: technical features of the Teach Pendants

Tab. 2.39 - Teach Pendants: available models

C5G-TP5 Teach Pendant

Feature
3 positions
With key, installed
Mode selector switch (Mode T1, AUTO, REMOTE)
on the Teach pendant
LCD with LED back-light
Display TFT 7” WVGA, 4096 colours
touch, resolution 800 x 480
Dimensions 350 x 225 x 70 mm
Weight (without cable) 1200 g
1
USB 2.0 port available on the Teach Pendant
power max 500 mA
Connection method Cable
Connector X124, 19 pins
Reachable distance between Control Unit and Teach
up to 70 m
Pendant
Requirement to keep the Teach Pendant matched
Yes
with only one Control Unit
Colour Grey RAL 7016
Processor Freescale® i.MX6
Operating system Linux
Internal memory 512 Mbyte
TCP-IP
Communication protocol / method
through cable
Connection safety wired
Safety in compliance with the EN ISO 13849-1
PL = d
standard
Autonomy of usage unlimited

Tab. 2.40 - Teach Pendants C5G-TP5 with cable (without holder):

available models

Description Cable length Code Comau Part No.

C5G-TP5 Teach Pendant with cable
10 m (33 ft) C5G-TP510 CR17910185
3 positions key selector switch
R1C-4 TP5
Connection adapter cable CR17233265
ADAPTER
It includes: C5G-TP5 Teach Pendant with cable (3 positions key selector switch) and adapter cable for
connection to the R1C-4 Control Unit.

If necessary, it is also possible to install an additional optional extension, to be selected

among the models of various lengths. For details and order part numbers, see
par. 2.6.11 C5G-TP5Exx: Extension Cable for Teach Pendant C5G-TP5 on page 90.

88
 Comau Robotics Product Instruction

OPTIONS

2.6.10 R1C-4 TP5 - Connection adapter cable (CR17233255)

To connect the Teach Pendant to R1C-4 Control Unit is required a specific adapter
cable. The adapter consists of a multipolar cable already equipped with connectors at
the ends. The Teach Pendant side end (labeled with the code X124/F) is provided with
Hummel 19 pins multipolar female connector, while the R1C-4 Control Unit side end
(labeled with the code X124/M) is equipped with a D-SUB 25 pins multipolar male
connector

89
Comau Robotics Product Instruction

OPTIONS

2.6.11 C5G-TP5Exx: Extension Cable for Teach Pendant

C5G-TP5
The option C5G-TP5Exx*¹ makes available an extension cable for Teach Pendant
C5G-TP5.
The option consists of:
– Extension cable
– 19 pins female and male connectors (already wired on the cable ends). The female
connector is equipped with flange with 4 fixing holes to allow a stable wall
installation.
It is possible to order cables of different lengths, according to Tab. 2.41.

*¹ The last 2 digits of the option code indicates the length (in meters) of cable

Tab. 2.41 - C5G-TP5Exx: technical features

Feature Description
Comau Part No. – CR17240165 (code C5G-TP5E10): cable length 10 m (33 ft)
– CR17240265 (code C5G-TP5E20): cable length 20 m (66 ft)
– CR17240365 (code C5G-TP5E30): cable length 30 m (98 ft)
Usage limitations – It is allowed to install up to 2 consecutive cable extensions

90
 Comau Robotics Product Instruction

OPTIONS

2.6.12 C5G-FPB: Free Position Bracket

The C5G-FPB (Free Position Bracket) option is a metal holder equipped with a hook for
housing the TP5 Teach Pendant and cable.
The holder is equipped with 3 through holes Ø 6 mm to allow the wall fixing.
The components for the holder fixing (screws and sleeve anchors M5) are on User
charge.

Fig. 2.36 - C5G-FPB: overview

A: C5G-FPB

Tab. 2.42 - C5G-FPB: technical features

Feature Description
Comau Part No. – CR82409201
Installation position – Wall fixing, according to the need of the User

Fig. 2.37 - C5G-FPB: sizes and dimensions for the installation

A: Through hole ø 6 mm
A B: 485.5 mm (19.11 in)
A C: 376 mm (14.8 in)
D: 280 mm (11.02 in)

D
B

91
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3. TRANSPORT AND INSTALLATION

– Installation requirements
– Control Unit transporting and carrying
– Control Unit installation and connection
– The first power up

3.1 Installation requirements

In this chapter are described the following topics:
– Staff in charge of installation
– Storage environmental conditions
– Installation environment requirements
– Required equipment.

3.1.1 Staff in charge of installation

Staff in charge of installation must be trained to operate correctly with lifting devices.
Moreover the staff members shall be warned or trained (in electrics) and therefore aware
of dangers associated with electricity and of the precautions to be taken while
performing the electric connections on the power supply and interconnection signals
(safety and control signals).

3.1.2 Storage environmental conditions

The storage of the Control Unit must fulfil the following requirements:
– the packed Control Units must not be overlapped
– store only in closed, dry and protected from weather conditions environments
– the allowable room storage temperature is between -25 °C and +55 °C (-13 to 131
°F). For short periods (less than an hour) are permissible temperatures up to 70°
C (158 °F).

92
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.1.3 Installation environment requirements

The work environment where the Control Unit will be installed shall comply with the
following aspects:
– The Control Unit has been designed and manufactured in order to be installed
inside a 19” RACK cabinet.
– The Control Unit occupies the space of 6U RACK.
– The usable space between the front panel of the Control Unit and the inside of the
RACK cabinet door, must be at least 100 mm, in order to ensure a proper
ventilation and an adequate cables bending.
– The environment conditions (climate, etc.) shall fulfil therequirements specified in
chapter Technical Specifications. Moreover, it is forbidden to install the Robot
and the Control Unit in environments:
• with deflagration risk
• subject to nuclear radiations.
– The space inside the RACK cabinet must be sufficient to allow a proper ventilation
(see par. 3.2.2 Control Unit installation dimensions, weights and spaces (without
packaging) on page 96).
– Make sure that the installation area does not interfere with the accessibility of the
control devices on the cabinet and Teach Pendant.
– Arrange the cable ducts for the cable passing.
– In case of positioning of more Control Units within the same RACK cabinet, comply
with the space and operating temperature requirements. If necessary, consider the
use of appropriate cooling / air conditioning systems.
– The Control Units cannot be overlapped

93
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.1.4 Required equipment

The installation of the Control Unit requires the following equipment:
– Lifting device appropriate for the installation area
– Standard equipment such as screwdrivers, wrenches, etc.
– Gloves
– A pair of scissors
– Wire stripper
– For X30 connector:
• Crimp tool for Harting contacts Part No. 09 99 000 0175
• Removal tool for Harting contacts Part No. 09 99 000 0171

94
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.2 Control Unit transporting and carrying

This paragraph contains:
– Control Unit dimensions and weights (with packaging)
– Control Unit installation dimensions, weights and spaces (without packaging)
– Lifting and carrying methodologies
– Packaging removal

3.2.1 Control Unit dimensions and weights (with packaging)

The Control Unit is packed in cardboard box. The total weight of the packaging is
approximately 21 kg (46 lb). The dimensions (H x W x D) of the packaging are
approximately 300 x 520 x 540 mm (11.81 x 20.47 x 21.26 in).

Fig. 3.1 - Control Unit Dimensions and Weight (with packaging)

21kg

D
W

95
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.2.2 Control Unit installation dimensions, weights and spaces

(without packaging)
In the following Tab. 3.1 - Control Unit installation dimensions and spaces on page 96
are given the dimensions and the weight of the Control Unit free of packaging. Moreover,
there are indicated the dimensions useful for the installation of the Control Unit inside
the RACK cabinet. In order to allow a correct aeration and adequate cables bendings, it
is necessary a minimum distance of 100 mm between the connectors panel and the
internal part of the RACK cabinet door.

Tab. 3.1 - Control Unit installation dimensions and spaces

19 kg

A C

B E D

H
= RACK cabinet

Dimension Value
A 265.9 mm (10.46 in)
B 483 mm (19.01 in)
C 259 mm (10.19 in)
D 47.6 mm (1.87 in)
E 498 mm (19.60 in)
F*² Minimum 1U RACK *¹
G 6U RACK *¹
H Minimum 100 mm (3.93 in)
Weight 19 kg (42 lb)

*¹ 1U RACK = 44.45 mm (1.75 in)

*² Minimum distance to be interposed in case of installation of more elements in the same RACK cabinet

96
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.2.3 Lifting and carrying methodologies

The carrying of the Control Unit must be carried out using suitable lifting devices,
considering the overall weight of 21 kg (46 lb).
During lifting and carrying pay special attention not to bump the external surfaces of the
packaging; in case of bumping, the Control Unit can indeed be damaged and no longer
ensure proper operation.

3.2.4 Packaging removal

During unpackaging pay special attention not to bump and/or damage the connectors
on the front panel of the Control Unit. Do not use sharp metal tools (cutter, screwdrivers,
etc.) to avoid damaging the coating of the Control Unit external surfaces.

97
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3 Control Unit installation and connection

This paragraph contains:
– Control Unit positioning inside the RACK cabinet
– Mains electrical power supply: features and connection
– Safety circuits: minimum principles for integration
– Teach Pendant connection

98
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.1 Control Unit positioning inside the RACK cabinet

Status: – Is recommended the disconnection of

the electrical power supply of any
component already present inside the
RACK cabinet.
Material: – RACK cabinet fitted for Control Unit
installation
– 4 nuts for fixing the equipment to the
RACK
– 4 socket hex head screws M6x20
(compatible with the nuts)
Equipment: – Set of Allen wrenches
– Torque wrench with bits set

Preliminary procedures / notes

The operations of Control Unit positioning and fixing inside the RACK
cabinet, must be carried out in collaboration by two operators.
During the carrying of the Control Unit, consider the weight of 19 kg (42 lb).

If inside the RACK cabinet are already present other components, operate
carefully in order to avoid shocks or damages to the components.

Operating procedure
a. Open the RACK cabinet door.

b. Install the 4 nuts for fixing the

equipment to the RACK in the
desired position, with a distance
between centers of 190.5 mm.

c. Working in two, lift the Control

Unit using the apposite handles
A installed on the front part.
A A

99
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

Operating procedure (Continued)

d. Manually position the Control
Unit inside the RACK cabinet,
up to match the 4 holes B on the
front plate, with the holes on the
guides of the RACK cabinet.

B B

e. Manually supporting the Control

Unit, screw the 4 fixing screws
(socket hex head M6x20). It is
recommended to screw first the
2 screws on the lower side of
the Control Unit.

f. Tighten the screws to the 10.4

Nm. tightening torque.

Follow-up procedures
– Not necessary

100
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.2 Mains electrical power supply: features and connection

The following paragraphs present indications useful for connecting the Control Unit to
the electrical power supply:
– Precautions before starting
– Required equipment
– Power supply plug wiring

3.3.2.1 Precautions before starting

Before carrying out the connection to the power supply, read carefully the notes in
par. 3.1 Installation requirements on page 92.
Perform all the connection operations described in the following paragraphs with the
main switch in 0 (OFF) position and the electric power supply disconnected directly from
the power supply.

3.3.2.2 Required equipment

– Set of screwdrivers
– A pair of scissors
– Wire stripper

101
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.2.3 Power supply plug wiring

Status: – Energy supply disconnected directly

from the power supply
Material: – IEC C19 Connector (supplied with the
Control Unit - Part. No. CR19190080)
– Power supply cable (User charge)
Equipment: – Set of screwdrivers
– Torque screwdriver with bits
– Scissors for electricians
– Wire stripper

Preliminary procedures / notes

The power supply cable must have section and appropriate features to
withstand a current of 16A @ 230Vac.

Operating procedure
a. If necessary, cut the cable
coming from the power supply,
to the required length.

b. Remove the insulating sheath

on the conductors end.

c. Wire the conductors on the

supplied mating plug
connecting the phase, the
neutral and the ground as
indicated in the figure on the
side.
d. Once completed the connection, close the socket by tightening the fixing screws
to the proper torque.

e. Pull softly the cables to check the correct connection.

Follow-up procedures
– Not necessary

102
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.3 Safety circuits: minimum principles for integration

The following paragraphs present the indications useful to successfully integrate safety
signals of the Control Unit with the rest of the machine in which the robotic system is
installed:
– Precautions before starting
– Required equipment
– X30 Connector wiring
– Safety signals: principle electrical circuit diagram
– Troubleshooting for safety signals caused by inadequate mechanical installations
of safety devices

3.3.3.1 Precautions before starting

The robotic system (consisting of Robot and Control Unit) shall be used in an industrial
environment by a qualified staff member that is acquainted with the integration principles
of a Robot in a complete machine, in compliance with the basic safety requirements
listed in the machine Directive.
For the sake of convenience, the qualified staff member that will carry out the activities
described here will be referred to as the “integrator”.
This chapter describes the minimum activities that must be carried out by the integrator
for the proper integration of the control devices and emergency stop circuits of the
Control Unit into the cell.

In order to comply with the standard requirements, the integrator is responsible for the
correct integration of the safety circuits in the Robot system.

3.3.3.2 Required equipment

– Ordinary electromechanical equipment
– Crimp tool for Harting contacts Part No. 09 99 000 0175
– Removal tool for Harting contacts Part No. 09 99 000 0171
– Harting contacts (already provided with the X30 connector).

103
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.3.3 X30 Connector wiring

Status: – Energy supply disconnected directly

from the power supply
Material: – Harting stamped male contacts Part
No. 09 67 000 7176 (Q.ty 15, supplied
with the Control Unit)
– Connector and cap (supplied with the
Control Unit)
Equipment: – Set of screwdrivers
– Torque screwdriver with bits
– Crimp tool for Harting contacts Part
No. 09 99 000 0175
– Removal tool for Harting contacts Part
No. 09 99 000 0171

Preliminary procedures / notes

– The I/O signals for stop circuits are available on the X30 connector installed on
the front panel of the Control Unit.
The emergency stop push-button on the Teach Pendant is not controlled
by the stop circuit inside the Control Unit. The integrator shall connect the
above mentioned contacts to the machineemergency stop circuit by means
of the connection available on the X30 connector.
Failing to perform the connection creates a high risk for the person involved
in the programming and for the person who will run the machine.

Operating procedure
a. Depending on the intervention modalities and the machine requirements, identify
the input types to be connected (consult also the par. 2.4.4.1 Further details
about the stop circuit signals on page 37 and Tab. 2.6 - X30 Connector: pinout
on page 36).

b. Connect the signals as specified in par. 3.3.3.4 Safety signals: principle electrical
circuit diagram on page 105.

c. In case the signals analysis is required, check the status through the system
variables given in par. 2.4.4.1 Further details about the stop circuit signals on
page 37.
d. Crimp the male contacts on the conductors and assemble the connector and the
cap.

e. Insert the connector and block it using the appropriate fixing screws. Pull softly
the cables to check the correct connection.

104
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

Follow-up procedures
– Not necessary

3.3.3.4 Safety signals: principle electrical circuit diagram

.

The mushroom-shaped push-button in the Control Unit shall be included in the

emergency stop circuit.
The wiring diagrams below are to be used only as guidelines to understand the
connections. The integrator shall assess the cell/line safety requirements and carry out
the connections accordingly.

Fig. 3.2 - Stand-alone control principle diagram

Stand Alone
Operations
X30
R1C series

2
Pulse4
1
Pulse3

TP 5

Internal 12

E-Stop
13

Emg. Stop
14

External 15

E-Stop

10
Pulse4
9
Pulse3
Safety Gate
7

Auto-Stop 8

(Safety Gates)

TP = Teach Pendant E-Stop

105
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

Fig. 3.3 - Centralized control principle diagram

Line
Operations
X30 Safety Restore
R1C Series Safe Logic

TP 14 T0 Emg. Stop
Internal
15 T1

E-Stop Safe
17 I2 Inputs
16 I1

Safety Gate

Safe
2 Outputs
Pulse4
1
Pulse3
E-Stop
Line contacts
14

15

External
E-Stop

10
Pulse4
9
Pulse3
Safety Gates
Line contacts
7

8
Auto-Stop
(Safety Gates)

TP = Teach Pendant E-Stop

In the absence of TP5 Teach Pendant it is necessary to connect the bypass circuit in the
X124 connector of the R1C-4 Control Unit (which closes the contacts of the Emergency
Stop and Enabling Device).
The disconnection of the bypass circuit must be carried out with the Control Unit turned
off.

The signals electric features are given in X30 Connector: safety signals definition.

106
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.3.5 Troubleshooting for safety signals caused by inadequate

mechanical installations of safety devices
In unusual cases, when the safety devices (e.g. safety limit switch) are matched with
doors of strong or precarious structure, the door closing may cause irregular bounces
on the contacts, that affect the electric signal. These interferences on the signals can
lead the I/O modules to perform a wrong evaluation and activation of the system failure.
The involved inputs are E-Stop, Auto-Stop (on the Auto-Stop is usually connected the
safety limit switch of the cell / line access doors). The diagnosis is possible checking the
variables (bit) listed below.

Variable Function

$SLI[9]
E-Stop status.
Emergency stop
Values: 1 input closed, 0 input open
external
$SLI[12] Auto-Stop status (ignored in Programming mode)
Auto stop (fence) Values: 1 input closed, 0 input open

The reset of system failure is possible with reopening of both contacts of the
corresponding signal or with the shutdown and then restarting of the Control Unit.

107
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.4 Teach Pendant connection

Status: – Electric power supply turned off

Material: – C5G-TP5 Teach Pendant and adapter
cable for connecting to the Control
Unit
Equipment: – Not necessary

Preliminary procedures / notes

Not necessary.

Operating procedure
a. The connection of the X124 connector of the Teach Pendant, via the adapter
cable, shall be carried out on the front panel of the Control Unit.
b. Insert the mating connector (A)
of the adapter cable and screw A
tight the two fixing screws (B).
B
c. Connect the adapter cable to
the Teach Pendant cable.

d. Pull out the cable of the Teach

Pendant from the RACK
cabinet avoiding excessive
bending.

When closing the door of the RACK cabinet, avoid damaging the cable:
make sure the cable does not get pinched or in contact with sharp metal
pieces that could damage the outer sheath.
e. Roll up neatly the cable on the appropriate holder (if present).

Follow-up procedure
– Not required.

108
 Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.3.5 Suggestions for completion of the installation

After installation and connection of the Control Unit, connecting cables shall be arranged
and fixed (possibly using plastic cable ties) to the RACK cabinet structure.
It is advisable:
– Divide the power cables (motor cable, power supply cable, etc.) from the signal
cables (encoder cable, services cable, etc.).
– Avoid 90° angle bending.
– Avoid rolling up the excess power cables in many overlapped wound coils.
– Avoid the contact of the cable sheaths with sharp corners or sharp metal surfaces
in order to preserve the integrity of the sheaths.

109
Comau Robotics Product Instruction

TRANSPORT AND INSTALLATION

3.4 The first power up

– To start the Control Unit, close the main switch (position “I”).
– During the first seconds after the power up, the system carries out the required
self-tests to check the functionality of the modules. This activity is signalled by the
lighting on of the LED present on the modules.
– After performing the tests and the following system loading, the Teach Pendant will
be the interface for any kind of activity required on the Robotic system (moving,
programming, diagnostics, etc.).

The vastness of the topics related to the Control Unit power up, motion, programming
and other necessary topics, requires the consultation of additional handbooks.
Depending on requirements, the following documents are recommended:
– for power up, robotic system usage: Use of the Control Unit
– for specific applications: various handbooks of the applications

110
 Comau Robotics Product Instruction

MAINTENANCE

4. MAINTENANCE
This chapter deals with the following topics:
– General requirements for the maintenance
– Assistance for troubleshooting
– How to disconnect the electrical power supply on the Control Unit
– How to access the modules inside the Control Unit
– Maintenance structure
– Preventive maintenance
– Special maintenance
– Spare parts
– Decommissioning and disposal.

The maintenance activities that are not expressly mentioned in this handbook are not
authorized. If necessary, require the manufacturer intervention.

111
Comau Robotics Product Instruction

MAINTENANCE

4.1 General requirements for the maintenance

4.1.1 Precautions before starting

– Most maintenance activities foreseen on the Control Unit are to be carried out with
the electrical power supply turned off. In these cases the maintenance sheet is
labeled “Main switch open (OFF)”.
With main switch open, the X120 connector and the related upstream cable of the
main switch are under voltage. It is recommended to remove the power cable from
the X120 connector before performing maintenance operations.
– Use only original spare parts. The spare parts are provided by Comau. The spare
parts list is given in par. 4.8 Spare parts on page 177.

4.1.2 Precautions during the maintenance

– If the type of fault allows the Robot repositioning, it is recommended to set it in idle
position before starting the maintenance operations.

If maintenance and/or troubleshooting activities are carried out on the safety

circuits, do not stand near the Robot and move in jog at a suitable distance.

During maintenance operations that require the disassembly and removal of

the Control Unit top cover, pay attention to the braking resistor that may be hot.

112
 Comau Robotics Product Instruction

MAINTENANCE

4.1.3 Precautions at the end of the maintenance activities

– At the end of the maintenance operations check the proper functioning of the
Control Unit and the matched Robot. Check the correct execution of some Robot
working cycles and the correct functioning of safety devices before leaving the
station.

At the end of each maintenance operation, the first machine power up shall be
regarded as a test for the whole system. During this phase the operator must
stand outside the Robot range of action but in a position that allows to observe
its movements. Moreover, the Teach Pendant must be placed in close
proximity to the operator.

4.1.4 Maintenance staff

The staff in charge for maintenance activities must be instructed in order to handle
properly the lifting means (in case of the complete Control Unit replacement).
Moreover, the staff must be warned or trained (in electrical field) and therefore be aware
of the dangers associated with electric energy and of the precautions to be taken to
access in safety conditions the Control Unit modules.

4.1.5 Required equipment

The systems fixing the components (screws, nuts) have been standardised, using as
few variations as possible.
The minimum required equipment for maintenance intervention on R1C-4 Control Unit
is divided depending on the type of maintenance operation:
– for preventive maintenance see par. 4.6.2 Required equipment on page 124.
– for special maintenance see par. 4.7.2 Required equipment on page 128.

4.1.6 Tightening torques of the screws

While disassembling and reassembling the components, comply with the screw
tightening torques. Unless otherwise noted, use the tightening torques specified in the
following table:

Screw / steel stud bolt nominal

Preloading N Tightening torque [Nm]
diameter

M3 1700 1

M4 3825 3

M5 5100 5
M6 8500 10

M8 12750 20

113
Comau Robotics Product Instruction

MAINTENANCE

4.2 Assistance for troubleshooting

4.2.1 Problem analysis

The R1C-4 Control Unit provides information on the system status through:
– LEDs positioned on modules and on boards
– diagnostic messages displayed on the Teach Pendant (if present).
For troubleshooting operation it could be useful to use one or both modes (LEDs,
messages), depending on the system status:
– during the boot phase, the Teach Pendant is not functional and it is necessary to
consult the warning messaged issued by LEDs present on the modules
– when the Teach Pendant is enabled, the diagnostic messages provided are more
efficient
– in all cases, in particular for the auxiliary circuit power supplies, LEDs represent the
most immediate diagnostic procedure
– for connection between modules and further information on circuits, see the wiring
diagram of the Control Unit.

4.2.2 Diagnostic messages and alarm reset

Diagnostic messages are codified by means of numerical codes with a brief description
and can be seen on the Teach Pendant.
To facilitate the understanding of the message, find the cause that generated it and the
corresponding remedy to be taken, it is possible to use the WinR1C software.
In the main window of the software (Fig. 4.1) the above information can be viewed. To
recall the information indicate in the field (A) the error code and then press the "Find"
button (B).

Fig. 4.1 - WinR1C main window regarding error codes

A B

114
 Comau Robotics Product Instruction

MAINTENANCE

For further information on Win R1C software, error messages and recovery mode
consult the "Use of Control Unit" handbook.

4.2.3 Comau service center

In case of need it is possible to contact the Comau Service Centre at the following
addresses:

Sector Address Service provided

Assistance in troubleshooting and software
[email protected]
options request
Service
[email protected] To require spare parts
[email protected] To require repair activities

As an alternative refer to the manufacturer according to what is indicated in par. 2.1.1.4

Name and address of the manufacturer on page 24.

115
Comau Robotics Product Instruction

MAINTENANCE

4.3 How to disconnect the electrical power supply on

the Control Unit

4.3.1 Precautions and risks associated with the electrical power

supply disconnection
– After the Control Unit shutdown wait for at least 30 seconds before power it up
again.
– Before removing a connector wait for at least 30 seconds.
The non-compliance with these warnings may result in:
• blocking of one or more internal modules of the Control Unit
• impairing the functioning of one or more internal modules of the Control Unit
– In case of occurring blocking of one or more modules, shut down the system, wait
for at least 30 seconds and reconnect the power supply.
– To increase the battery life do not shut down the Control Unit before carrying out
the shutdown software procedure.
– The shutdown software procedure ensures the files and applications closing
without requiring the using of the buffer battery.

Shutting off the Control Unit when the Robot is moving, forces the system and
consequently the Robot to immediately stop without deceleration ramps, with resulting
kinematic chain stress, trajectory direction deviation (unpredictable due to the force of
gravity) with consequent risks of impact. The constant repetition of this modality of
stopping can damage the Robotic System and/or the equipment connected to the
Robot.

116
 Comau Robotics Product Instruction

MAINTENANCE

4.3.2 Disconnection of the electrical power supply

Status: – Before disconnecting the electrical

power supply, it is recommended to
disable the Robotic system by means
of the shutdown software procedure.
Material: – Not necessary
Equipment: – Not required

Preliminary procedures / notes

– Most maintenance activities foreseen on the Control Unit are to be carried out
with the electrical power supply turned off. In those cases the maintenance sheet
bears the inscription “Main switch open (OFF)”.
– Some activities, especially those related to cabinet main power supply
disconnecting, must be carried out only after having completely disconnected the
power supply of the electric mains. In these cases the maintenance sheet bears
the inscription “Electrical power supply turned off".
The main switch located on the Control Unit disconnects the power supply
only of the Robot connected to it and occasionally of the application.

– To verify the area or devices powered by a specific Control Unit it may be

necessary to refer also to the Instructions Handbook of the machine in which the
Robotic System is integrated.

117
Comau Robotics Product Instruction

MAINTENANCE

Operating procedure
Main switch open (OFF)
a. Carry out the software
shutdown. Use the specific
command on the Teach
Pendant.

b. Wait for the ending of the

shutdown procedure.

c. Position the main switch in 0

(OFF) position.

With main switch open, the X120 connector and the upstream cables of the
main switch are under voltage.

Electrical power supply turned off

The X120 connector must not be removed with the Q100 main switch
closed.

a. Disconnect the electrical power

supply as indicated in the
previous steps.

b. This activity requires the

removal of X120 connector,
located in the front of the
Control Unit.

c. Remove the X120 mating

connector

Follow-up procedure
– Not necessary.

118
 Comau Robotics Product Instruction

MAINTENANCE

4.4 How to access the modules inside the Control Unit

Status: – Whenever possible, turn off the

electrical power supply before
accessing inside the Control Unit.
Material: – Not necessary
Equipment: – Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit

Preliminary procedures / notes

When removing the top cover of the Control Unit, pay attention to the
braking resistor that may be hot.

Operating procedure
Top cover removal
a. Using a cross-head screwdriver
unscrew and remove the 2 A 1
screws (A) that fix the top cover,
positioned on the upper side of 2
the Control Unit.

b. Using a 3 mm Allen wrench, B

unscrew and remove the socket
hex head screw M4 (B) that fix
the top cover, positioned on the
rear side of the Control Unit.

c. Remove the top cover by lifting and pulling it out as indicated in the figure.

119
Comau Robotics Product Instruction

MAINTENANCE

Operating procedure (Continued)

Top cover repositioning
d. After maintenance operations,
reposition the top cover of the A 2
Control Unit, hooking it from the
front part firstly, and then
1
rotating it as indicated in figure.

e. Fix the top cover using the 2 B

screws (A)

f. Tighten the socket hex head

screw M4 (B), tightening it to
the 3 Nm. torque.

120
 Comau Robotics Product Instruction

MAINTENANCE

4.5 Maintenance structure

4.5.1 Overview
The Control Unit maintenance is divided into:
– Summary diagram of the maintenance operations
– Preventive maintenance
– Special maintenance
To facilitate the recognition of the different modules inside the Control Unit, in the
following Tab. 4.1 is given an overview of the modules and their main features.

121
Comau Robotics Product Instruction

MAINTENANCE

Tab. 4.1 - Control Unit main modules

A J

B H
C

D
G

E F

Top view, without the top cover

Position Denomination Functionality description

Control Module dedicated to the management of Robot axes.
A Acopos P3 module
There are 2 modules
B CFast for APC module Storage device for APC module
C APC2100 module Industrial PC for Control Unit management
Resistance for absorption and dissipation of the energy generated
D Braking resistor
during the motors braking
E Line filter Line EMI filter
Protection of the Teach Pendant and I/O signals 24 Vdc power
F Fuse
supply
I/O digital modules on X20 interface used for the safety signals
G X20 I/O modules
and I/O signals management for User use.
Main module for management and processing of the Control Unit
H X20 SLU module + Safe Key
safety signals
J OPS module 24 Vdc Power supply

122
 Comau Robotics Product Instruction

MAINTENANCE

4.5.2 Summary diagram of the maintenance operations

Figure Fig. 4.2 gives a schematic diagram of the complete maintenance plan where are
identified the positions and frequency of maintenance operations to be performed.
In the figure are shown the intervention points which can be identified with the
references given in the summarising tables of Tab. 4.3 - Preventive maintenance plan
on page 125 and Tab. 4.5 - Special maintenance activities on page 131.

Fig. 4.2 - Summary diagram of the maintenance operations

Fault S12
1800

480
P1

S5
S09 - S10
S2
S1
S6
S3

S07 - S08

S11

Top view, without the top cover

The periodicity in the diagram is expressed in days

123
Comau Robotics Product Instruction

PREVENTIVE MAINTENANCE

4.6 Preventive maintenance

– Precautions before starting
– Required equipment
– Preventive maintenance plan

4.6.1 Precautions before starting

– Read carefully what described in par. 4.1 General requirements for the
maintenance on page 112.
– To guarantee the Control Unit proper functioning, it is necessary to carry out
periodically preventive maintenance operations, to reduce the amount of faults
caused by the ordinary deterioration over time and maintain longer its functional
features.

4.6.2 Required equipment

The minimum equipment necessary to carry out the preventive maintenance of the
R1C-4 Control Unit is:

Tab. 4.2 - Required equipment

Flat-tip screwdriver
Cross-head screwdriver
3 mm Allen wrench
Ratchet wrench with 8 mm socket and extension rod
Torque wrench
3 mm bit for torque wrench
8 mm socket for torque wrench
Extension rod for torque wrench
Pliers for electronics
Brush with soft bristles
Vacuum cleaner
Gloves

124
 Comau Robotics Product Instruction

PREVENTIVE MAINTENANCE

4.6.3 Preventive maintenance plan

Tab. 4.3 - Preventive maintenance plan

Frequency Intervention / Sheet Ref. *¹

16 months E110: fan cleaning (see par. 4.6.4 on page 126) P1

*¹ The reference is to be found in Fig. 4.2 - Summary diagram of the maintenance operations on page 123.

125
Comau Robotics Product Instruction

PREVENTIVE MAINTENANCE - E110

4.6.4 E110: fan cleaning

Status: – Main switch open (OFF)

Material: – Not necessary
Equipment: – Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– Brush with soft bristles
– Vacuum cleaner
– Gloves

Top view, without the top cover

Preliminary procedures / notes

– To easily access the E110 fan located under the top cover of the Control Unit, it
is advisable to remove the Control Unit from inside the Rack cabinet in which it
is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
– The cooling system in perfect working order ensures the correct operation of the
Control Unit.
– The amount of dirt on the cooling fan depends on the quality of the air
circulatingin the installation area. The times given in the maintenance plan
consider a typical situation, with the Control Unit installed inside the Rack
cabinet.
The use of compressed air is not recommended, because it would be
impossible to control the removed dirt, risking to project it against the
operator's face.

Operating procedure
a. Carry out the Top cover removal.

126
 Comau Robotics Product Instruction

PREVENTIVE MAINTENANCE - E110

Operating procedure (Continued)

b. Use a brush to remove the dirt
from the fan (A) sucking up
A
simultaneously from outside
with the vacuum cleaner to
collect the dirt.

c. Carefully clean the fan blades

and the protective grilles placed
internally and externally to the
Control Unit.

d. Carry out the Top cover repositioning.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

127
Comau Robotics Product Instruction

SPECIAL MAINTENANCE

4.7 Special maintenance

– Precautions before starting
– Required equipment
– Components subject to special maintenance activities

4.7.1 Precautions before starting

– Read carefully what described in par. 4.1 General requirements for the
maintenance on page 112.

4.7.2 Required equipment

The minimum equipment necessary to carry out the special maintenance of the R1C-4
Control Unit is:

Tab. 4.4 - Required equipment

Flat-tip screwdriver
Cross-head screwdriver
Torque screwdriver with bits set
3 mm Allen wrench
Torque wrench
3 mm bit for torque wrench
8 mm socket for torque wrench
Ratchet wrench
7 and 8 mm socket for ratchet wrench
Pliers for electronics
Moreover, only in case of Connection of the PC to the Control Unit
PC with operating system (preferably Microsoft ® Windows ®, Apple OSx or Linux
distributions) and fitted with Ethernet port
Browser web (preferably updated Mozilla Firefox, Google Chrome or Apple Safari
versions)
Ethernet connection cable 5e category (it is recommended to use the crossover cable
in case of point to point connection).

128
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE

4.7.3 Connection of the PC to the Control Unit

After some maintenance operations, it is necessary to perform a series of software
configuration operations (described in the related procedures), in order to restore the
correct functionality of the system.
These operations can be performed directly from the Teach Pendant or, alternatively,
through PC by accessing the configuration web pages.
To connect your PC to the Control Unit the following steps must be carried out:
– Identification of the IP address of the Control Unit
– Connection of the PC via Ethernet cable
– Access to Web pages in the Control Unit

4.7.3.1 Identification of the IP address of the Control Unit

The IP address of the Control Unit is displayed in the main page of the Teach pendant
(see Fig. 4.3).

Fig. 4.3 - Main page of the Teach Pendant

4.7.3.2 Connection of the PC via Ethernet cable

It is necessary to connect the Ethernet port of the Personal Computer (PC) with the ETH
Connector on the front panel of the Control Unit, using for example a connection
Ethernet cable 5e category or higher.
In case of point to point connection it is recommended to use the crossover cable and it
should be noted that the Control Unit does not have the DHCP server; on the PC it is
necessary, therefore, to set an IP address (and related parameters) compatible with the
sub-network of the Control
Unit.

129
Comau Robotics Product Instruction

SPECIAL MAINTENANCE

4.7.3.3 Access to Web pages in the Control Unit

In the web browser insert the URL composed of the IP address of the Control Unit, in
the following format:
http://172.22.179.17

The example shows the address as shown in Fig. 4.3; adjust according to what appears
on your own Teach Pendant.

The browser displays the main Control Unit web page showing the main identification
data.

Fig. 4.4 - The main web page

To access the configuration pages, click on the CSE (Control Safety Equipment)
application button, then, on the next page (Fig. 4.5), click the Service button.

Fig. 4.5 - CSE pages, Service

From the Service page it is possible to perform the software configuration operations
necessary after replacement of some Control Unit components, similarly to what
indicated in the related maintenance procedures.

130
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE

4.7.4 Components subject to special maintenance activities

Tab. 4.5 - Special maintenance activities

Intervention / Sheet Ref.

APC: module replacement S1
CFast: replacement S2
Line filter: replacement S3
OPS: module replacement S5
Braking resistor: replacement S6
X20 Input / Output: module replacement (or power supply) S07
X20 Input / Output Safe: module replacement S08
X20 SLU: replacement S09
Safe-key: replacement S10
Teach Pendant: replacement S11
Control Unit: complete replacement S12

131
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

4.7.5 APC: module replacement

Status: – Main switch open (OFF)

Material: – Module APC
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– Torque screwdriver with bits for slotted
head screws

Top view, without the top cover

Preliminary procedures / notes

– To easily access the APC module located under the top cover of the Control Unit,
it is advisable to remove the Control Unit from inside the Rack cabinet in which it
is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
– After replacement of the APC module it is necessary to perform one of the
following software configuration procedures:
• System configuration with TP5 Teach pendant, with CFast recovery in case
it has been carried out the replacement only of the APC module
• System configuration with TP5 Teach pendant, with new CFast in case it
has been carried out simultaneously the replacement of the APC
module and of the CFast

Operating procedure
a. Carry out the Top cover removal.

132
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure (Continued)

b. Disconnect
• RJ45 connectors (A):
press the tab and keep it
pressed during the
extraction.
• USB connectors (B): C B A A D A
direct extraction.
• power supply connector
(C): unscrew the screws
and extract the connector.
• 10 pin RS232 connector
(D): unscrew the screws
and extract the connector.
c. Using a ratchet wrench with
extension rod and socket of 8 E F
mm, unscrew and remove the
nuts (E) that fix the APC module
(F) to the wall of the Control
Unit.

d. Remove the APC module

extracting it as indicated in
figure being careful not to bump
the support bracket of the
braking resistor.
e. Only in case of C-Fast
recovery extract the C-Fast
H G
from the old APC module. Lift
3
the flap (H) then press the 1
2
specific button and extract the
C-Fast (G).

f. Insert the C-Fast in the new

APC module, ensuring the
correct insertion followed by a
sharp click.

g. Close the flap (H).

h. Reposition the new APC
module (F) being careful not to E F
bump the support bracket of the
braking resistor.

i. Fix the APC module to the

Control Unit wall tightening the
nuts (E) to the 5 Nm. tightening
torque.

133
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure (Continued)

j. Reconnect
• RJ45 connectors (A):
ensure the proper
insertion followed by a
sharp click.
• USB connectors (B): C B A A D A
direct insertion.
• power supply connector
(C): insert the connector
and tighten the fixing
screws to the 0.5 Nm.
torque.
• 10 pin RS232 connector
(D): insert the connector
and tighten the fixing
screws to the 0.5 Nm.
torque.
k. Carry out the Top cover repositioning.

134
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

4.7.5.1 System configuration with TP5 Teach pendant, with CFast recovery

Operating procedure - system configuration with the TP5 Teach Pendant

a. Access the Control Unit with maintainer rights
a.1 Access the “Home” page (press
the Menu key, then press
Home)

a.2 Press the “Login” key

a.3 Use the virtual keyboard to fill in

the user name with the “MU”
value and confirm with the
Enter key.

a.4 Use the virtual keyboard to fill in

the password with the “MU”
value and confirm with the
Enter key.

b. Loading the system configuration

b.1 Access the “Configure” page
(press the Menu key, then press
Setup, System, Configure key).

135
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with the TP5 Teach Pendant

b.2 Choose with the softkey “...” the
adequate configuration file, so
typically referred to as:
UD:\sys\cnfg\CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

b.3 Press the “Load” key and

confirm with “Yes” key.

c. Saving the new configuration

c.1 This operation aligns the
contents of all storage areas of
the Control Unit.

c.2 Access the “Configure” page

(press the Menu key, then press
Setup, System, Configure key).

c.3 The configuration file that

appears on the screen is the
default, so typically referred to
as:
UD:\sys\cnfg\CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

c.4 Press the “Save” key and

confirm with “Yes” key.

136
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with the TP5 Teach Pendant

c.5 Reset the possible alarms “64584 New restart sequence” and “64569 Detected
the new system software restart”. In order to access the “Alarm” page (press the
Menu key, then Alarm key).
d. System restart
d.1 Access the “Home” page (press
the Menu key, then press
Home)

d.2 Press the “Restart” key

d.3 Use the arrows, select the item

1 “Complete (Cold)” and
confirm with “Enter” key.

d.4 Confirm with "Ok" key

e. Run the axes Turn Set

e.1 The system loses absolute reference coordinates and requests the Turn Set
procedure.

e.2 position each single axis of the Robot on the calibration notch in jog mode;

e.3 access the “Calib” page (press the Menu key, then press Setup, Motion, Calib
key).

e.4 select one axis at a time and confirm with "Turn Set" key;

e.5 if necessary, consult the procedure in the “Use of the Control Unit” handbook.
f. Saving the new configuration
f.1 Carry out the Saving the new configuration as indicated previously.
g. The system restart
g.1 Carry out the System restart as indicated previously.
h. Access the Control Unit with maintainer rights
h.1 Carry out the Access the Control Unit with maintainer rights procedure as
indicated previously.

137
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with the TP5 Teach Pendant

i. Check machine parameters
i.1 Verify that the parameters (machine description, calibration constants, etc.) are
consistent with what is indicated in the machine sheet. If discrepancies are
detected, perform an accurate analysis in order to identify which of the
parameters corresponds to that prior to the APC module replacement.

i.2 If necessary, it is possible to change the parameters separately or load them from
NVRAM performing in order the following operations:
• Loading the machine description parameters, calibration constants, value of
the hour meter
• Saving the new configuration
• System restart

i.3 If after Check machine parameters, there are no discrepancies, the procedure
can be considered completed.
j. Loading the machine description parameters, calibration constants, value of the
hour meter
j.1 access the “Calib” page (press
the Menu key, then press
Setup, Motion, Calib key).

138
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with the TP5 Teach Pendant

j.2 Press the “Load” key and
confirm with “Yes” key.

j.3 Exit by pressing the "Esc" key, then select the "Folder back" key.
k. Saving the new configuration
k.1 Carry out the Saving the new configuration as indicated previously.
l. System restart
l.1 Carry out the System restart as indicated previously.

139
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

4.7.5.2 System configuration with TP5 Teach pendant, with new CFast

Preliminary procedures / notes

– In order to successfully perform the system configuration procedure after the
APC and CFast replacement is indispensable to have a full backup of the last
working configuration (it is recommended to perform the backup operation on
a daily basis).
– The type of recommended backup is “Backup of the Saveset ALL” and can be
run from the Teach Pendant via the “Files Page” / “Disk” / “Backup” page.

Operating procedure - system configuration with TP5 Teach Pendant

a. Access the Control Unit with maintainer rights
a.1 Access the “Home” page (press
the Menu key, then press
Home)

a.2 Press the “Login” key

a.3 Use the virtual keyboard to fill in

the user name with the “MU”
value and confirm with the
Enter key.

a.4 Use the virtual keyboard to fill in

the password with the “MU”
value and confirm with the
Enter key.

b. Full loading of the Software version previously used

The system software is typically delivered to the User on CD-Rom when
purchasing the Control Unit. In case the CD-Rom was not available, it is
possible to request the system Software directly to Comau service center.

b.1 Copy the System software on a

USB storage device, then insert
it into the USB port on the front
panel of the Control Unit.

b.2 Access the “Reload-SW” page

(press in sequence the “Setup”,
“System”, “Reload-SW”
push-buttons).

140
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with TP5 Teach Pendant

b.3 In the “Device” field, select through the drop down menu the device on which is
present the system Software to be loaded, and then set the version of the
Software.

b.4 Select the item “Full loading of system and TP”.

b.5 Perform the loading procedure as described in detail in the "Use of Control Unit"
handbook.

b.6 After the procedure it is possible to remove the USB device.

c. Loading and saving the system configuration
c.1 Insert the USB device that
contains the backup of the
system configuration into the
USB port on the front panel of
the Control Unit.

c.2 Access the “Configure” page

(press the Menu key, then press
Setup, System, Configure key).

c.3 Press soft key "..." then choose

the appropriate configuration
file, typically referred to as:
XD:\CNTRLC5G_xxx\UD\sys\
cnfg\CNTRLC5G_xxx.C5G
(xxx = serial number of the
C5G).
c.4 Load the file by pressing "Load" and confirm with "Yes" key.

c.5 Save the configuration by pressing “Save” and confirm with “Yes” key.
d. System restart
d.1 Access the “Home” page (press
the Menu key, then press
Home)

d.2 Press the “Restart” key

d.3 Use the arrows, select the item

1 “Complete (Cold)” and
confirm with “Enter” key.

d.4 Confirm with "Ok" key

e. Access the Control Unit with maintainer rights

e.1 Carry out the Access the Control Unit with maintainer rights procedure as
indicated previously.

141
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with TP5 Teach Pendant

f. Restore with overwrite option
f.1 Carry out the Restore with overwrite option procedure, as indicated in the CFast:
replacement procedure.
g. The system restart
g.1 Carry out the System restart procedure as indicated previously.
h. Running the programs io_lib.cod and epl_gen.cod
h.1 Carry out the Running the programs io_lib.cod and epl_gen.cod procedure, as
indicated in the CFast: replacement procedure.
i. System restart
i.1 Carry out the System restart procedure as indicated previously.
j. Running the program epl_gen.cod
j.1 Run again just the epl_gen.cod program as indicated in point h.1
k. The system restart
k.1 Carry out the System restart procedure as indicated previously.
l. Run the axes Turn Set
l.1 The system loses absolute reference coordinates and requests the Turn Set
procedure.

l.2 position each single axis of the Robot on the calibration notch in jog mode;

l.3 access the “Calib” page (press the Menu key, then press Setup, Motion, Calib
key).

l.4 select one axis at a time and confirm with "Turn Set" key;

l.5 if necessary, consult the procedure in the “Use of the Control Unit” handbook.
m. Saving the new configuration
m.1 Access the “Configure” page
(press the Menu key, then press
Setup, System, Configure key).

142
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with TP5 Teach Pendant

m.2 The configuration file that
appears on the screen is the
default, so typically referred to
as:
UD:\sys\cnfg\CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

m.3 Press the “Save” key and

confirm with “Yes” key.

m.4 Reset the possible alarms “64584 New restart sequence” and “64569 Detected
the new system software restart”. In order to access the “Alarm” page (press the
Menu key, then Alarm key).
n. The system restart
n.1 Carry out the System restart procedure as indicated previously.
o. Access the Control Unit with maintainer rights
o.1 Carry out the Access the Control Unit with maintainer rights procedure as
indicated previously.
p. Check machine parameters
p.1 Verify that the parameters (machine description, calibration constants, etc.) are
consistent with what is indicated in the machine sheet. If discrepancies are
detected, perform an accurate analysis in order to identify which of the
parameters corresponds to that prior to the APC module replacement.

p.2 If necessary, it is possible to change the parameters separately or load them from
NVRAM performing in order the following operations:
• Loading the machine description parameters, calibration constants, value of
the hour meter
• Saving the new configuration
• System restart

p.3 If after Check machine parameters, there are no discrepancies, the procedure
can be considered completed.

143
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Operating procedure - system configuration with TP5 Teach Pendant

q. Loading the machine description parameters, calibration constants, value of the
hour meter
q.1 Access the “Configure” page
(press the Menù key, then press
Setup, Motion, Calib key).

q.2 Press the “Load” key and

confirm with “Yes” key.

q.3 Exit by pressing the "Esc" key, then select the "Folder back" key.
r. Saving the new configuration
r.1 Carry out the Saving the new configuration procedure as indicated previously.
s. The system restart
s.1 Carry out the System restart procedure as indicated previously.

144
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - APC

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

145
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CFAST

4.7.6 CFast: replacement

Status: – Main switch open (OFF)

Material: – CFast sheet
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– Torque screwdriver with bits for slotted
head screws

Top view, without the top cover

Preliminary procedures / notes

– The CFast is installed inside the APC module. To easily access the APC module
located under the top cover of the Control Unit, it is advisable to remove the
Control Unit from inside the Rack cabinet in which it is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.

Operating procedure
a. Carry out the Top cover removal.
b. Pull out the damaged C-Fast
from the APC module. Lift the
A B
flap (A) then press the specific
3
button and extract the C-Fast 1
2
(B).

c. Insert the new C-Fast in the

APC module, ensuring the
correct insertion followed by a
sharp click.

d. Close the flap (A).

e. Carry out the Top cover repositioning.

146
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CFAST

4.7.6.1 System Configuration with the TP5 Teach Pendant

Preliminary procedures / notes

– In order to successfully perform the system configuration procedure after the
CFast replacement is indispensable to have a full backup of the last working
configuration (it is recommended to perform the backup operation on a daily
basis).
– The type of recommended backup is “Backup of the Saveset ALL” and can be
run from the Teach Pendant via the “Files Page” / “Disk” / “Backup” page.

Operating procedure - system configuration with the TP5 Teach Pendant

a. Full loading of the Software version previously used
The system software is typically delivered to the User on CD-Rom when
purchasing the Control Unit. In case the CD-Rom was not available, it is
possible to request the system Software directly to Comau service center.

a.1 Copy the System software on a

USB storage device, then insert
it into the USB port on the front
panel of the Control Unit.

a.2 Access the “Reload-SW” page

(press in sequence the “Setup”,
“System”, “Reload-SW”
push-buttons).

a.3 In the “Device” field, select through the drop down menu the device on which is
present the system Software to be loaded, and then set the version of the
Software.

a.4 Select the item “Full loading of system and TP”.

a.5 Perform the loading procedure as described in detail in the "Use of Control Unit"
handbook.

a.6 After the procedure it is possible to remove the USB device.

147
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CFAST

Operating procedure - system configuration with the TP5 Teach Pendant

b. Loading and saving the system configuration
b.1 Insert the USB device that
contains the backup of the
system configuration into the
USB port on the front panel of
the Control Unit.

b.2 Access the “Configure” page

(press the Menu key, then press
Setup, System, Configure key).

b.3 Press soft key "..." then choose

the appropriate configuration
file, typically referred to as:
XD:\CNTRLC5G_xxx\UD\sys\
cnfg\CNTRLC5G_xxx.C5G
(xxx = serial number of the
C5G).
b.4 Load the file by pressing "Load" and confirm with "Yes" key.

b.5 Save the configuration by pressing “Save” and confirm with “Yes” key.
c. System restart
c.1 Access the “Home” page (press
the Menu key, then press
Home)

c.2 Press the “Restart” key

c.3 Use the arrows, select the item

1 “Complete (Cold)” and
confirm with “Enter” key.

c.4 Confirm with "Ok" key

148
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CFAST

Operating procedure - system configuration with the TP5 Teach Pendant

d. Access the Control Unit with maintainer rights
d.1 Access the “Home” page (press
the Menu key, then press
Home)

d.2 Press the “Login” key

d.3 Use the virtual keyboard to fill in

the user name with the “MU”
value and confirm with the
Enter key.

d.4 Use the virtual keyboard to fill in

the password with the “MU”
value and confirm with the
Enter key.

e. Restore with overwrite option

e.1 Access the “Restore” page
(press in sequence the “Files”,
“Disk”, “Restore” buttons).

e.2 Select the “Saveset” item and in

the drop down menu below,
select the “All” item.

e.3 Select the “Overwrite” item.

e.4 In the “From” field, select from the drop down menu the device within which are
found the backup files of which it is necessary to perform the restore.

e.5 Carry out the restore by pressing “OK” and confirm by pressing “Yes”
f. The system restart
f.1 Carry out the System restart procedure as indicated previously.

149
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CFAST

Operating procedure - system configuration with the TP5 Teach Pendant

g. Running the programs io_lib.cod and epl_gen.cod
g.1 Access the “Prog Page” page.

g.2 Press the “Memory” button,

then the “Load” button.

g.3 Press the “Disk” button, then

the “Device Change” button.

g.4 Select the disk UD:.

g.5 Access the directory

UD:\sys\util and carry out the
io_lib.cod program.

g.6 From the same directory run the

epl_gen.cod program.

The epl_gen.cod program requires a few tens of seconds to be executed

completely. Wait at least one minute before performing other operations,
in order to avoid to accidentally interrupt the program running.

h. The system restart

h.1 Carry out the System restart procedure as indicated previously.
i. Running the program epl_gen.cod
i.1 Run again just the epl_gen.cod program as indicated in point g.6
j. The system restart
j.1 Carry out the System restart procedure as indicated previously.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

150
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - LINE FILTER

4.7.7 Line filter: replacement

Status: – Main switch open (OFF)

Material: – Line filter
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Ratchet wrench with 8 mm socket
– 3 mm Allen wrench
– Cross-head screwdriver
– Torque wrench with 3 mm bit and 8
mm socket
– Pliers for electronics

Top view, without the top cover

Preliminary procedures / notes

– To easily access the filter located under the top cover of the Control Unit, it is
advisable to remove the Control Unit from inside the Rack cabinet in which it is
installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.

Operating procedure
a. Carry out the Top cover removal.
b. Using a ratchet wrench with 8
mm socket, unscrew and A B
remove the 2 nuts (A) that fix
the bracket to the wall of the
Control Unit. 3
D
c. Remove the bracket including
the filter, being careful not to C
pull excessively in order not to 1
damage the cables and
2
connectors connected to the
filter itself.
d. Using a pair of pliers for electronics, disconnect the wires connected to the filter
through wire terminal.

e. Using a 3 mm Allen wrench, unscrew and remove the 2 screws (B) that fix the
filter (C) on the bracket (D), then remove the filter.

151
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - LINE FILTER

Operating procedure (Continued)

f. Reassemble the new filter (C)
on the bracket (D), fixing it with A B
2 socket hex head screws M4
(B), tightening them to the 3
Nm. torque. 1
D
g. Using a pair of pliers for
electronics, reconnect the wires C
connected to the filter through
wire terminal. Connect correctly 3 2
the wires, referring to the
wiremarker labels and to the
marking stamped on the filter.
h. Reposition the bracket with the
filter in proper position, then fix
it to the wall of the Control Unit
tightening the nuts (A)
tightening them to the 5 Nm.
torque.

i. Carry out the Top cover repositioning.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.

152
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - OPS

4.7.8 OPS: module replacement

Status: – Main switch open (OFF)

Material: – Module OPS
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– Torque screwdriver with bits for slotted
head screws

Top view, without the top cover

Preliminary procedures / notes

– To easily access the OPS module located under the top cover of the Control Unit,
it is advisable to remove the Control Unit from inside the Rack cabinet in which it
is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.

Operating procedure
a. Carry out the Top cover removal.
b. Insert a flat-tip screwdriver in
the appropriate release lever B
(A) placed on the lower part of C
the OPS module (B). 1
2
c. Pull down the lever in order to
obtain the release of the OPS
module from the DIN rail (C) to
which it is fixed.

A
OPS - rear view

In the picture is represented only the rear wall of the

Control Unit
d. Keeping the lever in low position (A) remove the OPS module from the DIN rail
without pulling excessively, in order to avoid possible damage to the conductors
connected on the front of the module.

153
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - OPS

Operating procedure (Continued)

e. Using a flat-tip screwdriver
unscrew the screws of the Input D
AC (D) and Output DC (E)
terminals then remove the
conductors. It is recommended
to remove the power wires first,
and then the ground wires. E
f. Reconnect on the new OPS
module the conductors on Input
AC (D) and Output DC (E)
terminals referring to
wiremarker labels and markings
stamped on the front of the OPS
module.
g. Tighten the screws of the terminals to a 0.5 Nm. torque.
h. Reposition the OPS module (B)
on the DIN rail (C), hooking it
from the upper side first.
C 1
2

i. Rotate the OPS module as

indicated in the figure until
obtaining the correct B
attachment of the module on
the DIN rail, followed by a sharp
click.

In the picture is represented only the rear wall of the

Control Unit

j. Carry out the Top cover repositioning.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

154
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - BRAKING RESISTOR

4.7.9 Braking resistor: replacement

Status: – Main switch open (OFF)

Material: – Braking resistor
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Flat-tip screwdriver
– 3 mm Allen wrench
– Ratchet wrench with 7 mm socket
– Torque wrench with 3 mm bit

Top view, without the top cover

Preliminary procedures / notes

– To easily access the resistor located under the top cover of the Control Unit, it is
advisable to remove the Control Unit from inside the Rack cabinet in which it is
installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
The braking resistor may be hot. Wait a few minutes before performing the
replacement.

Operating procedure
a. Carry out the Top cover removal.

b. To facilitate the resistor disassembly operations, it is recommended to remove

the line filter (as indicated in the Line filter: replacement (see par. 4.7.7 on
page 151) procedure).

155
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - BRAKING RESISTOR

Operating procedure (Continued)

c. Disconnect the X6 connector
connected in the front of the A A
Acopos P31 module. To
disconnect the connector it is 2

necessary to apply a pressure

1 1
on the plastic tabs (A) present
on the connector itself, as
shown in figure, then pull out Acopos P32
the connector.
Acopos P31

d. Insert a flat-tip screwdriver in

the appropriate slots (B) on the
3
B
connector, in order to allow the
The image represents a front section of the Control Unit in
disconnection of the order to identify the connector to remove.
conductors.
e. Using a 3 mm Allen wrench and
a ratchet wrench with 7 mm E D
socket as second key, unscrew
and remove the socket hex
head screws M4 (C) and the
nuts (D) that fix the resistor (E)
on the related bracket.

f. Remove the resistor including

the cables.

g. During the resistor removal, be C F

careful not to lose the washers
(F).
The image represents the already removed line filter, as
indicated in point b. of the procedure.
h. Reassemble the new resistor
(E) on the bracket. E D
i. Fix the resistor with the socket
hex head screws M4 (C) and
the previously removed nuts
(D), interposing properly the
washers (F).

j. Using a torque wrench with 3

mm bit, tighten the screws (C)
to the 3 Nm. torque. C F

156
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - BRAKING RESISTOR

Operating procedure (Continued)

k. Insert a flat-tip screwdriver in
the appropriate slots (B) on the 2
connector and reconnect the
conductors, referring to
wiremarker labels and markings
stamped on the connector.

l. Reinsert the X6 connector in the

Acopos P32
appropriate seat on the Acopos
P31 module. Acopos P31

1 B

The image represents a front section of the Control Unit in

order to identify the connector to remove.
m. If previously removed, reassemble the line filter (as indicated in the Line filter:
replacement (see par. 4.7.7 on page 151) procedure).
n. Carry out the Top cover repositioning.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.

157
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT

4.7.10 X20 Input / Output: module replacement (or power supply)

Status: – Main switch open (OFF)

Material: – According to the needs:
• Module X20 Input / Output
(see par. 4.8.3 Spare parts list on
page 178)
• Power supply for X20 Input /
Output modules
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Flat-tip screwdriver
– Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit

Top view, without the top cover

Preliminary procedures / notes

– To easily access the X20 I/O modules located under the top cover of the Control
Unit, it is advisable to remove the Control Unit from inside the Rack cabinet in
which it is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
– In the following procedure is described the single module, free from other
possible X20 modules. It is recommended to remove from the DIN rail the entire
modules block lifting the specific levers, then pull out only the module to be
replaced, simply by sliding it into the appropriate guides, as shown in figure.
1

– The procedure is valid both in case of I/O modules replacement (both single and
double) and in case of power supply replacement.

Operating procedure
a. Carry out the Top cover removal.

158
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT

Operating procedure (Continued)

b. Remove the module which needs to be replaced (as shown in Preliminary
procedures / notes).
c. Keeping the locking clip (A)
pressed on the upper side of the A 1 3 D
terminal block (B) without E
disconnecting the cables,
remove the terminal block 2
pulling it out first from the upper
4
side, then rotating it around the
lower coupling point (C).
B F
C
The anticipated removal of the terminal block from the I/O module, is
essential to avoid possible mechanical damages on the modules during
the later stages of the procedure.

d. Keeping the trigger (D) pressed on the upper side of the I/O module (E), remove
the module from the base (F) by pulling it out in the direction indicated by the
arrow. Do not tilt the module in order to avoid possible damages to the
connectors.
e. Make sure that the connectors
areas on the new I/O module A D
(D) and on the base (E) are both 3

perfectly clean.
2
f. Insert and hook the new I/O
module (D) to the base (E), 1
holding it perfectly aligned, to
prevent possible damage to the
B E
connectors.

C
g. Insert the terminal block (B) first positioning it from the coupling point (C), and
then rotating it as indicated in figure until obtaining the coupling of the locking
lever (A), followed by a sharp click.

h. If previously removed, reinsert the module within the entire modules block, then
reposition the entire block on the DIN rail locking it with the appropriate levers.

159
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT

Operating procedure (Continued)

i. Carry out the Top cover repositioning.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

160
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT SAFE

4.7.11 X20 Input / Output Safe: module replacement

Status: – Main switch open (OFF)

Material: – Module X20 Input / Output Safe
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Flat-tip screwdriver
– Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– In case of connection via PC and web
pages:
• PC with operating system
(preferably Microsoft ®
Windows®, Apple OSx or Linux
distributions) and fitted with
Ethernet port
Top view, without the top cover • Browser web (preferably
updated Mozilla Firefox, Google
Chrome or Apple Safari versions)
• Ethernet connection cable 5e
category (it is recommended to
use the crossover cable in case
of point to point connection).

Preliminary procedures / notes

– The I/O Safe modules can be distinguished from the normal I/O modules due to
their yellow colour.
– The removal and the reassembly of the I/O module can be performed carrying
out, with the necessary adjustments, the various steps of the X20 Input / Output:
module replacement (or power supply) procedure (see par. 4.7.10 on page 158)
– In the following procedure are described only the software operations to be
performed through the Teach Pendant, after physical replacement of the module:
• Access to CSE software
• Acknowledge modules.
– The same operations can also be carried out by means of PC connection to the
Control Unit via Ethernet cable (on ETH connector located on the front panel) and
accessing web pages through the browser. For details on how to connect the PC
to the Control Unit consult the par. 4.7.3 Connection of the PC to the Control Unit
on page 129.

161
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT SAFE

Operating procedure
Access to CSE software
a. On the Teach Pendant, press
the membrane button “MENU”
to enter the “Desktop” panel.

b. Press in sequence “Service”,

“System”, “CSE” to access the
“Control Safety Equipment”
configuration pages.

162
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 INPUT / OUTPUT SAFE

Operating procedure (Continued)

Acknowledge modules
c. After I/O Safe modules
replacement, the status LED on
the CSE page is yellow and the
message bar displays the
request “Please acknowledge
new modules”. Moreover,
depending on the number of
replaced modules, one of the
buttons of “Acknowledge
modules” will be of yellow
colour.

d. Press the highlighted and corresponding to the number of replaced modules

button (in case of more than 4 modules replacement, press the “N” button and
manually enter the number of replaced modules). The system confirms that the
acknowledge operation is in progress showing the inscription “Modules
acknowledge in progress...”.

e. Wait for the shutdown procedure to end.

f. After the acknowledge
procedure, the status LED is
green, and the system is ready.
The message bar displays the
inscription “No action needed”.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

163
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SAFE-KEY

4.7.12 Safe-key: replacement

Status: – Main switch open (OFF)

Material: – Safe-key
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Flat-tip screwdriver
– Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– In case of connection via PC and web
pages:
• PC with operating system
(preferably Microsoft ®
Windows®, Apple OSx or Linux
distributions) and fitted with
Ethernet port
Top view, without the top cover • Browser web (preferably
updated Mozilla Firefox, Google
Chrome or Apple Safari versions)
• Ethernet connection cable 5e
category (it is recommended to
use the crossover cable in case
of point to point connection).

Preliminary procedures / notes

– To easily access the Safe-key installed on SLU module, under the top cover of
the Control Unit, it is advisable to remove the Control Unit from inside the Rack
cabinet in which it is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
– After Safe-key replacement is necessary to perform, through the Teach Pendant,
a series of software configuration operations:
• Access to CSE software
• Safe-key formatting and CSE software loading
• Acknowledge Safe-key
• Acknowledge modules
• Acknowledge Firmware.
– The same operations can also be carried out by means of PC connection to the
Control Unit via Ethernet cable (on ETH connector located on the front panel) and
accessing web pages through the browser. For details on how to connect the PC
to the Control Unit consult the par. 4.7.3 Connection of the PC to the Control Unit
on page 129.

Operating procedure
a. Carry out the Top cover removal.

164
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SAFE-KEY

Operating procedure (Continued)

b. Gently pull the tab (A)
outwards, in order to obtain the C
B
release of the Safe-key (B).
A
c. Apply a light pressure on the
2
Safe-key as indicated by the
arrows in figure and then pull
out and remove the Safe-key
from the SLU module (C).
1
3

d. Insert the new Safe-key (B)

inside the SLU module (C) and C
B
block it by pushing the tab (A)
as shown in figure. It is not A
necessary to make any
pressure on Safe-key to
reinsert within its own seat.

e. After the Safe-key replacement

2
it is necessary to perform a 1
series of software operations
from the Teach Pendant, as
shown in the following steps of
the procedure.
f. Carry out the Top cover repositioning.
Access to CSE software
g. On the Teach Pendant, press
the membrane button “MENU”
to enter the “Desktop” panel.

165
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SAFE-KEY

Operating procedure (Continued)

h. Press in sequence “Service”,
“System”, “CSE” to access the
“Control Safety Equipment”
configuration pages.

Safe-key formatting and CSE software loading

i. Press the “Format Safe-key”
and then press “Yes” to confirm
the operation. The system
confirms that the formatting is in
progress showing the
inscription “Safe-key format in
progress...”.

j. After finishing the Safe-key

formatting, the message bar
displays the request “Please
Reload software CSE” and the
button “Reload software CSE”
will be highlighted in yellow.

k. Press the “Reload software

CSE” button and then press
“Yes” to confirm the operation.
The system confirms that the
operation is in progress
displaying the inscription
“Software CSE reload in
progress...”.

166
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SAFE-KEY

Operating procedure (Continued)

Acknowledge Safe-key
l. After finishing the software
loading, the status LED on the
CSE page is yellow. The
message bar displays the
request “Please acknowledge
Safe-key change” and the
“Acknowledge Safe-key” button
will be highlighted in yellow.

m. Press the “Acknowledge

Safe-key” button. The system
confirms that the operation is in
progress displaying the
inscription “Safe-key
acknowledge in progress...”.

Acknowledge modules
n. After finishing the software
loading, the status LED on the
CSE page is yellow. The
message bar displays the
request “Please acknowledge
new modules” and the button
corresponding to the number of
modules that require
acknowledge will be highlighted
in yellow (in the figure case, 3
modules). In case it is
necessary to make the
acknowledge of more than 4
modules is necessary to press
the “N” button and manually
enter the number of modules.
o. Press the highlighted button to acknowledge the modules. The system confirms
that the operation is in progress displaying the inscription “Modules acknowledge
in progress...”.

167
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SAFE-KEY

Operating procedure (Continued)

Acknowledge Firmware
p. After finishing the modules
acknowledge operation, the
status LED on the CSE page is
yellow. The message bar
displays the request “Please
acknowledge firmware” and the
corresponding button will be
highlighted in yellow.

q. Press the “Acknowledge

firmware” button. The system
confirms that the operation is in
progress displaying the
inscription “Firmware
acknowledge in progress...”.

r. After the acknowledge

procedure, the status LED is
green, and the system is ready.
The message bar displays the
inscription “No action needed”.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

168
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 SLU

4.7.13 X20 SLU: replacement

Status: – Main switch open (OFF)

Material: – Module X20 SLU
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Flat-tip screwdriver
– Cross-head screwdriver
– 3 mm Allen wrench
– Torque wrench with 3 mm bit
– In case of connection via PC and web
pages:
• PC with operating system
(preferably Microsoft ®
Windows®, Apple OSx or Linux
distributions) and fitted with
Ethernet port
Top view, without the top cover • Browser web (preferably
updated Mozilla Firefox, Google
Chrome or Apple Safari versions)
• Ethernet connection cable 5e
category (it is recommended to
use the crossover cable in case
of point to point connection).

Preliminary procedures / notes

– To easily access the SLU module located under the top cover of the Control Unit,
it is advisable to remove the Control Unit from the inside of the Rack cabinet in
which it is installed:
• Disconnect the cables/connectors connected to the Control Unit
• Reverse the steps described in the Control Unit positioning inside the RACK
cabinet (see par. 3.3.1 on page 99) procedure.
– After SLU module replacement, it is necessary to carry out through the Teach
Pendant, a series of software configuration operations:
• Access to CSE software
• Acknowledge SLU
– The same operations can also be carried out by means of PC connection to the
Control Unit via Ethernet cable (on ETH connector located on the front panel) and
accessing web pages through the browser. For details on how to connect the PC
to the Control Unit consult the par. 4.7.3 Connection of the PC to the Control Unit
on page 129.

Operating procedure
a. Carry out the Top cover removal.
b. Extract the Safe-key as indicated in the Safe-key: replacement procedure.

169
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 SLU

Operating procedure (Continued)

c. Keeping the lever (A) pressed, 2
located on the upper side of the A B E D
terminal block (B), remove,
without disconnecting the
cables, the terminal block
pulling it out first from the upper
side and rotating it around the 3
1
lower coupling point (D).

C
d. Lift up the levers (D) in order to obtain the release of the SLU module (E) from
the DIN rail on which it is fixed.

e. Remove the complete SLU module (E) from the DIN rail by pulling it out in the
direction indicated by the arrow in the figure.
f. Reposition the new SLU 2
module (E) on the DIN rail, A B E D
inserting it in the direction
indicated by the arrow in the
figure.

g. Fix the SLU module to the DIN 1

rail lowering the levers (D) as 3
indicated in figure.

C
h. Insert the terminal block (B) first positioning it from the coupling point (C), and
then rotating it as indicated in figure until obtaining the coupling of the locking
lever (A), followed by a sharp click.
i. Check that the X16 and X1
switch present on the front of
the SLU module are set
respectively on the values 9 and
0. If necessary, set them
correctly.

j. Reinsert the Safe-key

previously removed as
indicated in the Safe-key:
replacement procedure.

k. Carry out the Top cover repositioning.

170
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 SLU

Operating procedure (Continued)

Access to CSE software
l. On the Teach Pendant, press
the membrane button “MENU”
to enter the “Desktop” panel.

m. Press in sequence “Service”,

“System”, “CSE” to access the
“Control Safety Equipment”
configuration pages.

171
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - X20 SLU

Operating procedure (Continued)

Acknowledge SLU
n. After SLU module replacement,
the status LED on the CSE
page is yellow and the message
bar displays the request
1

“Please acknowledge new 1

module”. In addition, the button
“Acknowledge modules” “1” will
be of yellow colour.

o. Press the highlighted button to acknowledge the module. The system confirms
that the operation is in progress displaying the inscription “Modules acknowledge
in progress...”.
p. After the acknowledge
procedure, the status LED is
green, and the system is ready.
The message bar displays the
inscription “No action needed”.

Follow-up procedure
– Reposition the Control Unit inside the Rack cabinet as described in the Control
Unit positioning inside the RACK cabinet (see par. 3.3.1 on page 99) procedure.
– Reconnect to the Control Unit all the cables/connectors previously removed.
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

172
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - TEACH PENDANT

4.7.14 Teach Pendant: replacement

Status: – Main switch open (OFF)

Material: – Depending on the requirements:
• Teach Pendant
(see par. 4.8.3 Spare parts list on
page 178)
• Cable for Teach Pendant
(see par. 4.8.3 Spare parts list on
page 178)
• Adapter cable for connection to
the Control Unit
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Medium cross-head screwdriver PH2

Preliminary procedures / notes

– The procedure given below describes the replacement of the cable. The same
procedure can be used when replacing the Teach Pendant or the adapter cable
for connection to the Control Unit.

Operating procedure
a. Unscrew the fixing screws of
the X124 connector from the
B
front panel of the Control Unit
(A).

b. Remove the X 124 connector

(B) from the Control Unit and
remove the adapter cable from A
the Teach Pendant cable.

c. Bring the Teach Pendant on the

workbench.
d. Remove the 9 cross-slotted
screws (C).

e. Lift the cover and lean it on one

side. Pay attention to the flat C
cables that shall not be pulled or
removed. C

173
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - TEACH PENDANT

Operating procedure (Continued)

f. Disconnect the connectors (D)
and (E); pull and extract softly F E
the connector body.

g. Disconnect the connector (F);

press the lever of the RJ45
connector and pull out softly. D
h. Lift the cable guide (G) and
remove completely the cable. G

i. According to the needs, replace the adapter cable or the cable of the Teach
Pendant or the Teach Pendant.

j. Reassemble the cable guide (G), then reinsert the connectors previously
removed.
k. Reposition the rear cover.

l. Close the Teach Terminal cover

and pay attention not to pinch
the cables or conductors: check C
that both cables and conductors
are positioned in the lower side C
of the compartment and are
enough distant from the screws
fixing holes. In particular check
the flat cables.

m. Fix the rear cover screwing the 9 cross-slotted screws (C).

n. Connect the adapter cable to
the Teach Pendant cable and B
reinsert the X124 connector (B)
on the Control Unit.

o. Fix the connector tightening the

fixing screws (A).
A

Follow-up procedure
– After the Teach Pendant replacement it is not required any software updating.
The verification (check) of the proper software update is made
automatically during the next reboot. When the message that identifies the
verification appears, do not interrupt the process and wait for further
updating. Afterwards the system restarts automatically with a Restart Cold.

174
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CONTROL UNIT

4.7.15 Control Unit: complete replacement

Status: – Main switch open (OFF)

Material: – Control Unit
(see par. 4.8.3 Spare parts list on
page 178)
Equipment: – Set of Allen wrenches
– Torque wrench with bits set

Preliminary procedures / notes

The operations of Control Unit removal, repositioning and fixing inside the
RACK cabinet, must be carried out in collaboration by two operators.
During the carrying of the Control Unit, consider the weight of 19 kg (42 lb).

If inside the RACK cabinet are already present other components, operate
carefully in order to avoid shocks or damages to the components.

Operating procedure
a. Open the RACK cabinet door.

b. Set the main switch of the Control Unit in open position (0 - OFF)

c. Disconnect the cables and the connectors from the Control Unit
The amount and type of connectors and cables present, may differ
depending on the number of options installed on the Control Unit.
d. Manually supporting the Control
Unit unscrew and remove the 4
socket hex head screws M6x20
(A) that fix the Control Unit to
the Rack cabinet.

e. Using the appropriate handles

manually remove the Control
Unit from inside the RACK
cabinet. A

175
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - CONTROL UNIT

Operating procedure (Continued)

f. In case of CFast recovery
f.1 Pull out the CFast and insert it into the new Control Unit, as indicated in the
procedure CFast: replacement.

f.2 Carry out the System configuration with TP5 Teach pendant, with CFast recovery
procedure, as indicated in par. 4.7.5.1.
g. In case of new CFast
g.1 Carry out the System configuration with TP5 Teach pendant, with new CFast
procedure, as indicated in par. 4.7.5.2.
h. Working in 2 persons, manually
reposition the Control Unit
inside the RACK cabinet, up to
match the 4 holes (B) on the
front panel with the holes on the
guides of the RACK cabinet.

B B
i. Manually supporting the Control
Unit screw the 4 socket hex
head screws M6x20 (A) that fix
the Control Unit to the Rack
cabinet.

j. Tighten the screws to a 10.4

Nm torque.

k. Check that the main switch of the Control Unit is in open position (0 - OFF) then
reconnect all previously removed connectors. It is advisable to connect the power
supply cable last.

l. Set the main switch in closed position (I - ON).

m. Close the RACK cabinet door.

Follow-up procedure
– Do not stand near the Robot.
– Carry out some motion cycles at reduced speed to check the proper functioning.

176
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

4.8 Spare parts

4.8.1 Precautions regarding the spare parts usage

.

For Control Unit maintenance use only original spare parts, with particular attention to
the devices used in the status and safety circuits.

Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be carried out only by Comau.
Do not use spare parts for different purposes than those indicated.

4.8.2 Where to find the spare parts

The original spare parts can be requested from Comau service center.

177
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

4.8.3 Spare parts list

In this paragraph are listed the spare part numbers of:
– Control Unit main modules
– X20 modules
– TP5 Teach Pendant

In case it was necessary to replace the entire Control Unit, the spare part number is
CR17931882.

Tab. 4.6 - Control Unit main modules

B A

F
D
Top view, without the top cover

Position Comau Part No. Description

A CFast for APC module (B&R Part No. 5CFAST.2048-00)

B CR10140788 APC2100 module

C CR17233164 Braking resistor

D CR19190081 Line filter

E CR10140382 OPS110 module

F Glass fuse 6.3x32 UL 250V 5A

178
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

Tab. 4.7 - X20 modules

B A

D
C
E F G

Top view, without the top cover

Position Comau Part No. Description

A CR10143183 X20 SLU - Safe Logic Unit B&R X20SL8101

B CR10143283 Safe-Key 2MB B&R MK0201

C CR10143184 Complete Safe Input Module

D CR10143185 Complete Safe Output Module

X20-PSIO, power supply for I/O module, complete module
E CR10146483
Composed of: X20PS2100, X20TB12, X20BM01
X20-IM16, 16 Digital Input, complete module
F CR10146184
Composed of: X20DIF371, X20TB1F, X20BM11
X20-OM16, 16 Digital Output, complete module
G CR10146284
Composed of: X20DOF322, X20TB1F, X20BM11

179
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

Tab. 4.8 - TP5 Teach Pendant

B
C

Top view, without the top cover

Position Comau Part No. Description

TP5 Teach Pendant, without cable (key selector switch 3
CR17910085
positions)
A
TP5 Teach Pendant, with cable 10 m length (key selector switch
CR17910185
3 positions)
B CR17240065 Cable including connectors for TP5 Teach Pendant, 10 m length

C CR17233265 Adapter cable for connection to the Control Unit

180
 Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

4.9 Decommissioning and disposal

4.9.1 Precautions before starting

The robotic system (consisting of Robot and Control Unit) must be disposed of in an
environmentally correct way and according to the specific methodologies of the nation
where installed.
Prepare different containers to collect the different materials separately.

4.9.2 Staff in Charge of decommissioning and dismantling

Staff in charge of dismantling should be trained to operate correctly with lifting devices.
Furthermore, the personnel must be trained (in the area of electricity) and therefore
aware of the dangers associated with the electrical power supply and of the precautions
to be taken when working on electric connections.

4.9.3 Required equipment

– Ordinary mechanical and electric equipment
– Containers

4.9.4 Procedure for disassembly, decommissioning and

dismantling the Robotic system
The following paragraph contains the most important steps to perform the
decommissioning and the dismantling of the Robotic system at the end of its operating
life. The operations described below are to be performed only by the personnel in charge
of decommissioning and dismantling:
– create all around the Robotic system enough space to perform all the movements
without risks for the staff
– bring the Robot in transport position
– set the main switch of the Control Unit in open position (0 - OFF)
– disconnect the power supply cable from the Control Unit
– disconnect all the cables connected to the Control Unit and to the Robot
– if installed, disconnect the pneumatic system from air supply and blow off the
residual air
– before moving the Robot it is recommended to remove the oils or other chemical
liquids that may be present, as indicated in the Instructions Handbook.
– read carefully and follow the instructions in the chemicals safety sheets not to
endanger the operator and to avoid polluting the environment

The disposal operations must be carried out in compliance with the legislation in force
in the country where the Robotic system is installed; dispose of the batteries, oils and
other chemical liquids respecting the environment and in accordance with the
environmental laws, transferring them in suitable waste collecting sites.

181
Comau Robotics Product Instruction

SPECIAL MAINTENANCE - SPARE PARTS

– remove the Robot and the Control Unit from the work area, adopting the
requirements indicated in the relevant Instructions Handbooks.
– consign the Robot and the Control Unit to a centre responsible for the dismantling
and disposal.

182
 Original instructions

Made in Comau