Control Unit - gongkongfs.gongkong.com/files/technicalData/201401/2014012010141900001.pdf ·...

Comau RoboticsInstruction Handbook

Control UnitStandard Version

Technical Specification

Description and general characteristics of the Control UnitGuide to the choice of the Control Unit versionGeneral description of the expandability to I/O signals, communication networks, safety devicesDescription and order codes for option

CR00757596_en-00/1010

The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2008 by COMAU - Date of publication 10/2010

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manual content limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...21

Reliability and serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Calculation power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Expandability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Compliance with the norms in force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Directives and norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Statement of incorporation of quasi-machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Manufacturer’s details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Safety devices control procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Safety solutions installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Selecting the Control Unit version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Control Unit technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Teach Pendant operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Teach Pendant technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Programming terminal with cable connection (C5G-iTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3LB-RC-C5E-SPTTOC.fm

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SUMMARY

Programming terminal with wireless connection (C5G-WiTP) . . . . . . . . . . . . . . . . . . . . . . . . 38

Connection cables between C5G and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4. DETAILS ABOUT THE C5G CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..41

Modules installed in the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Arm Controller Electromechanical (ACE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CPU, power supplies and power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Modules installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

AMS-APC820 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

AMS-PPS8 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

AMS-ASM32 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

AMS-IAM module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Thermal dissipator AMS-FMP14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Safety Distribution Module (SDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Uninterruptible Power Supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Operator Panel Devices (OPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Connector Interface Panel (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Internal ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

General information about the communication networks inside the C5G Control Unit . . . . . . . 83

Ethernet POWERLINK Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Ethernet POWERLINK Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Address on ASM modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Address on Bus Coupler module for the X20 interface modules . . . . . . . . . . . . . . . . . . . . .88

CAN Bus network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Termination resistancec in the CAN Bus net . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Address on the CAN Bus network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connector pin structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

System variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5. INTERFACING WITH THE C5G CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . ..91

Overview of the C5G Control Unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Robot, positioning devices and auxiliary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93X10 connector (Robot signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93X60 connector (Robot Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95X10-EXT connector (Extension, Positioning device signals) . . . . . . . . . . . . . . . . . . . . . . . . . 96X60-EXT connector (Extension, motors and brakes of the positioning device) . . . . . . . . . . . 96X61..X64 connectors (Signals and power for auxiliary Axes). . . . . . . . . . . . . . . . . . . . . . . . . 97

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100X30 connector (Safety items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101ETH2 connector on AMS-APC820 (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102


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COM2 connector on AMS-APC820 (RS422 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102X90 cable gland connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104X31..X32 connectors (Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106X93..X94 connector (Master field Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107COM2 connector on AMS-APC820 (RS232 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Programming and User interface on PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Overview for 24 Vdc power supply in the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11024 Vdc distribution principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Meaning of the 24 Vdc power supplies inside the Control Unit . . . . . . . . . . . . . . . . . . . . . . 11024 Vdc distribution complete diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

How to use the 24 Vdc in the user’s applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113X106/SDM connector at the user’s disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Selecting the 24 Vdc power supply source (24V I/O and 24V SAFE only) . . . . . . . . . . . . . 113Selecting the 24 Vdc source (24V I/O and 24V SAFE only) . . . . . . . . . . . . . . . . . . . . . . . . 114

Safety circuits: E-Stop, Auto-Stop (Fence) and General Stop . . . . . . . . . . . . . . . . . . . . . . . . . 115

Digital Inputs / Output on the SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Position of the connectors on the Safety Distribution Module (SDM) . . . . . . . . . . . . . . . . . 116I/O electric features and pin structure of the connectors on the Safety Distribution Module (SDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Connection diagram for the I/O on the Safety Distribution Module (SDM). . . . . . . . . . . . . . 119Configuration of the I/O on the Safety Distribution Module (SDM). . . . . . . . . . . . . . . . . . . . 120Usage restrictions for the I/O on the Safety Distribution Module (SDM) . . . . . . . . . . . . . . . 120

Inputs / Outputs and field Bus on X20 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121X20 interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Bus Coupler PFG-BCO module on X20 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

General principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123Address on Bus Coupler module for the X20 interface modules . . . . . . . . . . . . . . . . . . . .124Technical features and purchase code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125Configuration of the Bus Coupler module in the system . . . . . . . . . . . . . . . . . . . . . . . . . .125

Field Bus Modules on the X20 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126General principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126Installation rules for the field bus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127Technical features and purchase code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129Configuration of the field Bus modules in the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Digital and analog I/O module on the X20 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131General principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Rules for the installation of I/O on X20 modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132Circuit Diagram for the connction of the I/O on X20 modules . . . . . . . . . . . . . . . . . . . . . .132Prearranged solutions and technical specifications related to the digital and analog I/O. .135Powering devices technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141Digital input/output technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142Analog inputs/output technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144Configuration of the I/O modules in the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

RS232 and RS422 serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149


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Serial port technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149RS232 serial connection cable to PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Communication via Ethernet network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151ETH2 connection technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Summary of connectors and corresponding function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

6. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..155

Option listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Information abut the option installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Options for the C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157C5G-AFK: Auxiliary Fan Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157C5G-AI2 - C5G-AO2, analog I/O options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158C5G-APK1 kit Auxiliary Plate 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160C5G-APK2 kit Auxiliary Plate 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161C5G-APK3 kit Auxiliary Plate 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162C5G-APK4 kit Auxiliary Plate 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163C5G-D12 - C5G-D24, digital I/O options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164C5G-DNM-DNMI: DeviceNet Master Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167C5G-DNM-DNSI: DeviceNet Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168C5G-DNPC: movable connector for Devicenet modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 169C5G-EDI: External digital I/O interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170C5G-ETHK: Ethernet kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172C5G-HFK kit fastening hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173C5G-HMK: Hour-meter kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174C5G-HSK5: High Speed Input Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175C5G-OPK: Option Panel kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177C5G-OTK: Axis Over Travel kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180C5G-PFG-BCO: Bus Coupler module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182C5G-PFM-PDPM: Profibus-DP Master Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184C5G-PFM-PDPS: Profibus-DP Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185C5G-PFPC: movable connector for Profibus-DP modules. . . . . . . . . . . . . . . . . . . . . . . . . . 186C5G-RSK100: 100-mm rising socket kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187C5G-SMK: Signal Machine Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188C5G-TDC400: 400V Tip Dresser Command kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191C5G-TDC400-2: 400V Double Tip Dresser Command kit . . . . . . . . . . . . . . . . . . . . . . . . . . 192C5G-TDS400: 400V Tip Dresser Supply kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193C5G-UCK: user connector kit, for SDM module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195C5G-USBK: USB kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196


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Preface

PREFACE

This chapter deals with the following topics:

– Reference documents

– Content of the C5G Control Unit manuals

– Document preservation

– Manual content limits

– Symbols in the manual.

Reference documents

This document refers to the C5G Control Unit.

The complete set of manuals concerning the C5G control units consists of:

Those manuals are to be supplemented by the following documents:

Comau C5G Control Unit – Technical Specification– Transport and installation– Maintenance– Control Unit usage modes

– Schema elettrico

Comau Robot – Technical Specifications *¹– Transport and installation *¹– Maintenance *¹

Programming – PDL2 Programming Language Manual – VP2 - Visual PDL2 – Motion programming

Applications – According to the required application type.

*¹ specific for the installed Robot type

The above mentioned manuals shall be preserved in good repair for the entire Robot System operating life and shall always be available for the staff members carrying out activities on the Robot System.

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Preface

Content of the C5G Control Unit manuals

Document preservation

All documents forwarded shall be preserved nearby the Robot System and be at the disposal of all staff members, who carry out activities on the Robot System. Moreover the documents shall be preserved in good repair for the entire Robot System operating life.

Manual content limits

The images in the instruction manuals are aimed at representing the product and may differ from the items actually installed on the Robot System.

Device Manuals Contents

C5G Control Unit

– Technical Specification

– Description and main features of the Control Unit– Guide to Control Unit model selection– General description about the expanding possibilities in

relation to I/O signals, communication networks and safety devices

– Description and purchase codes for the Control Unit and its optionals.

– Transport and installation

– Information about the preparing activities and prearrangements required to install the C5G

– Dimensions and weights, transport and lifting methods– Procedures to adapt the internal components and options for

the powering network– Procedure to perform the connection to the mains– Preliminary procedure to set the Control Unit at work

– Maintenance – Help to problem-solving– Preventive maintenance plan to guarantee the C5G

efficiency over time– Preventive and special maintenance procedures– Spare part list

– Wiring diagram

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Symbols in the manual

Find below the symbols highlighting WARNING, CAUTION and NOTES together with their meaning

This symbol applies to operating procedures, technical information and precautions that are to be complied with and/or properly performed to prevent possible injuries.

This symbol applies to operating procedures, technical information and precautions that are to be complied with and/or properly performed to prevent possible equipment damages.

This symbol applies to operating procedures, technical information and precautions that need necessarily to be highlighted.

This symbol concerns the material disposal procedures ruled by the RAEE Directive.

This symbol reminds the user to avoid polluting the environment and stimulate a sustainable attitude, i.e. disposing of the materials in the suitable waste collection sites.

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General Safety Precautions

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– Responsibilities

– Safety Precautions.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robot System (Robot and Control System) are installed and handled in accordance with the Safety Standards in force in the country where the installation takes place. The application and use of the protection and safety devices necessary, the issuing of declarations of conformity and any CE markings of the system are the responsibility of the Integrator.

– COMAU Robotics & Service shall in no way be held liable for any accidents caused by incorrect or improper use of the Robot System (Robot and Control System), by tampering with circuits, components or software, or the use of spare parts that are not included in the spare parts list.

– The application of these Safety Precautions is the responsibility of the persons assigned to direct / supervise the activities indicated in the Applicability sectionally are to make sure that the Authorised Personnel is aware of and scrupulously follow the precautions contained in this document as well as the Safety Standards in addition to the Safety Standards in force in the country in which it is installed.

– The non-observance of the Safety Standards could cause injuries to the operators and damage the Robot System (Robot and Control System).

It deals with a general specification that apply to the whole Robot System. Due to ist significance, this document is referred to unreservedly in any system instruction manual.

The installation shall be made by qualified installation Personnel and should conform to all national and local codes.

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1.2 Safety Precautions

1.2.1 Purpose

These safety precautions are aimed to define the behaviour and rules to be observed when performing the activities listed in the Applicability section.

1.2.2 Definitions

Robot System (Robot and Control System)The Robot System is a functional unit consisting of Robot, Control Unit, Programming terminal and possible options.

Protected AreaThe protected area is the zone confined by the safety barriers and to be used for the installation and operation of the robot

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

Assigned Personnel The persons assigned to direct or supervise the activities of the workers referred to in the paragraph above.

Installation and Putting into ServiceThe installation is intended as the mechanical, electrical and software integration of the Robot and Control System in any environment that requires controlled movement of robot axes, in compliance with the safety requirements of the country where the system is installed.

Programming ModeOperating mode under the control of the operator, that excludes automatic operation and allows the following activities: manual handling of robot axes and programming of work cycles at low speed, programmed cycle testing at low speed and, when allowed, at the working speed.

Auto / Remote Automatic ModeOperating mode in which the robot autonomously executes the programmed cycle at the work speed, with the operators outside the protected area, with the safety barriers closed and the safety circuit activated, with local (located outside the protected area) or remote start/stop.

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

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Putting Out of Service and DismantlingPutting out of service defines the activities involved in the mechanical and electrical removal of the Robot and Control System from a production unit or from an environment in which it was under study.Dismantling consists of the demolition and dismantling of the components that make up the Robot and Control System.

IntegratorThe integrator is the professional expert responsible for the installation and putting into service of the Robot and Control System.

Incorrect UseIncorrect use is when the system is used in a manner other than that specified in the Technical Documentation.

Range of Action The robot range of action is the enveloping volume of the area occupied by the robot and its fixtures during movement in space.

1.2.3 Applicability

These Specifications are to be applied when executing the following activities:

– Installation and Putting into Service;

– Programming Mode;

– Auto / Remote Automatic Mode;

– Robot axes release;

– Maintenance and Repairs;

– Putting Out of Service and Dismantling

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1.2.4 Operating Modes

Installation and Putting into Service

– Putting into service is only possible when the Robot and Control System has been correctly and completely installed.

– The system installation and putting into service is exclusively the task of the authorised personnel.

– The system installation and putting into service is only permitted inside a protected area of an adequate size to house the robot and the fixtures it is outfitted with, without passing beyond the safety barriers. It is also necessary to check that under normal robot movement conditions there is no collision with parts inside the protected area (structural columns, power supply lines, etc.) or with the barriers. If necessary, limit the robot working areas with mechanical hard stop (see optional assemblies).

– Any fixed robot control protections are to be located outside the protected area and in a point where there is a full view of the robot movements.

– The robot installation area is to be as free as possible from materials that could impede or limit visibility.

– During installation the robot and the Control Unit are to be handled as described in the product Technical Documentation; if lifting is necessary, check that the eye-bolts are fixed securely and use only adequate slings and equipment.

– Secure the robot to the support, with all the bolts and pins foreseen, tightened to the torque indicated in the product Technical Documentation.

– If present, remove the fastening brackets from the axes and check that the fixing of the robot fixture is secured correctly.

– Check that the robot guards are correctly secured and that there are no moving or loose parts. Check that the Control Unit components are intact.

– If applicable, connect the robot pneumatic system to the air distribution line paying attention to set the system to the specified pressure value: a wrong setting of the pressure system influences correct robot movement.

– Install filters on the pneumatic system to collect any condensation.

– Install the Control Unit outside the protected area: the Control Unit is not to be used to form part of the fencing.

– Check that the voltage value of the mains is consistent with that indicated on the plate of the Control Unit.

– Before electrically connecting the Control Unit, check that the circuit breaker on the mains is locked in open position.

– Connection between the Control Unit and the three-phase supply mains at the works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned appropriately for the power installed on the Control Unit. See the product Technical Documentation.

– The power supply cable is to enter the Control Unit through the specific fairlead and be properly clamped.

– Connect the earth conductor (PE) then connect the power conductors to the main switch.

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– Connect the power supply cable, first connecting the earth conductor to the circuit breaker on the mains line, after checking with a tester that the circuit breaker terminals are not powered. Connect the cable armouring to the earth.

– Connect the signals and power cables between the Control Unit and the robot.

– Connect the robot to earth or to the Control Unit or to a nearby earth socket.

– Check that the Control Unit door (or doors) is/are locked with the key.

– A wrong connection of the connectors could cause permanent damage to the Control Unit components.

– The C5G Control Unit manages internally the main safety interlocks (gates, enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the line safety circuits, taking care to connect them as required by the Safety standards. The safety of the interlock signals coming from the transfer line (emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe circuits, is the responsibility of the Robot and Control System integrator.

– The safety of the system cannot be guaranteed if these interlocks are wrongly executed, incomplete or missing.

– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is only active in Automatic states; in Programming the power is cut out (power contactors open) immediately. The procedure for the selection of the controlled stop time (that can be set on SDM board) is contained in the Installation manual .

– When preparing protection barriers, especially light barriers and access doors, bear in mind that the robot stop times and distances are according to the stop category (0 or 1) and the weight of the robot.

– Check that the environment and working conditions are within the range specified in the specific product Technical Documentation.

– The calibration operations are to be carried out with great care, as indicated in the Technical Documentation of the specific product, and are to be concluded checking the correct position of the machine.

– To load or update the system software (for example after replacing boards), use only the original software handed over by COMAU Robotics & Service. Scrupulously follow the system software uploading procedure described in the Technical Documentation supplied with the specific product. After uploading, always make some tests moving the robot at slow speed and remaining outside the protected area.

– Check that the barriers of the protected area are correctly positioned.

In the cell/line emergency stop circuit the contacts must be included of the control unit emergency stop buttons, which are on X30. The push buttons are not interlocked in the emergency stop circuit of the Control Unit.

Check that the controlled stop time is consistent with the type of Robot connected to the Control Unit. The stop time is selected using selector switches SW1 and SW2 on the SDM board.

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Programming Mode

– The robot is only to be programmed by the authorised personnel.

– Before starting to program, the operator must check the Robot System (Robot and Control System) to make sure that there are no potentially hazardous irregular conditions, and that there is nobody inside the protected area.

– When possible the programming should be controlled from outside the protected area.

– Before operating inside the Protected Area, the operator must make sure from outside that all the necessary protections and safety devices are present and in working order, and especially that the hand-held programming unit functions correctly (slow speed, emergency stop, enabling device, etc.).

– During the programming session, only the operator with the hand-held terminal is allowed inside the Protected Area.

– If the presence of a second operator in the working area is necessary when checking the program, this person must have an enabling device interlocked with the safety devices.

– Activation of the motors (Drive On) is always to be controlled from a position outside the range of the robot, after checking that there is nobody in the area involved. The Drive On operation is concluded when the relevant machine status indication is shown.

– When programming, the operator is to keep at a distance from the robot to be able to avoid any irregular machine movements, and in any case in a position to avoid the risk of being trapped between the robot and structural parts (columns, barriers, etc.), or between movable parts of the actual robot.

– When programming, the operator is to avoid remaining in a position where parts of the robot, pulled by gravity, could execute downward movements, or move upwards or sideways (when installed on a sloped plane).

– Testing a programmed cycle at working speed with the operator inside the protected area, in some situations where a close visual check is necessary, is only to be carried out after a complete test cycle at slow speed has been executed. The test is to be controlled from a safe distance.

– Special attention is to be paid when programming using the hand-held terminal: in this situation, although all the hardware and software safety devices are active, the robot movement depends on the operator.

– During the first running of a new program, the robot may move along a path that is not the one expected.

– The modification of program steps (such as moving by a step from one point to another of the flow, wrong recording of a step, modification of the robot position out of the path that links two steps of the program), could give rise to movements not envisaged by the operator when testing the program.

– In both cases operate cautiously, always remaining out of the robot’s range of action and test the cycle at slow speed.

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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to be executed with the Robot System (Robot and Control System) integrated inside an area with safety barriers properly interlocked, as specified by Safety Standards currently in force in the Country where the installation takes place.

– Before starting the automatic mode the operator is to check the Robot and Control System and the protected area to make sure there are no potentially hazardous irregular conditions.

– The operator can only activate automatic operation after having checked:• that the Robot and Control System is not in maintenance or being repaired;• the safety barriers are correctly positioned;• that there is nobody inside the protected area;• that the Control Unit doors are closed and locked;• that the safety devices (emergency stop, safety barrier devices) are

functioning;

– Special attention is to be paid when selecting the automatic-remote mode, where the line PLC can perform automatic operations to switch on motors and start the program.

Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of optional release devices and suitable lifting devices. Such devices only enable the brake deactivation of each axis. In this case, all the system safety devices (including the emergency stop and the enable button) are cut out; also the robot axes can move upwards or downwards because of the force generated by the balancing system, or the force of gravity.

– Enabling the brake releasing device may cause the axes falling due to gravity as well as possible impacts due to an incorrect restoration, after applying the brake releasing module. The procedure for the correct usage of the brake releasing device (both for the integrated one and module one) is to be found in the maintenance manuals.

– When the motion is enabled again following the interruption of an unfinished MOVE, the track recovery typical function may generate unpredictable paths that may imply the risk of impact. This same condition arises at the next automatic cycle restarting. Avoid moving the Robot to positions that are far away from the ones provided for the motion restart; alternatively disable the outstanding MOVE programmes and/or instructions.

Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with lubricant that does not contain substances harmful to health, however, in some cases, repeated and prolonged exposure to the product could cause skin irritation, or if swallowed, indisposition. First Aid. Contact with the eyes or the skin: wash the contaminated zones with abundant water; if the irritation persists, consult a doctor. If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as soon as possible.

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

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– Maintenance, trouble-shooting and repairs are only to be carried out by authorised personnel.

– When carrying out maintenance and repairs, the specific warning sign is to be placed on the control panel of the Control Unit, stating that maintenance is in progress and it is only to be removed after the operation has been completely finished - even if it should be temporarily suspended.

– Maintenance operations and replacement of components or the Control Unit are to be carried out with the main switch in open position and locked with a padlock.

– Even if the Control Unit is not powered (main switch open), there may be interconnected voltages coming from connections to peripheral units or external power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when operating on parts of the system that are involved.

– Removal of panels, protection shields, grids, etc. is only allowed with the main switch open and padlocked.

– Faulty components are to be replaced with others having the same code, or equivalent components defined by COMAU Robotics & Service.

– Trouble-shooting and maintenance activities are to be executed, when possible, outside the protected area.

– Trouble-shooting executed on the control is to be carried out, when possible without power supply.

– Should it be necessary, during trouble-shooting, to intervene with the Control Unit powered, all the precautions specified by Safety Standards are to be observed when operating with hazardous voltages present.

– Trouble-shooting on the robot is to be carried out with the power supply cut out (Drive off).

– At the end of the maintenance and trouble-shooting operations, all deactivated safety devices are to be reset (panels, protection shields, interlocks, etc.).

– Maintenance, repairs and trouble-shooting operations are to be concluded checking the correct operation of the Robot System (Robot and Control System)and all the safety devices, executed from outside the protected area.

– When loading the software (for example after replacing electronic boards) the original software handed over by COMAU Robotics & Service is to be used. Scrupulously follow the system software loading procedure described in the specific product Technical Documentation; after loading always run a test cycle to make sure, remaining outside the protected area

– Disassembly of robot components (motors, balancing cylinders, etc.) may cause uncontrolled movements of the axes in any direction: before starting a disassembly procedure, consult the warning plates applied to the robot and the Technical Documentation supplied.

– It is strictly forbidden to remove the protective covering of the robot springs.

After replacement of the SDM module, check on the new module that the setting of the stop time on selector switches SW1 and SW2 is consistent with the type of Robot connected to the Control Unit.

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Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be carried out by Authorised Personnel.

– Bring the robot to transport position and fit the axis clamping brackets (where applicable) consulting the plate applied on the robot and the robot Technical Documentation.

– Before stating to put out of service, the mains voltage to the Control Unit must be cut out (switch off the circuit breaker on the mains distribution line and lock it in open position).

– After using the specific instrument to check there is no voltage on the terminals, disconnect the power supply cable from the circuit breaker on the distribution line, first disconnecting the power conductors, then the earth. Disconnect the power supply cable from the Control Unit and remove it.

– First disconnect the connection cables between the robot and the Control Unit, then the earth cable.

– If present, disconnect the robot pneumatic system from the air distribution line.

– Check that the robot is properly balanced and if necessary sling it correctly, then remove the robot securing bolts from the support.

– Remove the robot and the Control Unit from the work area, applying the rules indicated in the products Technical Documentation; if lifting is necessary, check the correct fastening of the eye-bolts and use appropriate slings and equipment only.

– Before starting dismantling operations (disassembly, demolition and disposal) of the Robot and Control System components, contact COMAU Robotics & Service, or one of its branches, who will indicate, according to the type of robot and Control Unit, the operating methods in accordance with safety principles and safeguarding the environment.

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

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1.2.5 Performance

The performances below shall be considered before installing the robot system:

– Stop distances

– Mission time (typ. case).

Stop distances

– With Robot in programming modality (T1), if you press the sttop pushbutton (red mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you will obtain:

– Considering the Robot in automatico modality, under full extension, full load and maximmum speed conditions, if you press the stop pushbutton (red mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1) you will trigger the Robot complete stop with controlled deleration ramp. Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 ° motion, that correspond to about 3000 mm movement measured on TCP flange. Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5 seconds.

Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years (mission time of safety-related parts of control systems (SRP/CS), according to EN ISO 13849-1).

Tab. 1.1 - Stop spaces in programming modality (T1)

ModeExpected

speedCase

Stopping time

Stopping space

T1 250 mm/sNominal 120 ms 30 mm

Limit 500 ms 125 mm

Tab. 1.2 - Safety electronics reaction time in programming modality (T1)

ModeExpected

speedCase

Stopping time

T1 250 mm/s

For the safety inputs of the SDM module (e.g. stop pushbutton of TP in wired version)

150 msFor the stop stop and enabling device inputs from the TP in wireless version, when the safety wire trasmission is active.

For the time-out of stop input and enabling device from TP in wireless version, when the safety wire transmission is lost or interrupted.

350 ms

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Introduction to the control unit: reliability and safety

2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY

The C5G Control Unit is an industrial appliance created for user-friendly, efficient and multi-purpose management of all SMART5 Comau Robot range.

The C5G Control Unit:

– is powered directly from the factory mains with a voltage from 400 Vac -15% to 500 Vac +10% with no need of any adapting transformer. Optionally it is available the voltage extended range.

– with a total maximum power of 16 kVA, it can handle robot configured with up to 16 interpolated axes, supplied with brushless synchronous motors and high-resolution Encoder-type position transducer with EnDat 2.2 interface.

– can be interfaced through the most common communication interfaces (USB, serial, Ethernet) as well as with the most common field Bus and communication protocols (CanOpen, DeviceNet, Profibus-DP, EtherNet/IP, etc.). It can become an Ethernet net node on the plant network to facilitate remote updating and diagnostics.

– can be programmed through a user-friendly software and controlled using a chosen programming terminal featuring cable or wireless connection. The programming terminal is supplied with a TFT 6.4” 4096-colour graphic display, easy-to-understand user interface, is lightweight and ergonomically structured with on-board USB interface.

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– It is easily expandable through optional modules, to better adapt to the user’s applications and make them easier.

The C5G Control Unit has been conceived to guarantee:

– Reliability and serviceability

– Calculation power

– Expandability

– Programming

– Safety

– Control modes.

The results obtained has enabled us to develop a Control Unit suitable to fulfil the requirements of multiple applications featuring high-level sophisticated performances.

2.1 Reliability and serviceabilityThe C5G Control Unit has been conceived and developed applying care and precision principles and using high-quality components, according to the following concepts:

– minimum functional divisions, with specific high-potential modules

– limited interconnections among modules, accomplished mainly through communication networks

– high MTBF: the system main items have been developed to guarantee a high MTBF. The control unit internal wiring and interconnections have been carried out such as not to impact on the main item MTBF.

– reduced MTTR: the Control Unit main items assembly is such as to guarantee a quick replacement of all control unit internal items.

– sophisticated diagnostics in order to facilitate maintenance, with the possibility of remote diagnostics as well as SMS and e-mail sending.

This Control Unit shall be matched to a SMART5 series Comau robot only.


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2.2 Calculation powerThe C5G Control Unit features state-of-the-art processors to control the trajectory and the periphery, the application software and the user’s interface, in order to ensure the highest level of performance of both areas. The processors work through a real time VxWorks operating system.

The processor controlling the movements carries out the following functions reliably and accurately:

– Servo-adaptive algorithms, with dynamic pattern calculated in real time based on the load, position speed (Smart Move) and inertia conditions. The dynamic model is applied to all 6 axes.

– Acceleration/deceleration modulation for joint-like movements, to optimize the robot motor performances in terms of speed.

– Linear interpolation featuring fly-path total programmability and constant speed.

– Circular interpolation featuring different orientation evolution possibilities (even 2 angles in relation to the trajectory).

– Possibility to control up to 16 axes:• Synchronized movements - Sync Move (function provided for)• Integrated Arms the control arm chains (1 arm carries a second one that

performs the process) (function provided for)• is open to Cooperative Motion, to control two cooperating arms (1 arm

position the item, 1 arm carries out the process).

– Conveyor tracking, to carry out the process of items moving on conveyor lines or rotating plates that are not controlled by the robot.

– Weaving, for more sophisticated arc welding processes (Cartesian weaving and high frequency joints).

– Sensor Tracking, guaranteeing the highest tracking precision and the possibility to interfacing with different sensor typologies: 3D laser telecameras, arc parameter sensors, power sensors, others (function provided for).

– Reference systems: base, tool, users, to reuse programmes on different cells.

– Collision detection: it allows to detect collision situation between the robot and the surrounding environment.

– Load self-determination: a software tool is available that allows to correctly define the load parameters that will influence the robot movements, to optimize the performances and protect the components.


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2.3 ExpandabilityThe expandability is based on the usage of standard protocols and connections, usually available in industrial environments.

The C5G Control Unit is supplied with 6 base axes that can be expanded up to 11 inside the same cabinet.

Modules are available on the Ethernet POWERLINK network for the interfacing with field and application control Bus and parallel I/O signals.

The safety circuit basic prearrangement, that can be easily integrated on the line, can be expanded using modules for the safe control on Safety Bus and axes safe shutting.

Moreover, several options allow to adapt and customize the C5G Control Unit such as to fulfil the different installation requirements.

2.4 ProgrammingThe programming features:

– on-line and off-line programming facilities through a graphic programming terminal, Personal computer and dedicated CAD (e.g. RobCad)

– PDL2 easy language combined with the potential to guarantee the robot integration in the most demanding applications

– possibility to run simultaneously more PDL2 programmes

– possibility to customize application programmes through Java graphics and language.


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2.5 Safety– Compliance with the norms in force

– Directives and norms

– Statement of incorporation of quasi-machines

– Manufacturer’s details

– Safety devices control procedures

– Safety solutions installed.

2.5.1 Compliance with the norms in force

The C5G Control Unit consists of a functional area specifically designed to fulfil the safety requirements provided for by the norms in force:

– Compliance with norm EN ISO 10218-1: the Robot Control Unit to be used with the Comau robots has been developed to fulfil the norm requirements and facilitate the controller integration

– Safe stopping circuits: the emergency stop control, that is available also as connection outside the Control Unit, ensures a safe stop of the corresponding Comau robot, also under the most demanding conditions that are to be expected (full load at high speed)

– Safe movement control circuits: the motion is triggered and controlled by the Control Unit, which ensures the correct motion accomplishing. All trajectories are constantly checked and monitored and any possible deviation due to external causes is immediately detected and corrected. If the trajectory is compromised, the immediate stop will be triggered in good time.

– Safety circuit category: all safety circuits inside on Robot Control Unit standard models are in compliance with category 3 according to standard EN ISO 13849-1 (PL = d, DCawg = 95%, MTTFd > 100, CCF = 75). Also all internal circuits, external interconnection circuits and expansion modules, which allow to increase the number of contacts for the application interfacing, comply with the same category.

– Compliance with the European Directives: Machine Directive, Electromagnetic Compatibility Directive (EMC), Low Voltage Directive and Directives pertaning the environmental protection. The Control Unit matched to a Comau robot is an “quasi-machine” (according to the definition in the Machine Directive 2006/42/CE, item 2 paragraph g). The terms of compliance with the directives are described in details in par. 2.5.3 Statement of incorporation of quasi-machines on page 27.


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2.5.2 Directives and norms

The C5G Control Unit has been designed and manufactured in compliance with the directives and norms listed in Tab. 2.1.

Tab. 2.1 - Applicable Directives and norms

Directive / Norm Description and applicability

2006/42/CE DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) (for the sake of brevity referred to as Machine directive)

2006/95/CE DIRECTIVE 2006/95/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits (for the sake of brevity referred to as Low voltage directive)

2004/108/CE DIRECTIVE 2004/108/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC (for the sake of brevity referred to as EMC Directive)

2002/95/CE DIRECTIVE 2002/95/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical and electronic equipment (for the sake of brevity referred to as RoHS Directive) and later amendments (2008/385/EC)

EN ISO 13850 Safety of machinery - Emergency stop - Principles for design

EN ISO 13732-1 Ergonomics of the thermal environment - Methods for the assessment of human responses to contact with surfaces - Part 1: Hot surfaces

EN ISO 10218-1 Robots for industrial environments - Safety requirements - Part 1: Robot

EN ISO 13849-1 Safety of machinery - Safety related parts of control systems - General principles for design

EN 60068-2-6 Basic environmental testing procedures - part 2: Vibration (sinusoidal)

EN 60068-2-31 Basic environmental testing procedures - part 2: Drop and topple, primarily for equipment type specimens

EN 60068-2-64 Environmental testing - Test methods - Test FH: vibration, broad band random (Digital Control) and guidance

EN 60204-1 Safety of Machinery - Electrical equipment of machines - Part 1: General requirements

EN 60529 Degrees of protection provided by enclosures (IP code)

EN 61000-6-2 Electromagnetic Compatibility - Generic immunity standard - Part 6-2: Industrial environment

EN 61000-6-4 Electromagnetic Compatibility - Generic emission standard - Part 6-4: Industrial environment


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2.5.3 Statement of incorporation of quasi-machines

The group consisting of the C5G Control Unit and the SMART5 series robot is supplied with statement of incorporation of quasi-machines, as provided for in the Enclosure II b. of directive 2006/42/EC.

The Statement of incorporation of quasi-machines is supplied in original together with the group consisting of the C5G Control Unit and SMART5 serie Robot.

The C5G Control Unit identification plate is posted on the electric cabinet front side.

Fig. 2.1 - C5G Control Unit Identification Plate (facsimile for version C5G-ACC3)

2.5.4 Manufacturer’s details

The manufacturer, as defined in the Machine Directive, is:

COMAU S.p.A. Robotics Business LineVia Rivalta, 3010095 Grugliasco (TO) - ITALY

it is forbidden to set the group consisting of the C5G Control Unit and the SMART5 series Robot at work before the machine in which it is to be installed is declared to be in compliance with the provisions in directive 2006/42/EC.


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2.5.5 Safety devices control procedures

To facilitate the safety devices control procedures, the controlling circuits and basic interlocks, that are necessary to control a cell, have been integrated inside the C5GRobot Control Unit.This solution represents a noticeable advantage for the installation, as it will no longer be necessary to provide for the outside interlocks controlling the safety gates or other operator protecting devices and it will simply be sufficient to connect to the dedicated connector located by the cabinet base to make use of all available safety functions.This flexibility do not damage the reverse situation, i.e. the safety signals controlling by the external circuits. In that case all C5G Robot Control Unit safety and status signals are available on the same dedicated connector.If the number of contacts related to the safety and status signals available in the Control Unit are not sufficient to control one or more applications, it is possible to use the available expansion cards to increase the contact number without altering the safety circuit category.

(In compliance with norm EN 60204-1) the stopping procedure is accomplished according to category 0 (zero) in Programming (T1) mode and to category 1 in Local automatic (AUTO) and Remote automatic (REMOTE) mode

2.5.6 Safety solutions installed

The safety circuit and the connections for the external devices allow the compliance in according to norm EN ISO 13849-1.

Find below the solutions installed to guarantee the operators’ safety:

– Emergency stop push button The red mushroom-shaped push button triggering the emergency stop is installed on the programming terminal.The potential-free push button contacts are available on the interface connector and are not connected to the internal emergency stop circuit.

– Emergency stop control The cell emergency contacts (mushroom-shaped push buttons) can be connected to the internal safety circuit to trigger the robot stopping. In automatic mode, the robot stopping is accomplished through controlled decelation ramp, in compliance with category 1, according to norm EN 60204-1.

– Enabling Device pushbuttonThe programmig terminal hosts the three-position Enabling Device with hardware control. By pressing the enabling device power is delivered to the actuating devices and the robot movements are enabled in programming operating mode. The enabling device is active in programming mode only and disabled in the other machine modes.

– Cell access gates controlThe contacts of the limit switches installed on the cell access gates can be connected to the safety circuit to control the robot stopping in automatic mode. In programming mode, those contacts are cut off to allow the robot motion with open gates.

– Safe power cut-off The 24V I/O power supply to the dedicated interface connectors depends on the following items:• emergency stop• safety gate opening in automatic mode


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• enabling device releasing in programming mode• motor-off command (Drive Off).

2.6 Control modesThe group consisting of the C5G Control Unit and SMART5 series Robot features 3 control modes. The control modes can be selected using the key selector switch located on the programming Terminal.

– Programming (T1) Used for low speed motion, to programme the robot operating trajectory.The operator may remain inside the cell. The robot movements are accomplished at reduced speed, reaching maximum 250 mm/s by the flange centre. The robot is directly controlled by the operator. Movements and program running at reduced speed are allowed.

– Local automatic (AUTO) Used to run working programmes, in automatic mode with gates closed and at set speed, that are triggered from the programming terminal.

– Remote automatic (REMOTE) Used to run programmes, in automatic mode with gates closed and at set speed, that are triggered from external devices (PLC, others).


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Versions and Technical features

3. VERSIONS AND TECHNICAL FEATURES


– Selecting the Control Unit version:

– C5G Control Unit

– Teach Pendant

– Connection cables between C5G and Robot

3.1 Selecting the Control Unit versionTo choose the most suitable C5G Control Unit version it is necessary to take into account first of all the Robot family and the related required electric power. This manual does not deal with the selection of the Robot version, please refer to the Robot specific “Technical Specifications” manuals.

The C5G Control Unit configuration has to be chosen accomplishing the following steps:

– C5G Control Unit, depending on the Robot family it will be matched to

– Teach Pendant, depending on the type of connection required between Control Unit and Programming terminal

– Connection cables between C5G and Robot, depending on the Robot family and the installation distance.

– Customizing adding optional functions (refer to Chap.6. - Options on page 155).

Fig. 3.1 - C5G Control Unit: overall view

A: C5G Control Unit

B: Teach Pendant

-: Connection cables between C5G and Robot

-: Options

B

A


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3.2 C5G Control UnitDifferent configurations are available for the C5G Control Unit. The main feature that distinguishes the configuration is the available electric power and therefore the Robot family it can be matched to.

The Control Unit includes all modules necessary to control the Robot (powering from the mains, actuating devices, signal distribution module and safety devices control). The basic version does not include the Teach Pendant and the optional modules. Also the Connection cables between C5G and Robot are to be chosen separately.

*¹ As for the information related to the Robot features and available versions, please refer to the Robot specific “Technical Specifications” manuals*² The power value does not vary with the powering voltage fluctuations, as the system works at constant power.

Fig. 3.2 - C5G Control Unit: front and rear view

This picture shows the C5G Control Unit already supplied with iTP Programming terminal.

Tab. 3.1 - C5G: available basic versions

Robot family*¹(SMART5 series)

Suitable C5G Control UnitComau Code Power *²

SiX - NS C5G-ACC1 CR17930180 8 kVA

NM - NJ (up to 450) C5G-ACC3 CR17930380 8 kVA


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3.2.1 Control Unit technical features

In Tab. 3.2 are listed the technical features of the product basic version.

Tab. 3.2 - General technical feature

C5G-ACC1 C5G-ACC3 C5G-ACC5

Size

Height x width x depth (basics version, no options) 1110 x 800 x 510 mm

43.31 x 31.50 x 20.08 in

– Height with wheel option no difference

– Height with rising socket option 100 mm +100 mm (+3.94 in)

– Height with Application Box option +540 mm (+21.26 in)

Powering details

Powering voltage(according to norm EN 60204-1 § 4.3.3, voltage breaking not exceeding 20 ms)

from 400 Vac -15% to 500 Vac +10%

(optional from 400 Vac -15% to 575 Vac +10%)*¹

Frequency(according to norm EN 60204-1 § 4.3.3)

50 at 60 Hz (±2 Hz)

Main switch breaking power 6 kA at 500 Vac

Installed power 8 kVA 8 kVA 16 kVA

Auxiliary circuit voltage 24 Vdc

Axis controlling capability

Total for the system up to 16 axes

Control Unit without expansion cabinets up to 11 axes

Environmental conditions

Cabinet protection (non including rear space)(according to norm EN 60529)

IP 54 / NEMA 12

Rear space protection (according to norm EN 60529)

IP 2x

Room temperature without cooling systems(test conditions according to norm EN 60068-2-14)

from +5 °C to +45 °C *²from +41 °F to 113 °F

Room temperature with cooling systems(test conditions according to norm EN 60068-2-14)

from +5 °C to +55 °C *²to +41 °F a 131 °F

Storage room temperature(according to norm EN 60204-1 § 4.5)

from -25 °C to +55 °Cfrom -13 °F to 131 °F

+70 °C / 158 °F fro short periods, less than a hour.

Maximum thermal gradient1,5 °C/minute2.7 °F/minute

Relative humidity(according to norm EN 60204-1 § 4.4.4, test conditions HD 323.2.3. S2)

from 5% to 95% without condensate

Installation area altitude(according to norm EN 60204-1 § 4.4.5)

from 0 to 1.000 m / 0 to 3280 ftabove sea level

Cooling

Standard booth Natural convection

Booth with cooling options Conditioner

Actuation Forced air recirculation


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*¹ It is possible to widen the voltage range with the transformer option and voltage switch on terminal board.*² With restrictions (refer to par. 4.13 Internal ventilation system on page 82).

Weight

Control Unit (basic version) The weight specified may change depending on the configuration, in particular when it deals with the version featuring Application Box. Always refer to the plate posted on the Control Unit

125 kg / 275 lb without package

Conditioner (optional) 31 kg / 68 lb

Vibrations and impacts

Sinusoidal vibrations(according to norm EN 60068-2-64)

Frequency 10 - 250 Hzacceleration 0,6 g rms axis Z

acceleration 0,2 g rms axes X-Y

Colour

Cabinet body, painted items RAL 7024

Tab. 3.2 - General technical feature (Continued)



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3.3 Teach PendantThe Control Unit basic version shall be completed with the Teach Pendant that is available in models that differ depending on the type of connection required between Control Unit and Programming terminal.

There are 2 possible solutions:

– Programming terminal with cable connection (C5G-iTP)

– Programming terminal with wireless connection (C5G-WiTP).

The technical differences are to be found in par. 3.3.2 Teach Pendant technical featureson page 36.

Fig. 3.3 - Programming terminal: overall view

3.3.1 Teach Pendant operating principle

The Teach Pendant communicate with the C5G Control Unit through the Ethernet protocol. The connection starts on the dedicated Ethernet ETH1 port of the AMS-APC820 module and, depending on the terminal type, ends directly on the C5G-iTP terminal or connects to the access point on the docking station for the C5G-WiTP terminal.

Through the color user interface it is possible to easily access all parameters and perform the Robot movements as well as run the working programmes. Using suitable application softwares (that can be developed also by the user), the interface can be customized to fulfil the requirements of specific production environments and processes.

The Programming terminal functions are complex and are dealt with in details in the usage manual.


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3.3.2 Teach Pendant technical features

*¹ Each independent communication channel can be used to send and receive data from different Wi-Fi sources at the same time.*² Implementing the Pairing / Un-Pairing procedure (Comau Patented) it is possible to use an only one terminal for 2 or more Control UnitsNA: Not Applicable

Tab. 3.3 - Teach Pendant: versions available

FeatureC5G-iTP Terminal

C5G-WiTP Terminal

Modal selector switch (Modalty T1, AUTO, REMOTE)

Installed on terminalInstalled on the docking

station

Display lit-up LCD

4096-colour TFT 6.4” resolution 640 x 480

Sizes 360 x 210 x 80 mm

Weight 1090 g 1470 g

Port USB 1.1 available on terminal 1

Connection typology Cable Wireless

Reachable distance between Control Unit and Programming terminal

up to 30 m guaranteed up to 40 m

Need to combine the terminal with one only Control Unit

Yes No*²

Colour Grey Blue

Processor Intel® PXA 270 Intel® PXA 270

Operating system Microsoft® Windows® CE Microsoft® Windows® CE

Internal memory 128 Mbyte 128 Mbyte

Communication protocol / method TCP-IP

through cableTCP-IP

IEEE802.11a

Independent communication channels *¹ (as per standard 802.11 a)

NA 19 EU / 24 USA

Connection safety wiredPairing / Un-Pairing *² -

Comau Patented

Safety according to standar EN ISO 13849-1 PL = dPL = d, DCawg = 95%,

MTTFd > 100, CCF = 75

Usage endurance illimited 5 hours (typical)

Battery charging time NA 2 hours (typical)


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3.3.3 Programming terminal with cable connection (C5G-iTP)

At the time of purchase it is necessary to choose a Station, including programming terminal and medium.

The medium can be installed on the door or be delivered separately to allow the customized installation by the line/cell control station (installation to be carried out by the user). At the time of purchase the user shall specify if it shall be pre assembled on the Unit Control door.

When only the programming terminal with cable is needed, it is possible to choose among the versions listed below.

Tab. 3.4 - Programming terminals with cable, supplied with medium: available station versions

Description Cable length Abbreviation Comau Code

Station C5G-iRT10 10 m (33 ft) C5G-iRT10 CR17431980



It includes: C5G-iTP Programming terminal with inside-cabinet cable and connectors, C5G-iBK medium.

Tab. 3.5 - Programming terminals with cable (no medium): available versions

Description Cable length Abbreviation Comau Code

C5G-iTP Terminal with cable

10 m (33 ft) C5G-iTP10 CR17910381

20 m (66 ft) C5G-iTP20 CR17910382

30 m (98 ft) C5G-iTP30 CR17910383

It includes: C5G-iTP Programming terminal with cable.


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3.3.4 Programming terminal with wireless connection (C5G-WiTP)

At the time of purchase it is necessary to choose a Station, including Programming terminal and docking station.

Tab. 3.6 - Programming terminals with cable, equipped with docking station: available station versions

Description Abbreviation Comau Code

Station C5G-xxx

It includes : C5G-WiTP wireless programming terminal, inside-cabinet cables and connectors, medium and docking station C5G-xxx on cabinet door, antenna


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3.4 Connection cables between C5G and RobotThe connection cables between the C5G Control Unit and the Robot are connected from one end by the cabinet base to another end by the Robot base, on the corresponding connector panels respectively.

The cable supply kit includes the service, motor and earth cables. The cables are fixed-laying-type and can be chosen depending on the installation required length and the Robot family:

– service cable, X10 connector by cabinet base, X1 by Robot base

– motor cable, X60 connector by cabinet base, X2 by Robot base

– earth cable, supplied with eyelet lug by the ends.

Tab. 3.7 - Cable kit to connect C5G and Robot: available versions

Comau Code Description

For all Robot versions

CR18945880Kit consisting of service, motor and earth cables.Cable length 5 m (16 ft)







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Details about the C5G Control Unit

4. DETAILS ABOUT THE C5G CONTROL UNIT


– Modules installed in the Control Unit

– Arm Controller Electromechanical (ACE)

– CPU, power supplies and power modules

– AMS-APC820 module

– AMS-PPS8 module

– AMS-ASM32 module

– AMS-IAM module

– Thermal dissipator AMS-FMP14

– Safety Distribution Module (SDM)

– Uninterruptible Power Supply (UPS)

– Operator Panel Devices (OPD)

– Connector Interface Panel (CIP)

– Internal ventilation system

– General information about the communication networks inside the C5G Control Unit

– Ethernet POWERLINK Network

– CAN Bus network

– Connector pin structure

– System variables.


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4.1 Modules installed in the Control UnitThe C5G Control Unit basic version consists of the following homogeneous groups:

– Arm Controller Electromechanical (ACE), consisting of the electromechanical modules of the mains powering section

– CPU, power supplies and power modules, consisting of the actuating modules and control unit

– Safety Distribution Module (SDM), cosmogonist of a module to control the safety signal and the 24 Vdc distribution

– Uninterruptible Power Supply (UPS), consisting of a module for the 24 Vdc backup (through battery) to power the modules for the time necessary to the shutdown in case of missing power.

– Operator Panel Devices (OPD), consisting of the Control Unit front panel where the main switch control and the options for the robot system maintenance are installed

– Connector Interface Panel (CIP), consisting of the lower front panel where the connectors for the interfacing with the Robot and the applications are located

– Internal ventilation system, consisting of fans for the air forced circulation inside the cabinet and on the rear dissipator.

To guarantee an improved versatility and adaptability, the Control Unit basic version can be supplied with Options and/or complete solutions that allow the application customization.

Fig. 4.1 shows the position of the modules installed in the Control Unit.

Fig. 4.1 - Position of the modules installed in the Control Unit

A: Arm Controller Electromechanical (ACE)

B: CPU, power supplies and power modules

C: Safety Distribution Module (SDM)

D: Uninterruptible Power Supply (UPS)

E: Operator Panel Devices (OPD)

F: Connector Interface Panel (CIP)

A

B

C

E

F

D


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4.2 Arm Controller Electromechanical (ACE)

FunctionThe Arm Controller Electromechanical (ACE) controls the electric energy distribution from the mains and removes the possible electrical troubles using the network filter.

Technical featuresThe Arm Controller Electromechanical (ACE) consists of main switch, filter and terminal boards.

Structure

Fig. 4.2 - ACE: overall view

A: Handle for main switch

B: Main switch

C: Line EMI filter

D: Power supply input terminal board

Tab. 4.1 - ACE: product codes

Component Comau CodeNo. in the Control Unit


handle and extension for switch PKZO-XH-MCC

CR19191127 1

Main switch PKZMO-25 CR19191126 1

Line EMI filter CR10140283 1

A B C D


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4.3 CPU, power supplies and power modules

FunctionThe control device, power supply units and power modules feed and control the whole system, monitor all other modules in the Control Unit and interact with them.

Technical featuresThe system consists of control unit (AMS-APC820 module), DC bus power supply (AMS-PPS8 module), 24 Vdc power supply (AMS-ASM32 module) and the power and axes control modules (AMS-IAM module). The power of the Robot controlled by the Control Unit influences the no. of axes modules installed and the related supply currents.

Each installed module can take 1 or 2 slots; the size of each slot is equal to 53,5 mm (21.00 in).

With the exception of AMS-ASM32 module (that does not require any POWERLINK connection), the remaining modules exchange information through the Ethernet POWERLINK Network. Each module has an univocal IP address. The address definition is described in par. 4.15.1 Ethernet POWERLINK Address on page 84.

Structure

Fig. 4.3 - System: overall view

A: control unit AMS-APC820 module (Acopos PC)

B: DC bus power supply AMS-PPS8 module (Passive Power Supply)

C: 24 Vdc power supply AMS-ASM32 module (Auxiliary Supply Module)

D: power and axes control modules AMS-IAM module (Inverter Axis Module)

E: Thermal dissipator AMS-FMP14

F: DC bus and 24 Vdc connector

The picture shows the typical structure for the C5G-ACC1 Control Unit

A B C D E F


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X: Not required

4.3.1 Modules installed

The system consists of the following modules:

– AMS-APC820 module (Acopos PC) (A), calculation unit made up of a dual core industrial PC module.

– AMS-PPS8 module (Passive Power Supply) (B), feeder / converter to produce the actuation DC bus.

– AMS-ASM32 module (Auxiliary Supply Module) (C), feeder / converter to produce the 24 Vdc used to power the auxiliary circuits.

– AMS-IAM module (Inverter Axis Module) (D), complete axis module, made up of the power section, position control and brake control. The IAM modules no. and

Tab. 4.2 - System: product codes

Component Slot taken Comau CodeNo. in the Control Unit


AMS-APC 820Acopos PC

1 CR10140783 1

AMS-PPS 8Passive Power Supply

2 CR10140383 1

AMS-ASM 32Auxiliary Supply Module

1 CR10140483 1

AMS-IAM 22+22Inverter Axis Module

2 CR10141583 x 2

AMS-IAM 11+11Inverter Axis Module

2 CR10141483 1 1

AMS-IAM 5,5+5,5Inverter Axis Module

1 CR10141283 1 x

AMS-IAM 2,8+2,8Inverter Axis Module

1 CR10141183 1 x

AMS-ETI22Encoder trasducer

- CR10140883 6 6

AMS-FMP 14Thermal dissipator

- CR10140183 1

C5G-ERR Recovery resistance

- CR19191128 1

Spare battery for AMS-APC 820

-

Refer to Chap.8.3 - Spare part list on

page 57 in the “Maintenance” manual

1

AMS-AFUSpare fan for

AMS-APC 820-- 2

AMS-AFUSpare fan for AMS-PPS 8

AMS-ASM 32AMS-IAM x

-- 1 each module


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sizes differ depending on Robot power and/or no. of axes to be controlled. The position control interface is a AMS-ETI22 card fitted in the AMS-IAM module.

– C5G-ERR (Energy Recovery Resistance), recovery resistance 15 ohm 2 kW)

– Thermal dissipator AMS-FMP14, aluminium plate to fasten the modules and perform the module thermal dissipation. To the dissipator are connected the bus connectors that distribue the DC bus and 24 Vdc power supply used by the modules installed.


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4.4 AMS-APC820 moduleThe AMS-APC820 module is the calculation unit that controls the trajectory generator, the HMI interface, the system and application I/O. It is master of the real-time Ethernet POWERLINK (EPL) protocol and the CANopen serial connection.

The module is an industrial Personal Computer (PC) supplied with dual core processor.

The Ethernet POWERLINK Address do not require customization by the user.

Fig. 4.4 - AMS-APC820: overall view

Battery: CMOS battery

CAN Bus: CAN Bus port for the communication with the Safety Distribution Module (SDM)

CARD SLOT: reserved expansion slot

CompactFlash Slot 1: slot for system CF

CompactFlash Slot 2: slot for CF reserved

COM1: serial portRS232 reserved

COM2: serial port RS232/RS422 for user’s applications

ETH1: Ethernet network port for Teach Pendant

ETH2: Ethernet network port dor user’s applications

DVI / SDL: monitor port reserved

LED / Switch: CAN termination on-status LED and related switch

Power button: starting push button

XD: USB port for the connection to compatible storage pheriferals

XD2: USB port reserved for option C5G-USBK: USB kit

XD3:USB port reserved for option C5G-USBK: USB kit

XD4: USB port reserved for expansion

XD5: USB port reserved for expansions

X3A: Ethernet POWERLINK port

LEDs: Status LED

Topside

Frontside

XD2

COM2 COM1

XD3

XD4

X3A

ETH1

ETH2

CAN Bus

DVI/SDL

XD5

CARDSlot

Led / Switch

Battery

Co

mp

act

Fla

sh

Slo

t1

Co

mp

act

Fla

sh

Slo

t2

XD

Fans

Leds

AMS-APC820


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Tab. 4.3 - AMS-APC820: connections and devices

Connector / component

Description

Battery

Buffer battery

Features:– Type: “Renata” 950 mAh– Life: 5 years typ. The diagnosis system advises when

about 500-hour endurance are left.

CAN Bus

CAN Bus port for the communication with the Safety Distribution Module (SDM)

Features:– Admissible speed: Max. 500 kbit/s– Max cable length: 1000 m (3281 ft)

Pins:

Between the CAN Bus network connector and the close Ethernet one is installed a dip-switch to turn on the bus termination resistance and a LED that lights up to advises that the resistance is on. Although the dip-switch and the LED are positiond slightly inwards are easily visible and reachable.

The termination resistance shall always be on.

CARD SLOTExpansion slot reserved for options (Ethernet card for field bus (ETH3), second Ethernet card for POWERLINK)

CompactFlash Slot 1

Slot for CompactFlash card including the Operating System as well as the system and user’s files.

Features:– Size: 512 Mbyte– Formatting: proprietary– Available user’s space: 290 Mbyte (UD:)

CompactFlash Slot 2

Reserved

CAN Bus

1

4

CAN resistorOn

CompactFlashSlot 1

CompactFlashSlot 2


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COM1

Serial port RS232 reserved.DSUB (tray) 9-pin male connector.

Features:– RS232, modem-capable, not-electrically insulated– UART 16550-compatible, 16-byte FIFO– Speed: Max. 115 kbaud *¹– Max cable length: 15 m (49 ft)

Pins:

*¹ depends on the cable type and length

COM2

Serial port RS232/RS422 for user’s applications. The RS232 and RS422 ports cannot be used contemporaneously.

More details in par. 5.11 RS232 and RS422 serial communication on page 149.

ETH1

Ethernet 10/100/1000 network port, reserved for the connection with the Teach Pendant

Features:– Controller: Realtek RTL8111B– Speed: 10/100/1000 Mbit/s– Max cable length: 100 m (328 ft), minimum Cat5e– Cable type: S/STP (Cat5e)

ETH2

Ethernet 10/100/1000 network port for user’s applications (e.g. connection with factory Host)

Details in par. 5.12 Communication via Ethernet network on page 151.

Tab. 4.3 - AMS-APC820: connections and devices (Continued)


Description


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DVI / SDL Monitor port reserved: DVI / SDL (Smart Display Link)

LED / Switch

LED: CAN bus network termination status signalling:– when on, it means that the termination resistance is on

(correct condition)– when off, it means that the termination is off (wrong

condition)

Switch: termination resistance on / off:– ON, termination resistance on (correct condition)– OFF, termination resistance off (wrong condition)

XDUSB port for the connection to compatible storage peripherals. Max supply current 1 A.

XD2USB port reserved for the option C5G-USBK: USB kitMax supply current 500 mA.

XD3USB port reserved for the option C5G-USBK: USB kit Max supply current 500 mA.

XD4USB port reserved for future expiations.Max supply current 1 A

XD5USB port reserved for future expiations.Max supply current 1 A

Common features for USB XD, XD2, XD3, XD4, XD5 ports:– USB 2.0 (Universal Serial Bus)– Type-A female connector.– Admissible speeds: Low speed (1.5 Mbit/s), Full speed

(12 MBit/s) and High speed (480 Mbit/s)– Connection cable length: 5 m (without HUB)

X3AEthernet POWERLINK network port for the communication with the actuation modules (intended for AMS-PPS8 module)



Description

Resetbutton XD


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LEDs

Status LED:– PWR: Power LED:

• [ON] when on it means that the APC820 is powered

– CF: CompactFlash LED: • [ON] on when accessing the CF on slot 1

– SDL: Link LED: not used– RUN: Run LED: not used– CAN: CAN Bus LED:

• [ON] on in fixed modality during the bootstrap phase

– ACT LNK: Ethernet POWERLINK LED– SPD LNK: Ethernet ETH1 LED: not used– SPD LNK: Ethernet ETH2 LED: not used



Description


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4.5 AMS-PPS8 moduleThe AMS-PPS8 module is a feeder / converter to produce the actuation DC bus.

The Ethernet POWERLINK Address is predefined at “T1=0 e T2=1”.

Fig. 4.5 - AMS-PPS8: overall view

X1: DC Bus ready signal (intended for AMS-ASM32 module)

X3A:Ethernet POWERLINK port for the communication among modules (coming from AMS-APC820 module)

X3B: Ethernet POWERLINK port for the communication among modules (intended for the first AMS-IAM module)

X5A: input for power from the mains, three-phase

X5B: Recovery resistance connection

LEDs: Status LED

Tab. 4.4 - AMS-PPS8: connections and devices


Description

X1 DC Bus ready signal (intended for AMS-ASM32 module)

Bottomside

Topside

X1

X3B

X3A

X5B

X5A

Leds

Frontside

AMS-PPS8

X1

1


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X3AEthernet POWERLINK network port for the communication with the actuation modules (coming from AMS-PPS8 module)

X3BEthernet POWERLINK network port for the communication with the actuation modules (intended for the first AMS-IAM module)

X5A Input for power from the mains, three-phase

X5B Recovery resistance connection

Tab. 4.4 - AMS-PPS8: connections and devices (Continued)


Description

X3A

X3B

X5A

X5B


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*¹ Examples of permanent errors:

– Internal error on the device (e.g. IGBT heat sink temperature sensor defective)

*² Examples of temporary errors:

– 24 VDC supply voltage exceeds the tolerance range

– DC bus voltage exceeds the tolerance range

– Internal 15 VDC control voltage exceeds the tolerance range

– Over-temperature on the module (IGBT junction, heat sink)

– Powerlink network disturbance

– Over-temperature on the line filter / regeneration choke (temperature sensor)

LEDs

Status LEDs:Supply voltage:– 24V (green)

• [ON] The 24 Vdc internal system supply voltage is within the tolerance range

Inverter - power:– RDY (green)

• [ON] The module is operational and the power stage can be enabled (operating system present and booted, no permanent or temporary errors).

– RUN (orange)• [ON] The module power stage is enabled.

– ERR (red)• [ON] A permanent*¹ or temporary*² error exists on

the module.Ethernet POWERLINK:– R/E (green/red): see Tab. 4.5– L/D1 (green): see Tab. 4.5– L/D2 (green): see Tab. 4.5Encoder (section not used):– UP (yellow): not used– DN (yellow): not used

Tab. 4.4 - AMS-PPS8: connections and devices (Continued)


Description


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Tab. 4.5 - Ethernet POWERLINK status Leds

Description

Ethernet POWERLINK:– R/E Read/Error (green/red)

• [OFF] Supply voltage is not applied to the module or initialization of the network interface has failed.• [ON, Red] The POWERLINK node number of the module is 0.• [ON, Red/Green blinking] The client is in an error state (drops out of cyclic operation).• [ON, Green blinking x1] The client recognizes a valid POWERLINK frame on the network.• [ON, Green blinking x2] Cyclic operation on the network; however the client itself is not yet

participating in cyclic operation.• [ON, Green blinking x3] Cyclic operation of the client is in preparation.• [ON, Green] The client is participating in cyclic operation.• [ON, Green flickering] The client is not participating in cyclic operation and also does not detect any

other stations on the network that are participating in cyclic operation.– L/D1 Link / Data activity Port 1 (green)

• [ON] There is a physical connection to another station on the network.• [Blinking] Activity Port 1.

– L/D2 Link / Data activity Port 2 (green)• See L/D1, for Port 2.


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4.6 AMS-ASM32 moduleThe AMS-ASM32 module is a feeder / converter to produce the 24 Vdc used to power the auxiliary circuits.

Fig. 4.6 - AMS-ASM32: overall view

X1 input for DC Bus ready signal coming from AMS-PPS8 module

X2: 24 Vdc output to power the safety circuit section of the Safety Distribution Module (SDM) and input to disable the 24 Vdc output on the X3 connector, during the shutdown procedure.

X3: 24 Vdc output to power the distribution section of the Safety Distribution Module (SDM) and 24 Vdc input/output to power the Uninterruptible Power Supply (UPS) and receive the 24 Vdc power supply back in case of missing power from the mains.

LEDs: Status LED

Tab. 4.6 - AMS-ASM32: connections and devices


Description

X1 DC Bus ready signal coming from AMS-PPS8 module, used to enable the internal DC/DC converter and produce the 24 Vdc to power the auxiliary circuits.

Topside

Frontside

Leds

X1

X2

X3

AMS-ASM32

1

X1


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*¹ The module is enabled via the input CR_OK, no electrical contact to the backplane module - check bottom mounting screws.

X2

24 Vdc output to power the safety circuit section of the Safety Distribution Module (SDM) (terminals 1 and 2, +24V2). The output is available also in case of missing power from the mains thanks to the Uninterruptible Power Supply (UPS).

Input to disable the 24 Vdc output on the X3 connector, during the shutdown procedure.

X3

24 Vdc output to power the distribution section of the Safety Distribution Module (SDM) (terminals 2 and 3, +24V1). The output is available up until shortly before the end of the shutdown procedure, even in case of missing power from the mains thanks to Uninterruptible Power Supply (UPS).

24 Vdc input/output to power the Uninterruptible Power Supply (UPS) and receive the 24 Vdc power supply back in case of missing power from the mains (terminals 1 and 4, +24VUPS).

LEDs

Status LED:Supply voltage:– 24V (green, left)

• [ON] The 24 Vdc internal system supply voltage is within the permissible tolerance

– ERR (red, left)• [ON] The module is not supplied via the DC bus

voltage. The 24 VDC internal system supply voltage is outside of the permissible tolerance (overload, over-temperature, short-circuit, etc).

24Vdc out:– 24V (green, right)

• [ON] One of the switchable 24 VDC outputs is active and the output voltage is within the permissible tolerance. The 24 VDC internal system supply voltage is within the permissible tolerance.

– ERR (red, right)• [ON] The 24 VDC internal system supply voltage

is outside of the permissible tolerance (overload, over-temperature, short-circuit, etc). At least one of the switchable outputs is active and the electronic fuse has been triggered on one or more switchable outputs.

Tab. 4.6 - AMS-ASM32: connections and devices (Continued)


Description

X2

1

X3

1


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4.7 AMS-IAM moduleThe AMS-IAM modules are axis control cards dedicated to the axes control. Configured modules are available to control 1 or 2 axes; depending on the power, the modules take 1 or 2 slots.

The Ethernet POWERLINK Address shall be customized.

Fig. 4.7 - AMS-IAM (double-slot): overall view

ETIx: Encoder AMS-ETI22 interface module

X1:axis enabling signal coming from the Safety Distribution Module (SDM)

X2:digital inputs for options C5G-HSK5: High Speed Input Kit, C5G-OTK: Axis Over Travel kit and C5G-SMK: Signal Machine Kit (usage restrictions apply)

X3A: Ethernet POWERLINK port for the communication among modules (if it deals with the first module, it come from AMS-PPS8 module, otherwise it come from the adjoining AMS-IAM module)

X3B:Ethernet POWERLINK port for the communication among modules (intended for the next AMS-IAM module)

X4A:axis brake control (first axis)

X4B:axis brake control (second axis)

X5A axis motor (first axis)

X5B axis motor (first axis)

X11: encoder connection

Bottomside

Topside

Two axis Single axis


AMS-IAM


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Fig. 4.8 - AMS-IAM (single-slot): overall view

ETIx: Encoder AMS-ETI22 interface module

X1:axis enabling signal coming from the Safety Distribution Module (SDM)

X2:digital input for options C5G-HSK5: High Speed Input Kit and C5G-OTK: Axis Over Travel kit (usage restrictions apply)

X3A: Ethernet POWERLINK port for the communication among modules (if it deals with the first module, it comes from AMS-PPS8 module, otherwise it comes from the adjoining AMS-IAM module)

X3B: Ethernet POWERLINK port for the communication among modules (intended for the next AMS-IAM module)

X4A:axis brake control (first axis)

X4B:axis brake control (second axis, if installed)

X5A axis motor (first axis)

X5B axis motor (second axis, if installed)

X11: encoder connection

Bottomside

Topside



AMS-IAM


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Tab. 4.7 - AMS-IAM (double and single): connections and devices


Description

ETI 1ETI 2

AMS-ETI22 internal module, for interface for Encoder. each module controls one only axis. ETI 1 controls the first axis.ETI 2 controls the second axis, when installed.

X1

Axis/axes enabling signal coming from the Safety Distribution Module (SDM).The X1 connector features 6 pins in case of one-axis module and 12 pins in case of double-axis module.

Do not change the position of the movable connectors in relation to the module X1 connectors, in particular when the options for the axes safe cut-off options are available. The X1 movable connectors exchanging among modules may imply risks in case one single ARM is stopped.

X2

Digital inputs for options. A specific option is associated to each module: – first module: C5G-HSK5: High Speed Input Kit– second module: C5G-OTK: Axis Over Travel kit– third module: C5G-SMK: Signal Machine Kit.

IThe second module X2 connector is supplied with terminal board with jumpers, to close the circuits of the axes over-stroke limit switches. Removing the connector without installing the C5G-OTK option causes a system error for axes over-stroke exceeding.The third module X2 connector is supplied with terminal board with jumpers, to close the alarm signal circuits by the robot border area. Removing the connector without installing the C5G-SMK option causes a system error for Robot air and flange alarms.

ETI 1

ETI 2

X1

1

X2

1


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X3A

Ethernet POWERLINK network port for the communication with the actuation modules (if it deals with the first module, it comes from AMS-PPS8 module, otherwise it comes from the adjoining AMS-IAM module)

X3BEthernet POWERLINK network port for the communication with the actuation modules (intended or the next AMS-IAM module)

X4A Axis brake control (first axis)

Tab. 4.7 - AMS-IAM (double and single): connections and devices (Continued)


Description

X3A

X3B

X4A

X4A


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X4B Axis brake control (second axis, if installed)

X5A Axis motor (first axis)

X5B Axis motor (second axis, if installed)



Description

X4B

X4B

X5A

X5A

X5B

X5B


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X11Connection for Encoder. X11 (1) is connected to the first axis.If installed, X11 (2) is connected to the second axis.



Description

X11 (1)

X11 (2)


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*¹ Examples of permanent errors:

– Low level on an enable input

– Internal error on the device (e.g. IGBT heat sink temperature sensor defective)

– Motor feedback not connected or defective

– Motor temperature sensor not connected or defective

Leds

Status Leds:Supply voltage:– 24V (green)

• [ON] The 24 Vdc internal system supply voltage is within the tolerance range

Inverter first axis:– RDY (green, left)

• [ON] The module is operational and the power stage can be enabled (operating system present and booted, no permanent or temporary errors).

• [Blinking] No signal on or both enable inputs; otherwise there is no permanent or temporary error present on the module.

– RUN (orange, left)• [ON] The module power stage is enabled.

– ERR (red, left)• [ON] A permanent *¹ or temporary *² error exists

on the module.Ethernet POWERLINK:– R/E (green/red): see Tab. 4.5– L/D1 (green): see Tab. 4.5– L/D2 (green): see Tab. 4.5Encoder SLOT 1:– UP (orange, left): Encoder direction of rotation +

• The encoder position of the connected encoder changed in the positive direction. The faster the encoder position changes, the brighter the LED is lit.

– DN (orange, left): Encoder direction of rotation -• The encoder position of the connected encoder

changed in the negative direction. The faster the encoder position changes, the brighter the LED is lit.

Status leds (only for double axis module):Inverter second axis:– RDY (green, left) see “Inverter first axis”– RUN (orange, left) see “Inverter first axis”– ERR (red, left) see “Inverter first axis”Encoder SLOT 2:– UP (orange, right): see Encoder SLOT 1– DN (orange, right): see Encoder SLOT 1



Description


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*² Examples of temporary errors:

– 24 VDC supply voltage exceeds the tolerance range

– DC bus voltage exceeds the tolerance range

– Internal 15 VDC control voltage exceeds the tolerance range

– Over-temperature on the module (IGBT junction, heat sink)

– Powerlink network disturbance

– Over-temperature on the line filter / regeneration choke (temperature sensor)


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4.8 Thermal dissipator AMS-FMP14The thermal dissipator is an aluminium plate used also as support base where all actuation modules and the Safety Distribution Module (SDM) are fastened.

The module power thermal dissipation is accomplished on this plate, that is cooled at the back through the Internal ventilation system fans.

The dissipator can host modules up to a maximum of 14 slots. Each slot size is equal to 53,5 mm (21.00 in).

Fig. 4.9 - AMS-FMP14: overall view

A:rack / dissipator

A


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4.9 Safety Distribution Module (SDM)

FunctionThe Safety Distribution Module (SDM) is the one controlling the safety signals and the 24 Vdc distribution (auxiliary and user 24 Vdc power supply).

Technical featuresThe SDM module is mechanically fastened on the ACC rack and therefore takes a slot space. Tne module 24 Vdc power supply and all signals are connected through connectors; the bus on the rack is not used.This module is supplied with inside logics with double processor to control the safety signals and the communication with the APC module via CAN Bus. The safety signal controlling is compliant to standard EN13849-1 (see par. 2.5.1).Inside the module are 2 separate interconnected cards: one for the 24 V distribution and the other to control the safety logics.

Structure

Fig. 4.10 - SDM: overall view

X3/SDM: CAN Bus from APCX4/SDM: CAN Bus to other CAN modulesX10/SDM: Safety signal expansion. X100/SDM: Power supply input for FIA5 cardX101/SDM: Power supply input for ESM5 cardX102/SDM: 24 V output for X30 (line signal connector)X103/A/B/C: 24 Vdc output reserved for internet optionsX104/SDM: Status input and inhibition output of UPS moduleX106/SDM *¹: V Safe output and 24 V I/O outputX107/SDM: Output for hour-meter (optional)X108/SDM: Enabling signals for basic axes (AMS-IAM 1, AMS-IAM 2, AMS-IAM 3)X109/SDM: Enabling singles for additional axes (AMS-IAM 4 and following ones)X110/SDM: Signals and power supply for /fro Programming terminal with cable (Wired)X112/SDM: Selector switch signal and E-stop from OPD panelX119/SDM: 24 V output for the cooling fans inside the cabinetX122/SDM: Safety signals for X30 connector (line signal connector)X124/X126/X128/SDM: Signals for applicationsX302/SDM: Signal and power supply for/from Programming terminal without cable (Wireless). X310/X311/X312/SDM *¹: digital I/O available for the userJP200: 24 Vdc selection and 0V reference to earthSW1/SW2: rotating selector switch for the emergency circuit stop timingLEDs: Status LEDReset: Reset push button (reserved)*¹ it requires the option C5G-UCK: user connector kit, for SDM module

SW1

SW2

ML1

ML2ML2

WLK

ML3

AL1

AL2

EN1 EN2

X103A

X103B

X103C

X124

PSF PEC

SL1 SL2

DRO

PSA

PBA

PIO

EPR

RESET

X310

X126

X311

X312

X128

X10

X110

X106

X101

X112

X302

X3

X4

X107

X100

X108

X109

JP200

Bottomside

Topside

X119

X122

X102

X104

Frontside

SDM


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Tab. 4.8 - SDM: product codes

Component Comau CodesNo. in the Control Unit


Safety Distribution ModuleC5G-SDM

CR17430080 1

Tab. 4.9 - SDM: connections and devices


Description

X3/SDM

CAN Bus coming from AMS-APC820 module

Pins:

X4/SDM

Direct CAN Bus to other CAN modules. A CAN line cap is fitted, if no other modules are available. The cap consists of a connector featuring a 120-ohm resistance connected between pin 1 and 2.

Pins:

Cap for CAN network

Pin Signal

1 CAN H (CAN High)

2 CAN L (CAN Low)

3 CAN � (CAN Ground)

4 Not connected

5 Not connected

6 Not connected

7 Not connected

8 Not connected

Pin Signal

1 CAN H (CAN High)

2 CAN L (CAN Low)

3 CAN � (CAN Ground)

4 Not connected

5 Not connected

6 Not connected

7 Not connected

8 Not connected

1 = CAN H2 = CAN L3 = GND

CAN BusRj45 Pins

120 ohm1% ¼ W

120 ohm1% ¼ W

or Comau cod. 17201560


00/1010


X10/SDM

The SDM module does not supply the repeated contacts for any of the safety signal. To obtain the repetition it is necessary to install the optional modules C5G-ERM1: mod.1 expansion of the SDM module safety functions and/or C5G-ERM2: mod.2 expansion of the SDM module safety functions.ERM-1: It delivers the repetition of the signal: – E-Stop from line – Drive ON– Status selector switch in programming positionERM-2: It delivers the repetition of the signal: – A-Stop from line– PT Enabling device– Status selector switch in automatic position

X100/SDM

Power supply input for 24 Vdc coming from AMS-ASM32 module for the card inside the SDM module controlling the distribution of the 24 Vdc power supply

Features:– Voltage: 24 Vdc– Corresponding signal: +24V1, 0V(24V1)

X101/SDM

Power supply input for 24 Vdc coming from AMS-ASM32 module for the card inside the SDM module controlling the safety circuits. It includes also the signal to cut off the 24 Vdc on X100 during the shutdown phase. The UPS module guarantees the 24 Vdc on those terminals in case of missing power.

Features:– Voltage: 24 Vdc– Corresponding signal: +24V2, 0V(24V2)

X102/SDM

24 Vdc power supply input/output for X30 connector (Safety items)

Features:– Voltage: 24 Vdc– Max current: 1 A (V24 INTP), 8 A (V24 Ext), 4A

(V24 Ext FieldBus)– Corresponding signals: V24 INTP, V24 Ext,

V24 Ext FieldBus

X103/A/SDMX103/B/SDMX103/C/SDM

Direct and protected 24 Vdc power supply output for internal devices that do not require the cut-off with E-Stop. Those connectors are reserved for the option power supplies.The movable connector is supplied together with the option.

Features:– Voltage: 24 Vdc– Max total current between connector: 5 A– Corresponding signal: +24 Vint

Tab. 4.9 - SDM: connections and devices (Continued)


Description

X10


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X104/SDM

Status input and inhibition output of UPS module.The SDM module reads the Ready (UPS ready), Buffering (UPS in only-battery mode), Replace Battery (battery to be replaced) status. Moreover, an output allows to turn off the UPS by sending the inhibition signal.

X106/SDM

24 V Safe protected power supply output and 24 V I/O output to power the cards and devices that require the cut-off with E-Stop.

More details in par. 5.7 How to use the 24 Vdc in the user’s applications on page 113.

X107/SDMOutput to connect the hour-meter (C5G-HMK: Hour-meter kit optional).

X108/SDM Enabling signals for AMS-IAM module 1, 2 and 3.

X109/SDMEnabling signals for additional AMS-IAM module (AMS-IAM 4 and following ones)

X110/SDMSignals and power supply fro /from Programming terminal with cable (Wired).



Description

X110

1


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X112/SDMInput for signals from the mode selector switch (Auto-L, Auto-R, Local, T1), E-Stop.

X119/SDM24 V output and PWM signal to power and control the cooling fans inside the cabinet

X122/SDM Safety signals for X30 connector (Safety items)

X124/SDM Outputs for power supply for the applications





Description

X128

1


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X302/SDMSignals and power supply for the Docking Station of the Programming terminal without cable (Wireless).

X310/SDM

4 digital outputs available for the user’s applications.

More details in par. 5.9 Digital Inputs / Output on the SDM module on page 116.

X311/SDM

4 digital inputs available for the user’s applications.


X312/SDM

4 digital inputs available for the user’s applications.




Description

X312

1


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JP200/SDM

Movable connector:– to select the 24 Vdc powering source for +24 Vdc I/O e

+24 Vdc SAFE – to connect the 0 V with the equipotential circuit (PE).

Features:– Voltage: 24 Vdc – Connection between 0 V (GND of the 24 Vdc) and

equipotential circuit.The earth connector connected to terminal 5 shall be removed only for the time necessary to detect possible faults: the permanent removal of the connector neutralizes the solution of faults towards earth (EN 60204-1

§ 9.4.3.1).

Pins:

Usage modalities in par. 5.7 How to use the 24 Vdc in the user’s applications on page 113.

SW1/SW2

Rotating selector switches to set the stopping circuit stopping timing.

The settings shall be consistent with the Robot type.Usage modalities in par. 6.5 Safety stop: checking the stop circuit timer on page 45 of the “Transport and installation” manual.

RESET Reset push button (reserved to Comau technicians)



Description

Pin Signal

1 +24Vdc INT (from AMS-ASM32)

2 To internal 24 Vdc

3 +24Vdc EXT (from X30/pin 15 & 22)

4 Not connected

5 GND

6 Not connected


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LEDs

Status Leds

LEDs:– AL1: Auxiliary CPU LED 1.

• Active only when the Programming terminal with wireless connection (C5G-WiTP) is available, on in fixed modality when it is possible to perform the terminal pairing or unpairing procedure.

– AL2: Auxiliary CPU LED 2. • Off when all safety signals (E-Stop, General

Stop, Gates) are closed and no faults are occurring

• Flashing when one or ore safety signals (E-Stop, General Stop, Gates) are open

• On in fixed modality in case of fault – Note: the LEDs ML2 and AL2 are the result of

concurrent processing performed by CPUs inside the SDM and therefore light up almost always under the same conditions.

– DRO: Drive OFF – On in fixed modality in DRIVE-OFF, it signals the availability of 24 Vdc power supply intended for the brake releasing device by the Robot border area

– ML1: Master CPU LED 1 – Usually flashing: it signals the correct communication between the SDM CAN Bus node and the AMS-APC820 module.

– On in fixed modality or off, in case of faulty CAN Bus communication.

– ML2: Master CPU LED 2 – Off when all safety signals (E-Stop, General Stop, Gates) are closed and no faults are occurring

– Flashing when one or ore safety signals (E-Stop, General Stop, Gates) are open

– On in fixed modality in case of fault.– Nota: the LEDs ML2 and AL2 are the result of concurrent processing

performed by CPUs inside the SDM and therefore light up almost always under the same conditions.

– ML3: Master CPU LED 3 – Flashing when an error is occurring on the configuration connections of the SDM.

– WLK: Wireless Link – With Programming terminal with cable connection (C5G-iTP): off – WithProgramming terminal with wireless connection (C5G-WiTP):

• On in fixed modality when the pairing has been accomplished properly and the wireless communication among SDM, docking station and terminal is working fine

• Off when no terminal is matched to the Control Unit• Flashing when one of the pairing / unpairing procedures are in

progress (flashing time equal to the time needed for the procedure) or in case the communication with the matched terminal goes missing (constant flashing).



Description

Status leds

Drive leds

24 Powerleds


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Drive Leds

– EN1: Enable 1: – On in fixed modality in DRIVE-ON, it signals that the actuation enabling is available.

– Off in DRIVE-OFF.

– EN2: Enable 2: – It is usually always On in fixed modality, in DRIVE-ON and DRIVE-OFF. it signals than the actuation enabling is available, used both to enable the in DRIVE-ON and apply the dynamic braking in DRIVE-OFF.

– Off in case of fault on the actuation controlling branches.

24 Vdc Power Leds

– EPR: Electronics Power out of Range

– Usually Off– On in fixed modality in case of fault, then the powering on the X101

connector is not within the admissible limits (admissible values between 18 Vdc and 36 Vdc); or the internal circuits are overloaded; or one or more output mosfets is overloaded

– Note: the circuits controlled by the mosfets are EnT1, EnT2 and the safety output expansions.

– PEC: Power Enable Circuit

– On in fixed modality when the internal relay controlling the powering of all output mosfets is closed.

– Off in case of short-circuit of the output mosfets, that is detected during the self-test that the card performs periodically.

– Note: the circuits controlled by the mosfets are EnT1, EnT2 and the safety output expansions.

– PIO: Power I/O *¹ – On in fixed modality when the 24V I/O power supply is available.

– P5A: Power 5A *¹ – On in fixed modality when the 24V INT power supply is available down the 5 A protection.

– P8A: Power 8A *¹ – On in fixed modality when the 24V power supply is available down the 8 A protection. This 24 Vdc powers the 24V SAFE and 24V I/O.

– PSF: Power Safe *¹ – On in fixed modality when the 24V SAFE power supply is available (active in DRIVE-ON only)

– SL1: Supply Led 1 *¹ – On in fixed modality when the 24V power supply is available on the X100 input connector.

– SL2: Supply Led 2 *¹ – On in fixed modality when the 24V power supply is available down the JP200 connector, used to select the internal/external power supply.

*¹ Refer to the picture below for a better understanding.



Description


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*¹ Reference representation of the connection of the diagnostics LEDs dedicated to the status of the 24 Vdc in the Safety Distribution Module (SDM).



Description

ASM

AUX.

SUPPLY

MODULE

24V

0V

5A

X301A

X102

JP200

X100

INT./EXT.INT./EXT.

8A

1

8

15

22

29

2

9

16

23

30

24V EXT.24V EXT.

24V INT.24V INT.

24V EXT.24V EXT.

24V INTP24V INTP

24V EXT.24V EXT.

DRIVE ONDRIVE ONX126

1

7

2

8

3

9

0V

24V SAFE24V SAFE

24V I/O24V I/O

4

10

24V EXT. FIELD BUS24V EXT. FIELD BUS

X128

1

7

2

8

3

9

0V

24V SAFE24V SAFE

24V I/O24V I/O

4

10


FIELD BUSFIELD BUS

0V

5A

5A1A

DRIVE OFFDRIVE OFF

24

VIN

T.

0V

24

VD

RIV

EO

FF

24

VR

OB

OT

24

VF

AN

S

0V

X110X119

SDM MODULESDM MODULE

0V

0V

SL1 P5A

SL2 P8A PSF

PIO


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4.10 Uninterruptible Power Supply (UPS)

FunctionThe Uninterruptible Power Supply (UPS) is the module that guarantees the endurance needed during the system shutdown procedures when the power supply is missing.

Technical featuresThe UPS works at 24 Vdc and thanks to an internal battery delivers the 24 Vdc to the Control Unit for the time needed for the system shutdown. For the system diagnostics, System variables are available.

Structure

Fig. 4.11 - UPS: overall view

1

A: 24 Vdc input/output terminal board (connected to the ASM module).

B:Status signal terminal board (connected to the SDM module).

C:Status LED.

D: Diagnostics LED

E: Connection control LED.

F: adjusting device for the power supply buffering limit time.

It shall be set at 30 seconds.

Tab. 4.10 - UPS: product codes



Uninterruptible Power SupplyC5G-UPS

CR10140583 1

Battery Refer to Chap.8.3 - Spare part list on

page 57 in the “Maintenance” manual

1

Fuse 1


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Tab. 4.11 - UPS: connections and devices


Description

Green status LED (C)

Usually on in fixed modality, it flashed to signal a given operating status: – Ready *¹: on in fixed modality (normal status) to signal

that the battery is charged, no error are occurring on the connection, the input power supply is sufficient

– Charging *¹: slow flashing to signal that the battery is charging, endurance less than85%

– Buffering *¹: rapid flashing to signal that the battery is delivering power to maintain the output 24V

Yellow diagnosis LED (D)

Usually off, it flashes during the Control Unit shutdown phase. Moreover, during the operating phase lights up to signal that a fault is occurring: – Overload *¹: 24V output disabled due to the overload

protracting or high temperature– Replace batty *¹: battery replacement necessary, to

be performed asap– Buffer-time expired *¹: output disabled because the

power supply buffering set time has been exceeded. This signalling stays on for 15 minutes

– Inhibit active *¹: it signals that the power supply buffering function has been disabled due to the inhibition signal enabling (inhibit)

*¹ Find the LEDs status details in the picture below.

Red connection control LED(E)

Usually off, it lights on to signal an error occurring on the connections, battery, battery fuse or installation (e.g. input voltage too low)

Buffering limit time adjusting

device

Rotating selector switch to adjust the power supply buffering limit time.

The selector switch shall be set at 30 seconds.


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4.11 Operator Panel Devices (OPD)

FunctionThe Operator Panel Device (OPD) is the Control Unit from panel. It is supplied empty with prepunched shapings to install the maintenance options.

Technical featuresThe Operator Panel Device can be equipped with options to facilitate the robot system maintenance: USB connector, Ethernet network connector, hour-meter and PC power supply plug.

Structure

Fig. 4.12 - OPD: overall view

A: (optional) USB connector

B: second USB connector or Ethernet network connector (both optionals)

C: (optional) hour-meter

Tab. 4.12 - OPD: (optional) product codes



(Optional) USB connector C5G-USBK: USB kit

CR17130780 1 or 2

(Optional) Ethernet network connector

C5G-ETHK: Ethernet kitCR17130880 1

(Optional) Hour-meterC5G-HMK: Hour-meter kit

CR17132480 1

A B C


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4.12 Connector Interface Panel (CIP)

FunctionThe Connector Interface Panel (CIP) is the Control Unit lower pane, where all interface connector are installed.

Tehnical featuresThe panel features the connectors for the connection with the Robot, the programming terminal (wired version only) and the interfacing with the line. Moreover, other 3 blind panels are available for optional extensions as well as holes with caps to install connectors matched to options for the interfacing with the external environment.

Structure

Fig. 4.13 - CIP: overall view with the main connectors

Preferred installation positions for optional connectorThe connectors on CIP panel are to be installed preferably as described below:

– F1 panel to install X10-EXT connector (Extension, Positioning device signals) and X60-EXT connector (Extension, motors and brakes of the positioning device) or X61..X64 connectors (Signals and power for auxiliary Axes)

– F2 panel to install X61..X64 connectors (Signals and power for auxiliary Axes) or 4 M25 cable gland connectors (4 M25 dinkings available)

A: X60 connector (motors and brakes)

B: X124 connector (wired programming terminal)

C: X10 connector (position and signal transducers)

D: X30 connector (line interfacing)

E: Screw to connect earth wire intended for the Robot

F: dinkings to install panels for optional extensions (see details below under Preferred installation positions for optional connector)

G: X90 cable gland connector (cableway at the user’s disposal)

H: dikings to install X93..X94 connector (Master field Bus)

E

A B C D

F1 F2 F3 GH


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– F3 panel to install X31..X32 connectors (Applications)

– H: dinkings to install X93..X94 connector (Master field Bus).

Standard prearrangementsThe CIP panel is supplied with several dinkings to install one or more connectors,as described below:

– 4 x M25 connectors / cable glands M25, available on F2 panel

– 2 x connectors to install X93..X94 connector (Master field Bus).

Optional extensionsThe CIP panel can be extended with optional panels supplied with dinkings to suit the main requirements, as described below:

– C5G-APK1 kit Auxiliary Plate 1: panel for 2 72-pole connectors and 1 42-pole connector

– C5G-APK2 kit Auxiliary Plate 2: panel for 3 42-pole connectors

– C5G-APK3 kit Auxiliary Plate 3: panel for 1 72-pole connector, 1 42-pole connector and 4 holes for M25 connectors / cable glands.

For further details about the connectors and their function, please refer to par. 5.1 Overview of the C5G Control Unit connections on page 92 and following sections.


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4.13 Internal ventilation system

FunctionThe internal ventilation system ensures the necessary air exchange when the installation environment temperature does not exceed 40 °C, with peaks up to 45 °C.If the installation environment temperature is constant or exceeds 45 °C it will be necessary to install the cooling option.

Technical featuresThe fans are 24-Vdc-powered and the rotation speed is automatically controlled by the system using a PWM signal. All fans are connected in parallel on the X119/SDM connector of the Safety Distribution Module (SDM). For the fan diagnostics, System variables are available.

StructureThe cooling system is replaced by 1 internal fan for the air circulation and by 2 or more fans (maximum 4) located on the cabinet back, that perform the forced air exchange on the dissipator AMS-FMP14, that is located by the CPU, power supplies and power modules module base. Depending on the axis module no. it may be necessary to install the option C5G-AFK: Auxiliary Fan Kit.

Fig. 4.14 - Cooling system: overall view

A: air circulation internal fan (E110)

B: rear fans for forced air exchange on dissipator (E111...E114, view without cover panel)

A

B


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4.14 General information about the communication networks inside the C5G Control UnitThe module inside the Control Unit communicate with one another through the following protocols and connections:

– Ethernet POWERLINK Network

– CAN Bus network.

Fig. 4.15 - Reference diagram related to the Ethernet POWERLINK e CAN Bus networks

APC 820

PPS8 ASM32 IAM x

Ethernet POWERLINK

SDM

CAN Bus

X20 interface


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4.15 Ethernet POWERLINK NetworkThe Ethernet POWERLINK (EPL) network is use to connect all modules of the CPU, power supplies and power modules (see par. 4.3 on page 44) and the X20 interface modules (see par. 5.10.1 on page 121) to one another.

The Ethernet POWERLINK network is based on a proprietary protocol connected through the physical layer of an Ethernet network. Although it shares the logics and physical layers with a standard system, it cannot be used for the transport and connection with the traditional Ethernet network. Each module connected on the Ethernet POWERLINK network shall feature an univocal address (par. 4.15.1 Ethernet POWERLINK Address on page 84).

To connect the Control Unit with a traditional Ethernet system use the ETH2 connector on AMS-APC820 (Ethernet) (see par. 5.3.2 on page 102).

Fig. 4.16 - Reference diagram related to the Ethernet POWERLINK network

4.15.1 Ethernet POWERLINK Address

All modules connected to the Ethernet POWERLINK network are identified by a univocal address.

– Address on ASM modules

– Address on Bus Coupler module for the X20 interface modules.

APC 820

PPS8 ASM32 IAM x

Ethernet POWERLINK

X20 interface


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4.15.1.1 Address on ASM modules

The address of the ASM modules on the Ethernet POWERLINK network is configures through the 2 rotating selector switches T1 and T2 (Fig. 4.17), according to the instructions in Tab. 4.13.

Inside the same Control Unit, the address of a module on the Ethernet POWERLINK network shall be univocal.

The rotating selector switch T2 represents a homogeneous group of more modules while the rotating selector switch T1 the progressive no. within the group. For the sake of simplicity and immediacy, in the most simple configurations the no. represented by T2 is allocated directly to the ARM. To identify the address given to some of the possible configurations, please refer to Tab. 4.14 - Allocation of the Ethernet POWERLINK network addresses to the ASM modules for typical configurations on page 86.

Fig. 4.17 - Rotating selector switches T1 and T2 for Ethernet POWERLINK address

Tab. 4.13 - Rules to allocate the Ethernet POWERLINK network addresses to the CPU, power supplies and power modules modules

Module

Rotating selector switch

setting (address)

Notes about the addresses configuration

T1 T2

AMS-APC820 module - -Module connected to the Ethernet POWERLINK network with no need for the user to customize the address

AMS-PPS8 module 0 1 The address is pre-defined and shall not be modified

AMS-ASM32 module - -Module not connected to the Ethernet POWERLINK network.


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AMS-IAM module >= 1 >= 1See examples in Tab. 4.14 - Allocation of the Ethernet POWERLINK network addresses to the ASM modules for typical configurations on page 86.

Tab. 4.14 - Allocation of the Ethernet POWERLINK network addresses to the ASM modules for typical configurations

Axis Module


setting (address)

Arm

T1 T2

Control Unit and fitting: C5G-ACC1 with one Robot

- AMS-PPS8 module 0 1 -

1 and 2 AMS-IAM module 11+11 1 1



Control Unit and fitting: C5G-ACC3 with one Robot





Control Unit and fitting: C5G-ACC3 with 2 NM or NJ Robots


1 and 2 (Robot 1) AMS-IAM module 22+22 1 1



1 and 2 (Robot 2) AMS-IAM module xx+xx 1 2



Tab. 4.13 - Rules to allocate the Ethernet POWERLINK network addresses to the CPU, power supplies and power modules modules

Module


setting (address)

Notes about the addresses configuration

T1 T2


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Control Unit and fitting: C5G-ACC3 with NM or NJ Robot and saddle (Ax7) and electric welding gripper (Ax8)






Tab. 4.14 - Allocation of the Ethernet POWERLINK network addresses to the ASM modules for typical configurations (Continued)

Axis Module


setting (address)

Arm

T1 T2


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4.15.1.2 Address on Bus Coupler module for the X20 interface modules

The X20 interface modules communicate with the Ethernet POWERLINK network through a Bus Coupler PFG-BCO module on X20 interface. The module address on the Ethernet POWERLINK network is configured through 2 rotating sector switches, X1 and X16.

The address of a module on the Ethernet POWERLINK network shall be univocally inside the same Control Unit.

Control Unit and fitting: C5G-ACC3 with PTDV or PTDO main axis (Ax7), rotation axis A (Ax8) and rotation axis B (Ax9)





7 and 8 AMS-IAM module 22+22 4 22 (Ax7) / 3

(Ax8)

9 AMS-IAM module 11 5 3 4

For further details and usage modalities related to the Bus Coupler module refer to par. 5.10.3 Bus Coupler PFG-BCO module on X20 interface on page 122

Tab. 4.14 - Allocation of the Ethernet POWERLINK network addresses to the ASM modules for typical configurations (Continued)

Axis Module


setting (address)

Arm

T1 T2


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4.16 CAN Bus networkThe CAN Bus network is used to connect the AMS-APC820 module (see par. 4.4 on page 47) and the Safety Distribution Module (SDM) (see par. 4.9 on page 67) to one another.

The CAN Bus network is based on the free protocol connected through the physical layer of a CAN Bus network. Although it shares standard protocols on logics and physical layers with a standard system, it cannot be used for the connections with commercial CAN Bus modules.

The address of a module on the CAN Bus network shall be univocal inside the same Control Unit (par. 4.16.2 Address on the CAN Bus network on page 89).

Fig. 4.18 - CAN Bus network reference diagram

4.16.1 Termination resistancec in the CAN Bus net

The termination resistance of the CAN Bus net node ends shall always be on. In the basic Control Unit the termination resistance is installed in the CAN second connector of the Safety Distribution Module (SDM) (see par. 4.9 on page 67) .If the net needs to be extended by adding new modules, remove the resistance and install it on the last CAN module of the chain.

4.16.2 Address on the CAN Bus network

All modules connected to the CAN Bus network are identified through an univocal address. As the system features only customized COMAU modules, the latter are supplied already configured and the user does not need to customize them.

The pin arrangement of the connector and the termination resistance are to be found in the Tab. 4.9 - SDM: connections and devices on page 68.

As option, modules available in specific applications supplied by Comau Robotics can be connected to the CAN Bus network. For further information, please refer to the corresponding application manual.

APC 820

SDM

CAN Bus

To nextCAN Bus

device


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4.17 Connector pin structureTo facilitate the consultation, the connectors available for the user are also represented and described in this chapter and in Chap. Interfacing with the C5G Control Unit on page 91:

– Tab. 4.3 - AMS-APC820: connections and devices on page 48

– Tab. 4.4 - AMS-PPS8: connections and devices on page 52

– Tab. 4.6 - AMS-ASM32: connections and devices on page 56

– Tab. 4.7 - AMS-IAM (double and single): connections and devices on page 60

– Tab. 4.9 - SDM: connections and devices on page 68

– Tab. 4.11 - UPS: connections and devices on page 78.

4.18 System variablesFor the sake of convenience, the list of system variables in Tab. 4.15 summarizes the diagnostics available only for the main hardware modules installed in the Control Unit.

*¹ reading only

The pin structure of all connectors and the related electric connection among modules are also documented in the Control Unit Schema elettrico.

The system variable complete list is to be found in the usage manual.

Tab. 4.15 - System variables: concise list for the basic modules

Module Available diagnostics System variable

Uninterruptible Power Supply (UPS)

UPS status monitor:– Ready– Active– Replace battery– Disable input

$SDI[117]$SDI[118]$SDI[119]$SDO[5] *¹

Internal ventilation system Speed set on the fans coded at 16 levels, 4 bits

$SDO[9]$SDO[10]$SDO[11]$SDO[12]


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Interfacing with the C5G Control Unit

5. INTERFACING WITH THE C5G CONTROL UNIT


– Overview of the C5G Control Unit connections

– Summary of the Robot, positioning devices and auxiliary axes connections

– Summary of the Line connections

– Summary of the Application connections

– Summary of the Programming and User interface on PC connections

Moreover, detailed descriptions and connection methods are listed for the following items:

– Overview for 24 Vdc power supply in the Control Unit

– How to use the 24 Vdc in the user’s applications

– Safety circuits: E-Stop, Auto-Stop (Fence) and General Stop

– Digital Inputs / Output on the SDM module

– Inputs / Outputs and field Bus on X20 interface

– RS232 and RS422 serial communication

– Communication via Ethernet network.

To help the user to identify the functions of the main connectors:

– Summary of connectors and corresponding function.


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5.1 Overview of the C5G Control Unit connectionsThe C5G Control Unit connects and interface with:

– Robot, positioning devices and auxiliary axes (A). Those connections allow to control the Robot and the auxiliary axes.

– Line (B). Through this connection, the Control Unit connects with the production plant where the robot system is integrated.

– Application (C). It allows to control the application connected with the Robot and the related equipment or other items required by the integrator.

– Programming and User interface on PC (D). It allows to program, control and diagnose the robot system through the Programming terminal and related software supplied with it.

A - Robot, positioning devices and auxiliary axes

B - Line

C - Application

D - Programming and User interface on PC

The picture shows the main connections between the Control Unit and the peripherals

A

D

B

C


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5.2 Robot, positioning devices and auxiliary axesThe connection with the Robot, positioning devices and auxiliary axes is accomplished through suitable connectors installed on the Connector Interface Panel (CIP) by the C5G Control Unit base.

The typical configurations feature the following solutions:

5.2.1 X10 connector (Robot signals)

The X10 is a multipolar connector that collects all Robot position control signals (Encoders with EnDat 2.2 interface), for configurations featuring up to 6 axes.The X10 is installed on the Connector Interface Panel (CIP) and connects to the X1connector by the Robot base through the Connection cables between C5G and Robot.

Some I/O signal that can be used freely by the user are available on the Safety Distribution Module (SDM) and through suitable options can be made available by the Robot border area (on corresponding connectors on axis 3 or Robot wrist, depending on the version). For further details refer to the Robot specific manuals.

The High Speed Input (HSI) signals are available on the CPU, power supplies and power modules and are at disposal by the Robot border area only after the installation of the option C5G-HSK5: High Speed Input Kit (see par. 6.3.15 on page 175). As for the pin structure and the connections by the Robot border area, refer to the Robot specific manuals.

C5G peripheralInvolved

connectorDescription

RobotX10X60

the main Robot is connected through the Connection cables between C5G and Robot with the X10 connector (Robot signals) and the X60 connector (Robot Power)

Positioning device X10-EXTX60-EXT

the positioning device (e.g. series SMART5 PTDV, PTDORB, other ones) is connected through the Connection cables between C5G and Robot (uses the same Robot cables exploiting only the necessary wires, depending on the no. of available axes) with the X10-EXT connector (Extension, Positioning device signals) and the X60-EXT connector (Extension, motors and brakes of the positioning device)

Auxiliary axes

X61X62X63X64

the single auxiliary axes (e.g. saddle on axis 7, electric gripper for spot welding on axis 8, other ones) are connected through the Connection cables between C5G and Robot, each one with only one connector that includes both the power and the control signal, with the X61..X64 connectors (Signals and power for auxiliary Axes)

The X10, X60, X10-EXT, X60-EXT, X61..X63 connector pin structure is available in the wiring diagram of the C5G Control Unit.


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Fig. 5.1 - X10 connector: structure

A: Connector Interface Panel (CIP)

X10: Signal connector for the Robot

A

X10


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5.2.2 X60 connector (Robot Power)

The X60 is a multipolar connector that collects all power signals of the Robot axes (motor) and brakes, for configurations featuring up to 6 axes. The X60 is installed on the Connector Interface Panel (CIP) and connects to the X2connector by the Robot base through the Connection cables between C5G and Robot.



X60: Power connector for the Robot

A

X60


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5.2.3 X10-EXT connector (Extension, Positioning device signals)

The X10-EXT is a multipolar connector that collects all positioning device position control signals (Encoders with EnDat 2.2 interface), with the possibility to connect 5 additional axes in the most extended configuration. This connector and the corresponding connection cable are available only if optional auxiliary axes are installed in the configuration for the positioning device and is matched to the X60-EXT connector (Extension, motors and brakes of the positioning device).

The X10-EXT is installed on a plate fastened on the Connector Interface Panel (CIP)and connects to the X1 connector by the positioning device base through the Connection cables between C5G and Robot.

In case of need, the plate features an area for the installation of an additional auxiliary axis (refer to par. 5.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on page 97).

Fig. 5.3 - X10-EXT connector: structure

5.2.4 X60-EXT connector (Extension, motors and brakes of the positioning device)

The X60-EXT is a multipolar connector that collects all power signals of the axes of the positioning device (motors) and brakes, with the possibility to connect additional 5 axes in the most extended configuration. This connector and the corresponding connection cable are available only if optional auxiliary axes are installed in the configuration for the positioning device and is matched to the X10-EXT connector (Extension, Positioning device signals).

A: Area intended for the installation of the plate with the auxiliary axes connectors

X10E: Control signal connector (Encoders)

X60E: X60-EXT connector (Extension, motors and brakes of the positioning device) (see par. 5.2.4 on page 96)

X61:Additional auxiliary axis installed

A

X60E X10E

X61


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The X60-EXT connector is installed on the Connector Interface Panel (CIP) and connects to the X2 connector by the positioning device base through the Connection cables between C5G and Robot.

In case of need, the plate features an area for the installation of an additional auxiliary axis (refer to par. 5.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on page 97).

Fig. 5.4 - X60-EXT connector: structure

5.2.5 X61..X64 connectors (Signals and power for auxiliary Axes)

The X61, X62, X63 or X64 are multipolar connectors that collect the power, brake and the position control signals (Encoders with EnDat 2.2 interface) of the auxiliary axes. Those connectors and the corresponding cable are available only if optional auxiliary axes are installed.

Each auxiliary axis is matched to a specific connector and the latter is polarized such as to prevent connection errors; the axes and matching connectors are listed in the table below:

A: Area intended for the installation of the plate with the auxiliary axes connectors

X60E: Motor and brake connector

X10E: X10-EXT connector (Extension, Positioning device signals) (see par. 5.2.3 on page 96)

X61: Additional auxiliary axis installed

Tab. 5.1 - Axis-connector match

Auxiliary axis Matching connector

Axis 7(usually saddle)

X61

A

X60E X10E

X61


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The X61, X62, X63 or X64 connectors are installed on one or more plates fastened on the Connector Interface Panel (CIP) and connect to the connector on the motor switching case through the corresponding cables. Each plate can take up to 3 connectors.

Fin below some typical match examples:

– X61..X63 connector in a solution featuring up to 3 axes: structure

– X61 connector in a solution featuring 1 axis matched to X60-EXT and X10-EXT already available: structure

Fig. 5.5 - X61..X63 connector in a solution featuring up to 3 axes: structure

Axis 8 (usually electric gripper)

X62

Axis 9 X63

Axis 10 X64

A: Area intended for the installation of the plate hosting the auxiliary axes connectors

X61:First auxiliary axis installed

X62: Second auxiliary axis installed

X63:Third auxiliary axis installed

Note: the picture shows an example featuring 3 connectors with consecutive abbreviation.

Tab. 5.1 - Axis-connector match

Auxiliary axis Matching connector

A

X61 X62

X63


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Fig. 5.6 - Polarization of connectors X61..X64

Fig. 5.7 - X61 connector in a solution featuring 1 axis matched to X60-EXT and X10-EXT already available: structure

A: Area inteded for the installation of the plate hosting the auxiliary axes connectors

X61..X64: connector possible configurations

A: Area intended for the installation of the plate hosting the auxiliary axes connectors

X61: First auxiliary axis installed

X60E: X60-EXT connector (Extension, motors and brakes of the positioning device) (see par. 5.2.4 on page 96)

X10E: X10-EXT connector (Extension, Positioning device signals) (see par. 5.2.3 on page 96)

The cables, connector polarization, the connections between X61..X64 and the motors are dealt with in details in the instruction manuals of the auxiliary axes.

A X61 X62

X63

X61 X62 X63 X64

Axis 7Axis 7 Axis 8Axis 8 Axis 9Axis 9 Axis 10Axis 10

A

X60E X10E

X61


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5.3 LineThe connection with the line is accomplished through special connectors installed on the Connector Interface Panel (CIP) by the C5G Control Unit base.

The typical configurations include the solutions described below.

Peripheral connected to the

C5G

Involved connector

Description

Safety item X30the safety signals (e.g. emergency stop, cell access door limit switch, other ones) are available on the X30 connector (Safety items)

Host system --the communication with the Host systems (e.g. line PLC) can be controlled through field Bus (see Field Bus Modules on the X20 interface (see par. 5.10.4 on page 126)).

Host system for monitoring (Ethernet)

ETH2 / APC820

the communication with the Host systems (e.g. line PLC, factory production control PC, analysis devices, other ones) can be controlled through Ethernet connections (see ETH2 connector on AMS-APC820 (Ethernet) (see par. 5.3.2 on page 102))

Host system for monitoring

(Serial)

COM2 / APC820

the communication with the Host systems (e.g. line PLC, factory production control PC, analysis devices, other ones) can be controlled through the RS422 serial connection (see COM2 connector on AMS-APC820 (RS422 serial) (see par. 5.3.3 on page 102)). Also the RS232 serial connection is available.

Other connections (e.g. net or serial communcation cables output)

X90The cables that do not features a specific optional connector by the cabinet base and exit the Control Unit to reach the device on the line, use the way provided by the I X90 cable gland connector.

X30

ETH2COM2

X90 X20 modulesX20 modules


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5.3.1 X30 connector (Safety items)

The X30 is a multipolar connector that collects all safety signals to and from the C5GControl Unit. It is installed on the Connector Interface Panel (CIP).

To interface with the Control Unit, a movable connector equipped with cap and pins for crimping connection is supplied as standard.

The safety signal are connected internally with the Safety Distribution Module (SDM)and using special options it is possible to increase the no. and type of available signals. The auxiliary signals will be available on other connectors (being defines).



X30: X30 connector

More details about the safety signals connection are to be found in par. 5.8 Safety circuits: E-Stop, Auto-Stop (Fence) and General Stop on page 115.

A

X30


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5.3.2 ETH2 connector on AMS-APC820 (Ethernet)

The ETH2 is a RJ45 connector that allows to connect the Ethernet network to a host system. It is available on AMS-APC820 module.

Fig. 5.9 - ETH2 connector: structure

5.3.3 COM2 connector on AMS-APC820 (RS422 serial)

The COM2 is a tray-type 9-pin connector that allows the RS422 serial connection. It is available on AMS-APC820 module. On the same connector also the RS232 serial connection is available (refer to COM2 connector on AMS-APC820 (RS232 serial)).

Fig. 5.10 - COM2 connector: structure

A: ETH2 connector on AMS-APC820

Further details about the connection with the Ethernet network are available in par. 5.12 Communication via Ethernet network on page 151.

A: COM2 connector on AMS-APC820

Further details about the serial connection are available in par. 5.11 RS232 and RS422 serial communication on page 149.

XD2

COM2 COM1

XD3

XD4

X3A

ETH1

ETH2 XD5

A

XD2

COM2 COM1

XD3

XD4

X3A

ETH1

ETH2 XD5

A


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5.3.4 X90 cable gland connector

The X90 is a multiple-way cable gland that represents the crossing point of the cables of the Field Bus and/or Ethernet network/ serial connection or other cables that connect directly on the internal connectors located on the specific modules. It is installed on the Connector Interface Panel (CIP). The X90 connector is supplied as standard with the Control Unit.

A movable connector with cap and rubber cable glands is supplied to allow the cable passage while preserving the IP 54 protection category of the Control Unit.



X90: X90 connector

Further details about the Field Bus are available in par. 5.10.4 Field Bus Modules on the X20 interface on page 126.The connections with Ethernet network are described in par. 5.3.2 ETH2 connector on AMS-APC820 (Ethernet) on page 102.The connection with serial protocols are described in par. 5.3.3 COM2 connector on AMS-APC820 (RS422 serial) on page 102.

A

X90


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5.4 ApplicationUnder application we understand a set consisting of one or more tool or machine parts connected to the Robot and/or used in the production process associated to the Robot, typically integrated to obtain a homogeneous solution.

The typical configurations include the solutions described below.


C5G

Involved connector

Description

I/O and safety signal, on

connectors

X31X32

the I/O, safety and powering signals directly available on the optional X31..X32 connectors (Applications)

digital I/O for small applications

X310/SDMX311/SDMX312/SDM

the I/O signals are available as standard on the Safety Distribution Module (SDM) and described in par. 5.9 Digital Inputs / Output on the SDM module on page 116

remote I/O (C5G with

master role)

X93X94

the communication with the systems (e.g. measurement devices, remote I/O, other ones) can be controlled through Field Bus protocols with X93..X94 connector (Master field Bus) with X20 interface modules

COM2

X31..X32 X93..X94 X90

X20 modulesX20 modules




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Analysis, measurement

systems (serial)

COM2 / APC820

the communication with the systems (e.g. measurement systems, other ones) can be controlled through the serial RS232 on COM2 connector on AMS-APC820 (RS232 serial). The serial connection RS422 is also available.

Other connections (e.g. net or serial communication cables output)

X90The cables that do not features a specific optional connector by the cabinet base and exit the Control Unit to reach the device on the line, use the way provided by the I X90 cable gland connector.

Other connections (e.g. output for

electrode dresser powering cables)

--

The powering cables can exit from the box base through the cable glands (that are not part of the supply volume), which are to be fastened to the 25,5 mm dinking holes (M25 cable glands) located on the central panel.


C5G

Involved connector

Description


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5.4.1 X31..X32 connectors (Applications)

The X31..X32 is a multipolar connector that collects one or more solutions with digital I/O, power supplies and safety signals. It is installed on the Connector Interface Panel (CIP).

To interface with the Control Unit, a movable connector equipped with cap and pins for crimping connection is supplied as standard.

The I/O signals are internally connected with the Ethernet POWERLINK bus and using special options it is possible to increase the no. and type of available signals.

Fig. 5.12 - X31..X32 connector: structure

A: Area intended for the installation of the plate with the application connectors

X31: First application installed

X32: Second application installed

The options for the signal expansion are described in par. 5.10.5.4 Prearranged solutions and technical specifications related to the digital and analog I/O on page 135 (solutions with connection on connector and terminal board)

A

X31 X32


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5.4.2 X93..X94 connector (Master field Bus)

The connector for the Master field Bus allows to connect the field Bus between the master module inside the Control Unit and the slave modules available on the tooling and/or Robot border area.

The connector, matched to its specific cable, is a solution called Multibus, i.e. both the field bus signal (Device Net or Profibus-DP) and the 24 Vdc power supply for the remote slave modules are trasmitted through the same multipolar cable.The connector is installed by the Control Unit base on the Connector Interface Panel (CIP).

The X93 connector is matched to the first Master field Bus module while the X94 to the second master module, if available.

Fig. 5.13 - X93..X94 connector: structure


X93: Multibus connector for the first Master field Bus module

X94: Multibus for the second Master field Bus module

Further details on the Field Bus are available in par. 5.10.4 Field Bus Modules on the X20 interface on page 126.The usage, connector pin structure and connection cables examples are to be found in the manuals of the corresponding application.

A

X93

X94


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5.4.3 COM2 connector on AMS-APC820 (RS232 serial)

The COM2 is a tray-type 9-pin connector that allow the RS232 serial connection. It is available on AMS-APC820 module. Also the RS422 serial connection is available (see COM2 connector on AMS-APC820 (RS422 serial)).

Fig. 5.14 - COM2 connector: structure

A: COM2 connector on AMS-APC820

Further details about the serial connection are available in par. 5.11 RS232 and RS422 serial communication on page 149.

XD2

COM2 COM1

XD3

XD4

X3A

ETH1

ETH2 XD5

A


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5.5 Programming and User interface on PCThe programming and movement can be accessed through the Teach Pendant (see par. 3.3 on page 35).

The WinC5G program supplies a convenient interface to the Control Unit, to facilitate the diagnosis, setting and other operating procedures. WinC5G can be operated in Personal Computers (PCs) runnning Microsoft© Windows©.

A - Progrmaming terminal

B - Personal Computer

The Programming terminale and WinC5G program usage modalities are described in detaisl in the “Control Unit use” under chapter “WinC5G Program – Interface to C5G on Personal Computer”

A B


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5.6 Overview for 24 Vdc power supply in the Control Unit– 24 Vdc distribution principles

– Meaning of the 24 Vdc power supplies inside the Control Unit

– 24 Vdc distribution complete diagram.

5.6.1 24 Vdc distribution principles

The 24 Vdc voltage in the Control Unit is produced by the AMS-ASM32 module. For some power supply (V24 I/O and V24 SAFE) it is possible to select the source between the AMS-ASM32 module and an external powering device (details in par. 5.7 How to use the 24 Vdc in the user’s applications on page 113).

The 24 Vdc distribution is accomplished by the Safety Distribution Module (SDM), that includes also the protection items against the overloading and short-circuit on the 24 Vdc branches. The shortcircuit and overload protection is performed through self-restoring fuses.

The 0V signals of the 24 Vdc internal powering supplies (0V I/O, 0V SAFE, ...) and the 0V signal of the powering supply coming from outside (optional) are connected together and also to the GND.

5.6.2 Meaning of the 24 Vdc power supplies inside the Control Unit

Tab. 5.2 - Abbreviations and usage of the 24 Vdc power supplies

Abbreviation

Definition Connector

24V INTP

Source: the power supply comes from the AMS-ASM32 module.

Usage: to power components inside the Control Unit, at the user’s disposal.

Protection*¹: 1 A

X30 connector (Safety items) (see par. 5.3.1 on page 101)

24V INT


Usage: to power components inside the Control Unit.

Protection*¹: 5 A, shared with 24V INTP, 24V ROB and 24V DROFF

Not at the user’s disposal.

24V ROB


Usage: power supply always available on board of Robot, for user’s minor automation routines.

Protection*¹: 1 A

X10 connector (Robot signals) (see par. 5.2.1 on page 93)


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*¹ self-restoring fuses installed inside the Safety Distribution Module (SDM).

24V DROFF


Usage: power supply available in Drive OFF only, by the Robot border area, serves the purpose of release the robot axis brake with brake-release module installed on board of Robot.

Protection*¹: 5 A, shared with 24V INT, 24V INTP and 24V ROB.

Not at the user’s disposal.

24V I/O

Source: the power supply comes from the AMS-ASM32 module. Through the selection on the JP200/SDM connector it is possible to switch to the external source coming from the X30 connector

Usage: to power cards and devices requiring the power supply to be always available. It’s used for user’s applications.

Protection*¹: 24V I/O = 8 A, shared with 24V SAFE

– X106/SDM. For the connection the C5G-UCK: user connector kit, for SDM module (see par. 6.3.27 on page 195) is required.

– X124/SDM, X126/SDM, X128/SDM.

24V SAFE

Source: the power supply comes from the AMS-ASM32 module. Through the selection on the JP200/SDM connector it is possible to switch to the external source coming from the X30

Usage: to power cards and devices requiring the power supply to be turned off with E-Stop, Drive-Off and other emergency stop commands. It’s used for user’s applications.

Protection*¹: 24V SAFE = 8 A, shared with 24V I/O

– X106/SDM. For the connection the C5G-UCK: user connector kit, for SDM module (see par. 6.3.27 on page 195) is required.

– X124/SDM, X126/SDM, X128/SDM.

– X30 connector (Safety items) (see par. 5.3.1 on page 101)

24V EXTFIELD BUS

Source: the power supply comes directly from X30 connector (Safety items) (see par. 5.3.1 on page 101).

Usage: to power cards and devices requiring the 24 V power supply when Control Unit is off (deactivate).

Protection: protection isn’t present. Must to be installed a protection fuse on source for limit to max 4 A.

– X124/SDM, X126/SDM, X128/SDM.

Tab. 5.2 - Abbreviations and usage of the 24 Vdc power supplies

Abbreviation

Definition Connector


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5.6.3 24 Vdc distribution complete diagram

ASM

AUX.

SUPPLY

MODULE

24V

0V

5A

X301A

X102

JP200

X100

INT./EXT.

8A

1

8

15

22

29

2

9

16

23

30

24V EXT.24V EXT.

24V INT.24V INT.

24V EXT.24V EXT.

24V INTP24V INTP

24V EXT.24V EXT.

X124

1

7

2

8

3

9

0V

24V SAFE24V SAFE

X106

1

2

3

4

DRIVE ONDRIVE ON

24V I/O24V I/O

4

10


X126

1

7

2

8

3

9

0V

24V SAFE24V SAFE

24V I/O24V I/O

4

10


X128

1

7

2

8

3

9

0V

24V SAFE24V SAFE

24V I/O24V I/O

4

10


FIELD BUSFIELD BUS

X103

1

2

1

2

1

2

24V INT.24V INT.

0V

X122

A

B

C

0V

5A

5A1A

DRIVE OFFDRIVE OFF

0V

24V SAFE24V SAFE

24V I/O24V I/O

24

VIN

T.

0V

24

VD

RIV

EO

FF

24

VR

OB

OT

24

VF

AN

S

0V

A B

X110

X124X10

X119

3612

X60

11d10d

INT./EXT. FANSINT./EXT. FANS

79784243


0V

0V

ROBOT BRAKES RELEASERROBOT BRAKES RELEASER

24V ROBOT SUPPLY24V ROBOT SUPPLY

iTP

X1X2

SL1 P5A

SL2 P8A PSF

PIO

24 Vdc Power supplydistribution


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5.7 How to use the 24 Vdc in the user’s applications– X106/SDM connector at the user’s disposal

– Selecting the 24 Vdc power supply source (24V I/O and 24V SAFE only)

– Selecting the 24 Vdc source (24V I/O and 24V SAFE only).

5.7.1 X106/SDM connector at the user’s disposal

Te user can obtain 24 Vdc internal power supply through the X106/SDM connector.

5.7.2 Selecting the 24 Vdc power supply source (24V I/O and 24V SAFE only)

The following 24 Vdc power supply sources are at the disposal of the user:

– 24V I/O, always available. This source can be used to power the devices and I/O requiring power supply always ON.

– 24V SAFE, available in Drive ON only. This power supply can be used to power the outputs that shall be de-energized following a Drive OFF, E-Stop and other emergency stop commands.

Those power supply sources are available on the X106/SDM connector (at the user’s disposal) as well as on the X124/SDM, X126/SDM, X128/SDM ones (intended for the power supply travel towards to the options) located on the Safety Distribution Module (SDM).

The 24 Vdc source that delivers power to 24V I/O and 24V SAFE can be selected through the JP200/SDM connector, to get:

– internal powering, produced internally by the AMS-ASM32 module

– external powering, coming from an external powering device.

Tab. 5.3 - X106/SDM: pinout and 24Vdc power supply technical data

X106/SDM

Features:– Voltage: 24 Vdc– Max current: 8 A, shared between (V24 I/O) and (V24

SAFE)– Corresponding signals: V24 I/O, GND-V0, V24 SAFE

The movable connector shall be purchased separately together with the option C5G-UCK: user connector kit, for SDM module.

Pins:

* connected together internally. Moreover, connected to the common 0V GND-V0

Pin Signal

1 +24 Vdc I/O

2 0 Vdc I/O *1

3 0 Vdc SAFE *1

4 +24 Vdc SAFE


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To better understand the 24 Vdc distribution pattern, refer to par. 5.6.3 24 Vdc distribution complete diagram on page 112.

5.7.3 Selecting the 24 Vdc source (24V I/O and 24V SAFE only)

To select the powering source, take the following items into account:

– the internal powering source does not require devices and the selection on the JP200/SDM connector is already correct (default position A in Fig. 5.15).

– the external powering source requires an external powering device, (which is not supplied with the Control Unit), that shall be connected through the X30 connector (Safety items) (see par. 5.3.1 on page 101). After, the selection is required on the JP200/SDM connector (position B in Fig. 5.15).

Fig. 5.15 - Powering source selection reference diagram

To practical carry out the 24 Vdc source section jumper, refer to par. 7.3 Selecting the 24 Vdc power supply source on page 61 of the “Transportation and installation” manual.

SUPPLY

24V

0V

24V

EXT.

SUPPLY

24V

0V

24V

EXT.

AB

JP200

24V EXT.24V EXT.

24V INT.24V INT.

ASM

AUX.

SUPPLY

MODULE

24V

0V

5A

X301A

X102

JP200

X100

INT./EXT.

8A

1

8

15

22

29

2

9

16

23

30

24V EXT.24V EXT.

24V INT.24V INT.

24V EXT.24V EXT.

24V INTP24V INTP

24V EXT.24V EXT.

DRIVE ONDRIVE ON

FIELD BUSFIELD BUS

X122

0V

5A

5A1A


SL1 P5A

SL2 P8A PSF

PIO


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5.8 Safety circuits: E-Stop, Auto-Stop (Fence) and General StopThe input/output signals for the stop circuits are available on the X30 connector (Safety items) (see par. 5.3.1 on page 101) posto alla base dell’Unità di Controllo.

3 series of signals are available, for which specific functions are listed in Tab. 5.4.

Tab. 5.4 - Safety input signals and corresponding function

Input signal Function

E-Stop

The E-Stop input shall be used for the following connections:– stop push button located on the Programming terminal – emergency stop triggering device of the cell/line where the Robot system will be

installed.

This signal is always active and triggers a type of stop (norm EN60204-1) that depends on the selected operating mode:– according to category 1 in automatic mode – according to category 0 in programming mode.

Auto-Stop (Fence)

The Auto-Stop (Fence) input shall be used to connect the safety limit switches controlling the “close-status” of the access doors of the cell/line where the Robot system will be installed.

This signal is active in automatic operating mode only and triggers a stop according to category 1 (norm EN60204-1). By selecting the Programming mode, the C5G will be controlled by the Enabling Device (on programming terminal) and the Auto-Stop input will be disabled.

General Stop

The General Stop input can be used to trigger a safety stop that for functional purposes shall not correspond to an emergency stop (E-Stop), which h is typically used for bigger geographic areas and requires specific diagnostic warnings.

This input can be used to stop the robot system safely when operators are approaching the robot range of action (e.g. access to the loading/unloading area or other activity). If the input is not used, the signals shall be closed using a jumper.

This signal is always active (it is physically identical to the E-Stop input) and triggers a type of stop (norm EN60204-1) that depends on the selected operating mode:– according to category 1 in automatic mode – according to category 0 in programming mode.

Due to the importance of the connection carrying out at the time of installation, this topic is dealt with only in the “Transport and installation” manual in par. 6.6 E-Stop circuits: inputs and control procedure for stop circuits and mushroom-shaped push button on programming terminal on page 48.


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5.9 Digital Inputs / Output on the SDM module– General principles

– Position of the connectors on the Safety Distribution Module (SDM)

– I/O electric features and pin structure of the connectors on the Safety Distribution Module (SDM)

– Connection diagram for the I/O on the Safety Distribution Module (SDM)

– Configuration of the I/O on the Safety Distribution Module (SDM)

– Usage restrictions for the I/O on the Safety Distribution Module (SDM).

5.9.1 General principles

The Control Unit is supplied as standard with digital 8 inputs and 4 outputs (I/O), that are at disposal for the user’s applications. The I/O are available on the Safety Distribution Module (SDM) and can be used only on condition that the C5G-UCK: user connector kit, for SDM module (see par. 6.3.27 on page 195) option is purchased.

The digital I/O on the Safety Distribution Module (SDM) are used also on some C5Goptions. If such options are installed, the no. of I/O at the user’s disposal may be lesscompared to the one specified (refer to par. 5.9.6 Usage restrictions for the I/O on the Safety Distribution Module (SDM) on page 120).

5.9.2 Position of the connectors on the Safety Distribution Module (SDM)

Fig. 5.16 - I/O at the user’s disposal: connectors

X310/SDM: 4 24 Vdc outputs*¹

X311/SDM: 4 24 Vdc inputs*¹

X312/SDM: 4 24 Vdc inputs*¹

*¹ optional movable connectors C5G-UCK: user connector kit, for SDM module (see par. 6.3.27 on page 195)

X310

X126

X311

X312

X128

OUT

IN

IN


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5.9.3 I/O electric features and pin structure of the connectors on the Safety Distribution Module (SDM)

Tab. 5.5 - I/O at the user’s disposal: features and pin structure

FunctionConnector on

Safety Distribution Module (SDM)

Features

4 digital 24 Vdc Outputs

X310/SDM Features:– Voltage *¹: typical 24 Vdc (from 18 to 35 Vdc max) – Max current per output: 0,5 A (self-protected)– Output type: PNP (source), optoinsulated – I/O scanning/updating time: 10 ms

The movable connector shall be purchased separately with the option C5G-UCK: user connector kit, for SDM module.

Pins:

*¹ supplied externally, at expense of the user

4 digital 24 Vdc Inputs

X311/SDM Features:– Voltage: 24 Vdc (from 18 to 35 Vdc max)

(“1 logic” > 18 Vdc, “0 logic” < 4 Vdc)– Typical current: 8 mA– Input type: PNP (sink), optoinsulated – I/O scanning/updating time: 10 ms


Pins:

*¹ connected to the GND of the X312/SDM connector.

Pin Signal

1 Output common Supply *1

2 Output common Supply *1

3 Output 4

4 Output 3

5 Output 2

6 Output 1

7 GND Output

8 GND Output

Pin Signal

1 Input 1

2 Input 2

3 Input 3

4 Input 4

5 GND Input *1

6 GND Input *1


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4 digital 24 Vdc Inputs

X312/SDM Features:– Voltage: 24 Vdc (from 18 to 35 Vdc max)

(“1 logic” > 18 Vdc, “0 logic” < 4 Vdc)– Min current: 8 mA– Input type: PNP (sink), optoinsulated – I/O scanning / updating time: 10 ms


Pins:

*¹ connected to the GND of the X311/SDM connector

Tab. 5.5 - I/O at the user’s disposal: features and pin structure

FunctionConnector on

Safety Distribution Module (SDM)

Features

X312

1

Pin Signal

1 Input 5

2 Input 6

3 Input 7

4 Input 8

5 GND Input *1

6 GND Input *1


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5.9.4 Connection diagram for the I/O on the Safety Distribution Module (SDM)

Fig. 5.17 - I/O on SDM: connection diagram

Refer to the item Digital I/O on SDM module (see par. 7.4 on page 63) of the “Transport and installation” manual.

SDMC5G

Output

Input

Input


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5.9.5 Configuration of the I/O on the Safety Distribution Module (SDM)

The digital I/O on the Safety Distribution Module (SDM) can be used in the software only after being suitably configured.

The I/O configuration shall be carried out using specific programmes supplied together with the Control Unit (IO_MAP / IO_CNFG).

5.9.6 Usage restrictions for the I/O on the Safety Distribution Module (SDM)

The digital I/O on the Safety Distribution Module (SDM) are used also on some C5Goptions. If such options are installed, the no. of I/O at the user’s disposal may be less, i.e. according to the table below:

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

Tab. 5.6 - Reduction of the no. of I/O if options are available

Option installedI/O taken by the

optionI/O at the user’s

disposal

C5G-DMI Inp 3 on X311Inp 1..2 and 4 on X311

Inp 1..4 on X312Out 1..4 on X310

C5G-PMI Inp 3 on X311Inp 1..2 and 4 on X311

Inp 1..4 on X312Out 1..4 on X310

C5G-SMK: Signal Machine KitInp 1..4 on X311Out 1..4 on X310

Inp 1..4 on X312

C5G-TDC400: 400V Tip Dresser Command kitInp 1..2 su X311Out 1 su X310

Inp 3..4 su X311Inp 1..4 su X312Out 2..4 su X310

C5G-TDC400-2: 400V Double Tip Dresser Command kitInp 1..2 on X311Out 1..2 on X310

Inp 3..4 on X311Inp 1..4 on X312Out 3..4 on X310

C5G-TDS400: 400V Tip Dresser Supply kit Inp 1 on X311Inp 2..4 on X311Inp 1..4 on X312Out 1..4 on X310


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5.10 Inputs / Outputs and field Bus on X20 interfaceThe Control Unit may be expanded using optional modules for digital, analog I/O, and field Bus by means of the solution consisting of the X20 interface modules (see par. 5.10.1 on page 121).

5.10.1 X20 interface modules

– General principles

– Bus Coupler PFG-BCO module on X20 interface

– Field Bus Modules on the X20 interface

– Digital and analog I/O module on the X20 interface.


The flexibility of the optional modules for digital, analog I/O and field Bus on the X20 interface allows the coexistence of I/O and field Bus on the same small rack.

The (optional X20 interface module system is based on the following components:

– Bus Coupler PFG-BCO module on X20 interface, item essential for the interconnection between the internal Ethernet POWERLINK network and the expansion modules (I/O and/or field Bus). Each Bus Coupler module is configured with an univocal address on the Ethernet POWERLINK network. It is possible to install up to 2 Bus Coupler modules.

– Field Bus Modules on the X20 interface, optional item to connect Master and/or Slave to remote modules in Profibus-DP e DeviceNet protocol.

– Digital and analog I/O module on the X20 interface, optional item to connect digital or analog I/O.

The X20 system installation requires the software configuration. To carry out this task, refer to the “Control Unit Usage” instruction manual.

APC 820

PPS8 ASM32

IAM x

Ethernet POWERLINK

Bus Coupler

Profibus-DP DeviceNetDC/DC

Inp Out

Bus Coupler

Profibus-DP DeviceNetDC/DC

Inp Out


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5.10.3 Bus Coupler PFG-BCO module on X20 interface


– Connection diagram

– Address on Bus Coupler module for the X20 interface modules

– Technical features and purchase code

– Configuration of the Bus Coupler module in the system.

5.10.3.1 General principles

The Bus Coupler PFG-BCO 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 the X20 interface and Digital and analog I/O module on the X20 interface.

The Bus Coupler module is supplied as single unit and consists of:

– omega-guide fastening base (A), with 2 free slots for the Field Bus Modules on the X20 interface

– one interface for the connection with the Ethernet POWERLINK net (B)

– a DC/DC (C) powering device, identification abbreviation *¹ X20 PS 9400

– prearrangement to add Digital and analog I/O module on the X20 interface.

Fig. 5.18 - Bus Coupler PFG-BCO module

*¹ Identification abbreviation posted on the component front side

A: Base and bus of the X20 interface module system, with 2 free slots for field Bus modulesB:Interface for the connection with the POWERLINK networkC: DC/DC 24 Vdc powering device, identification abbreviation*¹ X20 PS 9400

Slot1

Slot2

Interface

DC/

DC

A B C


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5.10.3.2 Connection diagram

Each module is connected as additional node on the Ethernet POWERLINK network (see Fig. 5.19) and configured with an univocal address (see par. 5.10.3.3 Address on Bus Coupler module for the X20 interface modules on page 124). 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:

– uo to 2 Field Bus Modules on the X20 interface (see par. 5.10.4 on page 126), installed directly on the 2 available slots

– a solution with Digital and analog I/O module on the X20 interface, installed on the Bus Coupler module right side.

Fig. 5.19 - General connection principles for the Bus Coupler PFG-BCO module

From last Ethernet POWERLINK internal module

Bus Coupler#1

&H81

Bus Coupler#2

&H82

Ethernet POWERLINK Cable Ethernet POWERLINK Cable


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5.10.3.3 Address on Bus Coupler module for the X20 interface modules

The module address on the Ethernet POWERLINK network is configured through 2 rotating sector switches, X1 and X16 (Fig. 5.20), according to the instructions in Tab. 5.7.

The address of a module on the Ethernet POWERLINK network shall be univocally inside the same Control Unit.

Fig. 5.20 - X1 and X16 selector switches for Bus Coupler module for X20 interface modules

Tab. 5.7 - Ethernet POWERLINK network address configurations on the X20 interface module Bus Coupler module

Bus Coupler module function

Selector switch setting

(address) Notes about the address configuration

X16 X1

First module installed 8 1 Address of the first module installed.

Second module installed 8 2 Address of the second module installed.

Further details about the adresses and the setting modalities are to be found in the par. 4.15 Ethernet POWERLINK Network on page 84.


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5.10.3.4 Technical features and purchase code

5.10.3.5 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 supoplied together with the Control Unit. After carrying out the configuration, the system shall be restarted acting on the Restart Cold control.

Tab. 5.8 - C5G-PFG-BCO: technical features

Item Description

Comau Code – CR10146383

Electrical features – Power supply: 24 Vdc (-15% to +20%)– Available slots: 2 (for field bus modules only)

Installation position – Inside the C5G, on omega guide.

Usage restrictions – Only two options are allowed

Ethernet POWERLINK 1,5 m (4.9 ft) cable, Comau Code

– CR17231863

The module is described also in the option list in par. 6.3.18 C5G-PFG-BCO: Bus Coupler module on page 182.

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”.


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5.10.4 Field Bus Modules on the X20 interface


– Installation rules for the field bus modules

– Technical features and purchase code.

– Configuration of the field Bus modules in the system


The field bus module is available in the master and slave version, according to choice between the Profibus-DP and Device Net protocols.

The field bus modules are to be installed on the slot 1 and 2 of the Bus Coupler PFG-BCO module on X20 interface (see par. 5.10.3 on page 122) only.

It is possible to contemporaneously install field bus and I/O modules.

Before being used , the field bus modules require the later Configuration of the field Bus modules in the system (see par. 5.10.4.4 on page 130).

Fig. 5.21 - Field bus modules

A: Bus Coupler PFG-BCO module on X20 interface (empty)B: Device Net Module (example of master installation on slot 1)C: Profibus-DP module (example of slave installation on slot 2)

A

Slot1

DC/

DC

B C

Slot2

Interface


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5.10.4.2 Installation rules for the field bus modules

The installation rules for the field bus modules, (that apply to all versions) are:

– installation allowed on the Bus Coupler PFG-BCO module on X20 interface only

– installation of up to 3 (max no.) field bus modules in the same C5G Control Unit, using 2 Bus Coupler modules

– the master module:• takes always first available slot (1, then 2), but slot 1 is for slave module (when

present) • it is possible to install an only one master module on the same Bus Coupler

PFG-BCO module on X20 interface• if two master modaules are required, it will be necessary to install a second

Bus Coupler PFG-BCO module on X20 interface, creating a network whose connection pattern is shown Fig. 5.19

– the slave module:• the first slave module takes always slot 1 (slot on the right)• the second slave module tkes always slot 2 (slot on the left)• it is possible to isntall up to 2 (max no.) slave modules on the same Bus

Coupler PFG-BCO module on X20 interface• if two slave modules are required and a master module is already installed, it

is necessary to install a second Bus Coupler PFG-BCO module on X20 interface, creating a network whose connection pattern is shown in Fig. 5.19

Fig. 5.22 - Example of field bus module structure

The picture shows the structures possible with an only one Bus Coupler PFG-BCO module on X20 interface.

A: Bus Coupler PFG-BCO module on X20 interface (empty)M: Master moduleS, S1, S2: Slave module

Note: master and slave module, according to choice between the available protocols

A

M

S

MS

S2S2

S1S1

Slot 2 12 1


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The picture shows the structures possible with two Bus Coupler PFG-BCO module on X20 interface.

A: Bus Coupler PFG-BCO module on X20 interface (empty)M1, M2: Master moduleS, S1, S2: Slave module

Nota: master and slave module, according to choice between the available protocols

A

M2M2

M1M1

S

S2S2

M1M1

S1S1

M2M2

M1M1

A

Slot 2 12 1 2 12 1


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5.10.4.3 Technical features and purchase code

*¹ identification abbreviation posted on the component front side

Tab. 5.9 - Device Net: technical features

Item Description

Device Net Master module


Identification abbreviation *¹ – X20 IF1051-1

Electrical features – it requires the optional connector C5G-DNPC: movable connector for Devicenet modules (see par. 6.3.10 on page 169)

Mechanical features –

Installation position – Inside the C5G, on the Bus Coupler PFG-BCO module on X20 interface.

– Refer to Fig. 5.22 - Example of field bus module structure on page 127

Usage restrictions – Up to 2 modules installed (with two Bus Coupler modules)

Device Net Slave module



Electrical features – it requires the optional connector C5G-DNPC: movable connector for Devicenet modules (see par. 6.3.10 on page 169)




Usage restictrions – Up to 2 modules installed


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5.10.4.4 Configuration of the field Bus modules in the system

The field Bus modules can be used in the system only after being suitably configured .

The field Bus modules configuration shallbe accomplished using the special routines IO_CNFG (configuration of the module in the system) and IO_MAP (signal mapping) supplied together with the Control Unit. Following the configuration it may be necessary to restart the system acting on the Restart Cold control.

Tab. 5.10 - Profibus-DP: technical features

Item Description

Profibus-DP Master



Electrical features – It requires the optional connector C5G-PFPC: movable connector for Profibus-DP modules (see par. 6.3.21 on page 186)




Usage restictrions – Up to 2 modules installed (with two Bus Coupler modules)

Profibus-DP Slave



Electrical features – It requires the optional connector C5G-PFPC: movable connector for Profibus-DP modules (see par. 6.3.21 on page 186)




Usage restictrions – Up to 2 modules installed

Those modules are also described in the option list:– par. 6.3.8 C5G-DNM-DNMI: DeviceNet Master Interface on page 167– par. 6.3.9 C5G-DNM-DNSI: DeviceNet Slave Interface on page 168– par. 6.3.20 C5G-PFM-PDPS: Profibus-DP Slave Interface on page 185– par. 6.3.19 C5G-PFM-PDPM: Profibus-DP Master Interface on page 184.

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


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5.10.5 Digital and analog I/O module on the X20 interface


– Rules for the installation of I/O on X20 modules

– Circuit Diagram for the connction of the I/O on X20 modules

– Prearranged solutions and technical specifications related to the digital and analog I/O

– Powering devices technical features

– Digital input/output technical features

– Analog inputs/output technical features

– Configuration of the I/O modules in the system.


The I/O modules are available in predefined solutions (see Tab. 5.11), that includes already grouped digital and analog I/O cards as well as the corresponding 24 Vdc pwering devices.

The predefined solutions are to be instaled on the right side of the Bus Coupler PFG-BCO module on X20 interface (see par. 5.10.3 on page 122) only, for a maximum expansion of 10 adjoining modules. If more that 10 modules are required, it is necessary to use a second Bus Coupler module.

It is possible to install contemporaneously one or more I/O and field bus modules predefined solutions.

Before being used, the field bus modules require the later Configuration of the I/O modules in the system (see par. 5.10.5.8 on page 148).

Fig. 5.23 - I/O modules on X20 (configuration example)


A: Bus Coupler PFG-BCO module on X20 interface (empty)B: DC/DC powering device module or input card or output card (usually consisting of terminal board, card and fastening base)C: DC/DC powering device first module to separate I/O from Bus Coupler module (identification abbreviation*¹ X20 PS 2100)D: module for inputs powered through the first powering device module (e.g. digital ones, identification abbreviation*¹ X20 DI9371)E: module for outputs powered through the first powering device module (e.g. digital ones, identification abbreviation*¹ X20 DO6322)F: DC/DC powering device second module to separate the independent powering of the next outputs (identification abbrevition*¹ X20 PS 2100)G: module for outputs powered through the secondo powering device module (e.g. digital ones, identification abbreviation*¹ X20 DO6322)A

DC/

DC

Interface

DC/

DC

Inp Inp DC/

DC

OutOut

C D E F G

B

A


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5.10.5.2 Rules for the installation of I/O on X20 modules

The installation rules for the I/O modules, (that apply to all versions) are the following:

– installation nest to a Bus Coupler PFG-BCO module on X20 interface. The Bus Coupler module shall always be available.

– independent 24 Vdc power supply to separate the I/O from the Bus Coupler module and related Field Bus Modules on the X20 interface. To serve this purpose, in each configuration the first module is always a DC/DC powering device (identification abbreviation *¹ X20 PS 2100)

– installation of a second additional DC/DC powering device (identification abbreviation *¹ X20 PS 2100) per each output card group requiring independent powering (e.g. to separate the 24 Vdc delivered to the outputs disabled by the safety circuits from the ones that are always powered)

– the powering delivered to the powering device module requires a delayed 10 A external protection (same protection for the second powering device as well).


5.10.5.3 Circuit Diagram for the connction of the I/O on X20 modules

The following diagrams are available:

– Digital I/O on X20 modules: connection diagram

– Analog I/O on X20 modules: connection diagram.


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Fig. 5.24 - Digital I/O on X20 modules: connection diagram

*¹ Primo alimentatore DC / DC: fornisce il 24 Vdc a tutti i moduli di ingresso e i moduli di uscita *²*² Modulo/i di uscita alimentatore con il 24 Vdc comune agli ingressi*³ Secondo alimentatore DC / DC: fornisce il 24 Vdc indipendente per i moduli di uscita *4. L’alimentazione indipendente è tipicamente tagliata in condizioni di emergenza*4 Modulo/i di uscita alimentato/i con 24 Vdc indipendente, fornito dal secondo alimentatore *³

24 Vdc Power supply must to be protected with fuses.

C5G

Power supply *1

Input module

Input module

Output module *2

Power supply *3

Output module *4


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Fig. 5.25 - Analog I/O on X20 modules: connection diagram

*¹ DC / DC Power supply: source 24 Vdc to input or output module *² GNC Power supply of 0V ANALOG is connected with GND analog signal

24 Vdc Power supply must to be protected with fuses (max 1A).

C5G

Power supply *1

Input module

Output module

t

U

I

U

I

Power supply *1

*2


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5.10.5.4 Prearranged solutions and technical specifications related to the digital and analog I/O

The I/O modules shall be purchased selecting one of the predefined solutions lited in Tab. 5.11:

– C5G-D12: 12 inputs and 12 outputs, wiring on I/O modules terminal board

– C5G-D24: 24 inputs and 24 outputs, wiring on I/O modules terminal board

– C5G-EDI: 24 inputs and 24 outputs, wiring on 42-pin multipolar connector

– C5G-AI2: 2 analog inputs, wiring on I/O modules terminal board

– C5G-AO2: 2 analog outputs, wiring on I/O modules terminal board

The single I/O modules are described in:

– Tab. 5.12 - X20 PS2100PS2100: technical features on page 141

– Tab. 5.13 - X20 DI9371, digital inputs: technical features on page 142

– Tab. 5.14 - X20 DI 9322, digital outputs: technical features on page 143

– Tab. 5.15 - X20 AI2622, analog inputs: technical features on page 144

– Tab. 5.16 - X20 AO2622, analog outputs: technical features on page 146.


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Tab. 5.11 - Predefined solutions for I/O modules

Item Description

C5G-D12 12 Inp / 12 Out, digital, connection on module terminal block

Comau Code C5G-D12 – CR17130580

Structure – 1 powering device for the input modules and first output module (1 x “X20 PS2100”)

– 12 inputs 24 Vdc (1 x “X20 DI9371”) – 6 outputs 24 Vdc - 0,5 A, powering shared with the inputs (1 x “X20

DI 9322”)– 1 powering device for output independent powering (1 x “X20

PS2100”)– 6 outputs 24 Vdc - 0,5 A, independent powering (1 x “X20 DI 9322”)

Electrical features – Power supply: 24 Vdc (-15% to +20%)– First powering device:

• X20 PS2100PS2100: technical features• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 3 A

– Second powering device: • X20 PS2100PS2100: technical features• Power: 24 Vdc (-15% to +20%), typical current*¹ 3 A

– 24 Vdc digital inputs: Tab. 5.13 - X20 DI9371, digital inputs: technical features on page 142

– 24 Vdc - 0,5 A digital outputs: Tab. 5.14 - X20 DI 9322, digital outputs: technical features on page 143)

*¹ it depends on the load applied to the digital outputs. A protection is required on the 24 Vdc power supply to be delivered using a delayed 10A fuse.

Connection type – on module terminal block

Dimension – 5 modules size

Installation requirements – A C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182) shall already be installed and related free space for the new modules (refer to par. 5.10.5.2 Rules for the installation of I/O on X20 modules on page 132).


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C5G-D24 24 Inp / 24 Out, digital, connection on module terminal block


Structure – 1 powering device for the in put modules and the first 2 output modules (1 x “X20 PS2100”)

– 24 inputs 24 Vdc (2 x “X20 DI9371”)– 12 outputs 24 Vdc - 0,5 A, powering shared with the inputs (2 x “X20

DI 9322”)– 1 powering device for output independen powering (1 x “X20

PS2100”)– 12 outputs 24 Vdc - 0,5 A, independent powering (2 x “X20 DI

9322”)

Electrical features – Power supply: 24 Vdc (-15% a +20%)– First powering device:

• X20 PS2100PS2100: technical features• Pwer supply: 24 Vdc (-15% to +20%), typical current*¹ 6 A

– Second powering device: • X20 PS2100PS2100: technical features• Power supply: 24 Vdc (-15% a +20%), typical current*¹ 6 A






Instlalation requirements – A C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182) shall already be installed and related free space for the new modules (refer to par. 5.10.5.2 Rules for the installation of I/O on X20 modules on page 132).

Tab. 5.11 - Predefined solutions for I/O modules (Continued)

Item Description


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C5G-EDI 24 Inp / 12 Out, digital, connection on 42-pole connector

Comau Code C5G-EDI – CR17130380

Structure – 1 powering device for the input modules and first output module (1 x “X20 PS2100”)

– 24 inputs 24 Vdc (2 x “X20 DI9371”) – 6 outputs 24 Vdc - 0,5 A, powering shared with the inputs (1 x “X20

DI 9322”)– 1 powering device for output independent powering (1 x “X20

PS2100”)– 6 outputs 24 Vdc - 0,5 A, independent powering (1 x “X20 DI 9322”)

Electrical features – Power supply: 24 Vdc (-15% to +20%)– First powering device:

• X20 PS2100PS2100: technical features• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 3 A

– Second powering device: • X20 PS2100PS2100: technical features• Power: 24 Vdc (-15% to +20%), typical current*¹ 3 A




Connection type – On 42-pole multipolar connector




Item Description


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C5G-AI2 2 Inp, analog, connection on module terminal block

Comau Code C5G-AI2 – CR17130582

Structure – 1 powering device module to separate the power supplies from the analog channels (1 x “X20 PS2100”)

– 1 module with 2 analog inputs (1 x “X20 AI2622”)

Electrical features – Power supply: 24 Vdc (-15% a +20%)– Power supply device:

• X20 PS2100PS2100: technical features• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 50 mA

– analog inputs: Tab. 5.15 - X20 AI2622, analog inputs: technical features on page 144






Item Description


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C5G-AO2 2 Out, analog, connection on module terminal block

Comau Code C5G-AO2 – CR17130583

Structure – 1 powering device module to separate the power supplies from the analog channels (1 x “X20 PS2100”)

– 1 module with 2 analog outputs (1 x “X20 AO2622”)

Electrical features – Power supply: 24 Vdc (-15% a +20%)– Power supply device:

• X20 PS2100PS2100: technical features• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 50 mA

– analog outputs: Tab. 5.16 - X20 AO2622, analog outputs: technical features on page 146





Applies to all solutions


Usage restrictions – The optional device can be installed only if joined to a Bus Coupler PFG-BCO module on X20 interface (see par. 5.10.3 on page 122) or to another option already installed.

– The optional devices can be installed side by side up to a maximum of 10 adjacent modules. Over 10 modules, a second Bus Coupler module is required.


Item Description


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5.10.5.5 Powering devices technical features


Tab. 5.12 - X20 PS2100PS2100: technical features

Item Description

Identification abbreviation *¹ – X20 PS2100

Electrical features – Input for power supply for I/O modules connected down: • 24 Vdc (-15% a +20%)• Current: 10 A max• Not protected: it requires an external delayed 10 A protection

– used to optically insulate the power supply to I/O modules from 24 Vdc voltages in the Control Unit .


Pinout– +24 VI/O, power supply input, terminal 24– +24 VI/O, power supply input, terminal 25– GND, power supply input, terminal 26

Status LED – r (green):

• [OFF]: module off• [Single flash]: reset mode• [Flashing]: Preoperational mode• [ON]: Run mode

– e (red): • [OFF]: module off or everything all right• [Duble flash]: input/output powering or X2X bus powering not

sufficient.– e + r:

• [Red in fixed modality, Green single flash]: incorrect firmware


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5.10.5.6 Digital input/output technical features

– X20 DI9371, digital inputs: technical features

– X20 DI 9322, digital outputs: technical features


Tab. 5.13 - X20 DI9371, digital inputs: technical features

Item Description

Identification abbreviation * – X20 DI9371

Electrical features – Input: 24 Vdc (-15% to +20%) (“1 logic” > 15 Vdc, “0 logic” < 5 Vdc)

– Typical current: 3,75 mA @ 24Vdc– Input type: PNP (sink), optoinsulated– I/O scannning/updating time: 2 ms


Pinout– DI 1: digital input 1, terminal 11– DI 2, digital input 2, terminal 21– DI 3, digital input 3, terminal 12– DI 4, digital input 4, terminal 22– DI 5, digital input 5, terminal 13– DI 6, digital input 6, terminal 23– DI 7, digital input 7, terminal 14– DI 8, digital input 8, terminal 24– DI 9, digital input 9, terminal 15– DI 10, digital input 10, terminal 25– DI 11, digital input 11, terminal 16– DI 12, digital input 12, terminal 26

Staus LED – r (green):


– e (red): • [OFF]: module off or everything all right

– e + r: • [Red in fixed modality, Green single flash]: incorrect

firmware– 1..12 (green):

• [ON]: status of the associated input


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Tab. 5.14 - X20 DO6322, digital outputs: technical features

Item Description

Comau Code – X20 DO6322

Electrical features – Output: 24 Vdc (-15% to +20%)– Max current per output: 0,5 A (self-protected)– Voltage drop 0,3 V @ 0,5 A– Output type: PNP (sink), optoinsulated– I/O scanning/updating time: 2 ms


Pinout– DO 1: digital output 1, terminal 11– DO 2, digital output 2, terminal 21– DO 3, digital output 3, terminal 12– DO 4, digital output 4, terminal 22– DO 5, digital output 5, terminal 13– DO 6, digital output 6, terminal 23– GND, common 0V, terminal 14– GND, common 0V, terminal 24– GND, common 0V, terminal 15– GND, common 0V, terminal 25– GND, common 0V, terminal 16– GND, common 0V, terminal 26

Notes: – the GND are connected together. – The 24 Vdc supplied by the outputs is taken from the powering

device connected immediately up the module.

Staus LED– r (green):


– e (red): • [OFF]: module off or everything all right• [Single flash]: error on input / output channel.


firmware– 1..12 (amber):

• [ON]: status of the associated output


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5.10.5.7 Analog inputs/output technical features

– X20 AI2622, analog inputs: technical features

– X20 AO2622, analog outputs: technical features

Tab. 5.15 - X20 AI2622, analog inputs: technical features

Item Description

Identification abbreviation * – X20 AI2622

Electrical features – Up to 2 inputs with selection in voltage or current– Voltage input:

• Range: +10 Vdc to -10 Vdc (default)• Impedance: 20 M ohm• Resolution: ±12 bit

– Current input: *²• 0-20 mA / 4-20 mA• Resolution: 12 bit

– I/O scanning/updating time: 2 ms


Pinout– AI + 1 I, analog input 1 - current signal, terminal 11– AI + 1 U, analog input 1 - voltage signal, terminal 12– AI - 1 U/I, GND, input common 1, terminal 13– AI + 2 I, analog input 2 - current signal, terminal 21– AI + 2 U, analog input 2 - voltage signal, terminal 22– AI - 2 U/I, GND, input common 2, terminal 23


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*¹ Identification abbreviation posted on the component front side*² Check implementation referring to “Control Unit Usage” manual



– e (red): • [OFF]: modue off or everything all right• [ON]: Error or reset state


firmware– 1 - 2 (green):

• [OFF]: connection open or sensor disconnected• [Flashing]: signal input beyond minimum or maximum limit• [ON]: converter on and value ok.

Tab. 5.15 - X20 AI2622, analog inputs: technical features

Item Description


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Tab. 5.16 - X20 AO2622, analog outputs: technical features

Item Description

Identification abbreviation * – X20 AO2622

Electrical features – Up to 2 outputs with selection in voltage or current– Voltage output:

• Range: +10 Vdc to -10 Vdc (default)• Output current: < 10 mA• Impedance: > 1k ohm• Resolution: 12 bit

– Current output: *²• 0-20 mA • Impedance: 600 ohm

– Protection against short-circuit: 40 mA– Resolution: 12 bit– I/O scannning/updating time: 2 ms


Pinout– AO + 1 I, analog output 1 - current signal, terminal 11– AO + 1 U, analog output 1 - voltage signal, terminal 12– AO - 1 U/I, GND, output common 1, terminal 13– AO + 2 I, analog output 2 - current signal, terminal 21– AO + 2 U, analog output 2 - voltage signal, terminal 22– AO - 2 U/I, GND, output common 2, terminal 23


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*¹ Identification abbreviation posted on the component front side*² Check implementation referring to “Control Unit Usage” manual


• [OFF]: module off• [Single flashing]: reset mode• [Flashing]: Preoperational mode• [ON]: Run mode

– e (red): • [OFF]: module off or everything all right• [ON]: Error or reset state


firmware– 1 -2 (amber):

• [OFF]: value equal to 0 (zero)• [ON]: value other than 0 (zero).

Those modules are also described in the option list:– par. 6.3.2 C5G-AI2 - C5G-AO2, analog I/O options on page 158– par. 6.3.7 C5G-D12 - C5G-D24, digital I/O options on page 164– par. 6.3.11 C5G-EDI: External digital I/O interface on page 170.

Tab. 5.16 - X20 AO2622, analog outputs: technical features

Item Description


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5.10.5.8 Configuration of the I/O modules in the system

The I/O modules can be used in the system only after being suitably configured .

The I/O modules configuration shall be accomplished using the special routines IO_CNFG (configuration of the module in the system) and IO_MAP (signal mapping) supplied together with Control Unit. Following the configuration it may be necessary to restart the system acting on the Restart Cold control.

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


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5.11 RS232 and RS422 serial communication– General principles

– Serial port technical features

– RS232 serial connection cable to PC.


The Control Unit is supplied as standard with a serial communication port that supports the non-contemporaneous connection of the type RS232C and RS422. The communication port is available on the COM2 connector located on the AMS-APC820 module; the serial cable to the application can exit the C5G Control Unit through the X90 cable gland connector.

5.11.2 Serial port technical features

Tab. 5.17 - COM2 technical features

COM2

RS232/RS422 serial port for user’s applications. The RS232C and RS422 ports canno be used contemporaneously.DSUB (tray-type) 9-pin male connector.

Features:– RS232C / RS422, non modem-capable, electrically

insulated– UART 16550-compatible, 16-byte FIFO– Speed: Max. 115 kbaud *¹– Cable max length:

RS232: 15 m (49 ft) RS422: 1200 m (3937 ft)

Pins:

n.c.: disconnected in the specified configuration*¹ it depends on the cable type and length


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5.11.3 RS232 serial connection cable to PC

Fig. 5.26 - Typical RS232 serial cable to connect COM2 on AMS-APC820 to Personal Computer

Features:– RS232C– Crossed cable– 2 DSUB

(tray-type) 9-pin female movable connectors by the ends.

– No control signal.

This topic is dealt with also in the manual “Transport and instalation ” in par. 7.6 RS232 / RS422 serial communication on page 67.

Pin 2: RXPin 3: TX

Pin 5: GNDShield

Pin 3: RXPin 2: TXPin 5: GND

11

99

(female) (female)

Personal Computerside

AMS-APC820side

Pin 2: RXPin 3: TX

Pin 5: GNDShield

Pin 3: RXPin 2: TXPin 5: GND

11

99

(female) (female)

Personal Computerside

AMS-APC820side


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5.12 Communication via Ethernet network– General principles

– ETH2 connection technical features.


The ETH2 is a RJ45 connector, which allows to connect the Ethernet network to a host system. The connection is available on the AMS-APC820 module; the network cable to the application can exit the C5G Control Unit through the X90 cable gland connector.

5.12.2 ETH2 connection technical features

The ETH2 port is used also by the option C5G-ETHK: Ethernet kit (see par. 6.3.12 on page 172) and therefore may not be available. In that case an Ethernet industrial switch may be interposed to obtain the signal both for the C5G-ETHK option and the connection to a Host system.

Tab. 5.18 - Technica features

ETH2

Ethernet 10/100/1000 netwotk port for user’s applications (e.g. connection to factory Host)

Features:– Controller: Intel 82574– Speed: 10/100/1000 Mbit/s– Cable max length: 100 m (328 ft), minimum Cat5e– Tipo di cavo: S/STP (Cat5e)

Predefined TCP/IP configuration:– Address IP: 192.168.29.2– Subnet mask: 255.255.255.0– Factory host search address for download / FTP

functions: 192.168.29.1


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5.13 Summary of connectors and corresponding functionTo facilitate the identification of the functions of the main Control Unit connectors, find below the list in alphabetical order and the corresponding paragraph.

Tab. 5.19 - Summary of connectros

Connector Typical function Description

COM2 / APC820

Analysis, measurement

systems (via RS232 serial )

The communication with the systems (e.g. measurement systems, oher ones) can be contorlled through the RS232 serial connection on COM2 connector on AMS-APC820 (RS232 serial).

COM2 / APC820

Host systems for monitoring

(via RS422 seria )

The communication with the Host systems (e.g. line PLC, factory production controlling PC, analysis devices, other ones) can be controlled through the RS422 serial connection (see COM2 connector on AMS-APC820 (RS422 serial) (see par. 5.3.3 on page 102)).

ETH2 / APC820

Host systems for monitoring

(via Ethernet)

The communication with the Host systems (e.g. line PLC, factory production controlling PC, analysis devices, other ones) can be controlled through Ethernet connections (see ETH2 connector on AMS-APC820 (Ethernet) (see par. 5.3.2 on page 102))

X10 RobotThe main Robot is connected through the Connection cables between C5G and Robot con il X10 connector (Robot signals)

X10-EXT Positioning device

The positioning device (e.g. series SMART5 PTDV, PTDORB, other ones) is connected through the Connection cables between C5G and Robot (it uses the same Robot cables, exploiting only the necessary wires depending on the no. of axes available) with the X10-EXT connector (Extension, Positioning device signals)

X30 Safety itemsThe safety signals (e.g. emergency stop, cell access door limit switches, other ones) are available on the X30 connector (Safety items)

X31X32

wired I/O, on connector

The I/O, safety and power supply signals are directly available on the optional X31..X32 connectors (Applications)

wired I/O, on module and terminal

board

The I/O signals are directly available on the optional X31..X32 connectors (Applications)

X60 RobotThe main Robot is connected through the Connection cables between C5G and Robot with the X60 connector (Robot Power)

X60-EXT Positioning device

The positioning device (e.g. series SMART5 PTDV, PTDORB, other ones) is connected through the Connection cables between C5G and Robot (it uses the same Robot cables, exploiting only the necessary wires depending on the no. of axes available) with the X60-EXT connector (Extension, motors and brakes of the positioning device)

X61X62X63X64

Auxiliary axes

The single auxiliary axis (e.g. saddle on axis 7, electric gripper for spot welding, other ones) are connected through the Connection cables between C5G and Robot, each one with an only one connector that includes both the power and the control signals, with the X61..X64 connectors (Signals and power for auxiliary Axes)

X90Multiple cable input/output

The cables can be connected inside the Control Unit through the X90 cable gland connector with no interruption

X93X94

Remote I/O (C5G with master

role)

The communication with the systems (e.g. measurement systems, remote I/O, other ones) can be controlled through Field Bus protocols with X93..X94 connector (Master field Bus)


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X106/SDM 24 Vdc power

supply for user’s applications

The 24Vdc powering is available according to the modalities specified in par. 5.7 How to use the 24 Vdc in the user’s applications on page 113


24Vdc power supply and

emergency stop signal

Dedicated connectors. They are used with the Control Unit options to deliver 24Vdc powering and enable the emergency stop control.


digital I/O for minor applications

The I/O signals are available as standard on the Safety Distribution Module (SDM) and decribed in par. 5.9 Digital Inputs / Output on the SDM module on page 116

Tab. 5.19 - Summary of connectros (Continued)

Connector Typical function Description


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Options

6. OPTIONS


– Option listing

– Information abut the option installation

– Options for the C5G Control Unit

For the sake of immediacy, the “C5G Robot Control Unit” will be referred to simply as C5G.

6.1 Option listingThe basic version may be supplemented with additional options to better suit the installation requirements. If not otherwise specified, the available options can be selected and combined as required. Possible restrictions related to the mutual incompatibility or the maximum no. of admissible options are clearly specified.

To facilitate the search, the options are listed below according to function and application field, while in the whole chapter are listed according to their abbreviation alphabetical order.

Function list and corresponding options:

– Field Bus DeviceNet• C5G-PFG-BCO: Bus Coupler module• C5G-DNM-DNMI: DeviceNet Master Interface• C5G-DNM-DNSI: DeviceNet Slave Interface• C5G-DNPC: movable connector for Devicenet modulesProfibus-DP• C5G-PFG-BCO: Bus Coupler module• C5G-PFM-PDPM: Profibus-DP Master Interface• C5G-PFM-PDPS: Profibus-DP Slave Interface• C5G-PFPC: movable connector for Profibus-DP modules

– I/O modulesoptional movable connectors• C5G-UCK: user connector kit, for SDM moduleon X20 interface• C5G-PFG-BCO: Bus Coupler module• C5G-D12 - C5G-D24, digital I/O options• C5G-AI2 - C5G-AO2, analog I/O optionson multipolar connector• C5G-EDI: External digital I/O interface

– Special applications • C5G-HSK5: High Speed Input Kit• C5G-OTK: Axis Over Travel kit• C5G-SMK: Signal Machine Kit• C5G-TDC400: 400V Tip Dresser Command kit• C5G-TDC400-2: 400V Double Tip Dresser Command kit• C5G-TDS400: 400V Tip Dresser Supply kit


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Options

– Structural items• C5G-APK1 kit Auxiliary Plate 1• C5G-APK2 kit Auxiliary Plate 2• C5G-APK3 kit Auxiliary Plate 3• C5G-APK4 kit Auxiliary Plate 4• C5G-HFK kit fastening hangers• C5G-OPK: Option Panel kit• C5G-RSK100: 100-mm rising socket kit

– Services • C5G-AFK: Auxiliary Fan Kit• C5G-ETHK: Ethernet kit• C5G-HMK: Hour-meter kit• C5G-USBK: USB kit

6.2 Information abut the option installationThe options purchased together with the C5G Control Unit are supplied already installed. If the options are purchased later, the installation instructions are to be found in the option installation manual.

The options listed here shall be installed and used solely with the C5G Control Unit.


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Options

6.3 Options for the C5G Control Unit

6.3.1 C5G-AFK: Auxiliary Fan Kit

FunctionWith the C5G-AFK (Auxiliary Fan Kit) option an additional fan will be available to increase the forced air on the CPU, power supplies and power modules dissipator, when auxiliary axes are added.

Technical features and structureThe auxiliary fan is connected in parallel to the ones already installed in the Control Unit (for more details, refer to par. 4.13 Internal ventilation system on page 82). The no. of fans installed depends on the no. of available axis modules: a fan shall be available for each 3 slot taken on the ACC. Even when the 3-slot group is not complete and only 2 slots are taken an additional fan is required.

Fig. 6.1 - C5G-AFK: overall view

A: Fan installation area. The picture shows the 3 fans available in the Control Unit C5G-ACC3 (view with no cover panel)

B: C5G-AFK (the yellow fan serves the purpose of highlighting the option installed)

Tab. 6.1 - C5G-AFK: technical features

Item Description


Electrical features – 24 Vdc fan with speed control through PWM signal

Size and weight – Not relevant; do not influence the considerations about the size and weight for the Control Unit basic version

Installation position – On the rear panel only

Usage restrictions – Possible to install:

on Control UnitAvailable on the basic

versionAdmissible options

C5G-ACC1 2 2

C5G-ACC3 3 1

C5G-ACC5 being defined being defined

A

B


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Options

6.3.2 C5G-AI2 - C5G-AO2, analog I/O options

FunctionThe C5G-AI2 (Analog Input 2) and C5G-AO2 (Analog Output 2) options makes available digital inputs and outputs for the user’s applications.

Technical features and structureThe I/O are on X20 modules and shall be configured and used according to the instructions specified in Rules for the installation of I/O on X20 modules (see par. 5.10.5.2 on page 132).

To facilitate the installation, default units are available (see Tab. 6.2), consisting of fastening base, powering devices, cards and terminal boards.

Minimum requirementsThe C5G-AI2 (Analog Input 2) and C5G-AO2 (Analog Output 2) options may be installed only if the following items are already in place:

– C5G-OPK: Option Panel kit

– C5G-PFG-BCO: Bus Coupler module supplied with Ethernet (1,5 m long) cable and 24 Vdc powering cable.

*¹ they require one module. The size of one module is 12.5 mm.

Tab. 6.2 - I/O analog modules solutions

Item Description

C5G-AI2

Comau Code C5G-AI2 – CR17130582

Structure – 1 powering device for input module – 2 analog inputs*¹ (choise from -10 a +10 Vdc, 0-20 mA and 4-20

mA)

Electrical features – Refer to Prearranged solutions and technical specifications related to the digital and analog I/O (see par. 5.10.5.4 on page 135).


C5G-AO2

Comau Code C5G-AO2 – CR17130583

Structure – 1 powering device for output module– 2 analog outputs *¹ (choise from -10 a +10 Vdc and 0-20 mA)

Electrical features – Vedi Prearranged solutions and technical specifications related to the digital and analog I/O (see par. 5.10.5.4 on page 135).


Installation position (valid for C5G-AI2 and C5G-AO2)

– Inside the C5G, on omega guide.

Usage restrictions (valid for C5G-AI2 and C5G-AO2

– The optional device can be installed only if joined to a C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182) to another option already installed.



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Options

Fig. 6.2 - C5G-AI2: overall view

Fig. 6.3 - C5G-AO2: overall view


Usage modalities

A: Power supply module, X20 PS2100 *¹B: 2 analog inputs, X20 AI 2622 *¹

A: Power supply module, X20 PS2100 *¹B: 2 analog outputs, X20 AO 2622 *¹

For further details and the usage modalities, refer to par. 5.10.5 Digital and analog I/O module on the X20 interface on page 131.

See also C5G-D12 - C5G-D24, digital I/O options (see par. 6.3.7 on page 164).

A B

A B


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Options

6.3.3 C5G-APK1 kit Auxiliary Plate 1

FunctionThe C5G-APK1 (Auxiliary Panel Kit 1) option makes available an auxiliary plate to fasten the following items on the CIP panel by the box base:

– 2 x dinkings for 72-pin connectors, (Harting size 16)

– 1 x dinking for 42-pin connector, (Harting size 10).

Technical features and structureThe plate is supplied with 6 fastening screws and shall be installed by removing one of the dinking already available on the CIP panel. It shall be earthed through the supplied yellow/green wire.

Fig. 6.4 - C5G-APK1: overall view

A: C5G-APK1

Tab. 6.3 - C5G-APK1: technical features

Item Description

Comau code – CR17431480

Mechanical features – Metallic plate

Size and weight – 300 x 147 mm, 500 g

Installation position – On CIP panel by box base

Usage restrictions – Depending on the requirements, but in compliance with the instructions in par. 4.12 Connector Interface Panel (CIP) on page 80, item Preferred installation positions for optional connector.

A


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Options


FunctionThe C5G-APK2 (Auxiliary Panel Kit 2) option makes available an auxiliary plate to fasten the following items on the CIP panel by the box base :

– 3 x dinkings for 42-pin connectors, (Harting size 10).



A: C5G-APK2


Item Description




Installation position – On CIP panel by box base


A


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Options



– 1 x dinking for 108-pin connector, (Harting size 24)

– 1 x dinking for 42-pin connector, (Harting size 10).

– 4 x dinkings for M25 connector / cable gland.



A: C5G-APK3


Item Description




Installation position – Sul pannello CIP a base armadio


A


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Options



– 2 x dinkings for 42-pin connector, (Harting size 10).

– 1 x fastening hole for wall intallation cap, (Harting size 16).



A: C5G-APK4


Item Description


Mechanical features – Piastra metallica


Installation position – Sul pannello CIP a base armadio

Usage restrictions – Depending on th requirements, but in compliance with the instructions in par. 4.12 Connector Interface Panel (CIP) on page 80, item Preferred installation positions for optional connector.

A


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Options

6.3.7 C5G-D12 - C5G-D24, digital I/O options

FunctionThe C5G-D12 (Digital 12Input/Output) and C5G-D24 (Digital 24Input/Output) options makes available digital inputs and outputs for the user’s applications.

Technical features and structureThe I/O are on X20 modules and shall be configured and usee according to the instructions specified in Rules for the installation of I/O on X20 modules (see par. 5.10.5.2 on page 132).

To facilitate the installation, default units are available (see Tab. 6.27), consisting of fastening base, powering devices, cards and terminal boards.

Minimum requirementsThe C5G-D12 (Digital 12Input/Output) and C5G-D24 (Digital 24Input/Output) options may be installed only if the following items are already in place:


– C5G-PFG-BCO: Bus Coupler module supplied with Ethernet (1,5 m long) cable and 24 Vdc pwering cable.

Tab. 6.7 - I/O digital modules solutions

Item Description

C5G-D12


Structure – 1 powering device for input modules and first output module – 12 inputs *¹ 24 Vdc– 6 outputs *¹ 24 Vdc - 0,5 A, share the power supply with the inputs – 1 powering device for output independent powering– 6 outputs *¹ 24 Vdc - 0,5 A, independent powering

Electrical features – Refer to Prearranged solutions and technical specifications related to the digital and analog I/O (see par. 5.10.5.4 on page 135)


C5G-D24


Structure – 1 powering device for input modules and first 2 output modules– 24 inputs *²24 Vdc– 12 outputs *² 24 Vdc - 0,5 A, share the power supply with the inputs – 1 powering device for output independent powering– 12 outputs *² 24 Vdc - 0,5 A, independent powering

Electrical features – Refer to Prearranged solutions and technical specifications related to the digital and analog I/O (see par. 5.10.5.4 on page 135)


Installation position (valid for C5G-D12 and C5G-D24)

– Inside the C5G, on omega guide.


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Options

*¹ they require one module. The size of one module is 12.5 mm.*² they require two modules. The size of one module is 12.5 mm.

Fig. 6.8 - C5G-D12: overall view

Usage restrictions (valid for C5G-D12 and C5G-D24)

– The optional device can be installed only if joined to a C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182) to another option already installed.


A: Power supply module, X20 PS2100 *¹B: 12 inputs module, X20 DI9371 *¹C: 6 ouptus module, X20 DO6322*¹

Tab. 6.7 - I/O digital modules solutions (Continued)

Item Description

C A CA B


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Options

Fig. 6.9 - C5G-D24: overall view


Usage modalities

A: Power supply module, X20 PS2100 *¹B: 12 inputs module, X20 DI9371 *¹C: 6 ouptus module, X20 DO6322*¹

For further details and the usage modalities, refer to par. 5.10.5 Digital and analog I/O module on the X20 interface on page 131.

Se also C5G-AI2 - C5G-AO2, analog I/O options (see par. 6.3.2 on page 158)

C A CA B B C C


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Options

6.3.8 C5G-DNM-DNMI: DeviceNet Master Interface

FunctionThe C5G-DNM-DNMI (DeviceNet Module - DeviceNet Master Interface) option makes available a DeviceNet Master interface module inside the Control Unit.

Technical features and structureThis module shall be installed on the C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182). The corresponding connector is the C5G-DNPC: movable connector for Devicenet modules (see par. 6.3.10 on page 169), supplied as optional item.

Fig. 6.10 - C5G-DNM-DNMI: overall view

Usage modalities

A: C5G-DNM-DNMI

Tab. 6.8 - C5G-DNM-DNMI: technical features

Item Description


Electrical features –

Installation position – on C5G-PFG-BCO: Bus Coupler module

Usage restrictions – Up to 2 modules (for restrictions and position refer to par. 5.10.4.2 Installation rules for the field bus modules on page 127)

For further details and the usage modalities, refer to par. 5.10.4 Field Bus Modules on the X20 interface on page 126.

A


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Options

6.3.9 C5G-DNM-DNSI: DeviceNet Slave Interface

FunctionThe C5G-DNM-DNSI (DeviceNet Module - DeviceNet Slave Interface) option makes available a DeviceNet Slave interface module inside the Control Unit.

Technical features and structureThe module shall be installed on the C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182).The corresponding connector is the C5G-DNPC: movable connector for Devicenet modules (see par. 6.3.10 on page 169), supplied as optional item.

Fig. 6.11 - C5G-DNM-DNSI: overall view

Usage modalities

A: C5G-DNM-DNSI

Tab. 6.9 - C5G-DNM-DNSI: technical features

Item Description



Installation position – Inside the C5G, on the C5G-PFG-BCO: Bus Coupler module



A


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Options

6.3.10 C5G-DNPC: movable connector for Devicenet modules

FunctionThe C5G-DNPC (DeviceNet Plug Connector) option makes available the suitable connector to connect the DeviceNet network cable on the C5G-DNM-DNMI: DeviceNet Master Interface or C5G-DNM-DNSI: DeviceNet Slave Interface module.

Technical features and structure

Fig. 6.12 - C5G-DNPC: overall view

A: C5G-DNPC

Tab. 6.10 - C5G-DNPC: technical features

Item Description


A


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Options

6.3.11 C5G-EDI: External digital I/O interface

FuncionaThe C5G-EDI (External Digital Iinterface) option makes available 24 digital inputs e 12 digital outputs for the user’s applications, that can be accessed on a 42-pin connector (Harting size 10) installed by the box base on CIP panel.

Technical features and structureThis option inclides the I/O X20 interface modules, the internal cable, the 42-pin connector to be installed by the CIP panel base and the movable cap with male pins. The I/O are on X20 modules and shall be configured and used according to the instructions specified in Rules for the installation of I/O on X20 modules (see par. 5.10.5.2 on page 132).

Minimum requirementsThe C5G-EDI option may be installed only if the following items are already in place:


– C5G-PFG-BCO: Bus Coupler module with Ethernet (1,5 m long) cable and 24 Vdc powering cable, maximum 4 modules allowed on right side

– APK plate by box base (the user may choose among C5G-APK1 kit Auxiliary Plate 1, C5G-APK2 kit Auxiliary Plate 2, C5G-APK3 kit Auxiliary Plate 3, C5G-APK4 kit Auxiliary Plate 4).

Fig. 6.13 - C5G-EDI: overall view


A: Powering module, X20 PS2100 *¹B: 12-spot input module, X20 DI9371 *¹C: 6-spot output module, X20 DO6322*¹

Tab. 6.11 - C5G-EDI: technical features

Item Description


A CA B B C


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Options

*¹ take one module. The module size is equal to 12,5 mm.*² take two modules. The module size is equal to 12,5 mm.

Components – 1 power supply for the input modules and the first output one– 24 inputs *² 24 Vdc – 6 outputs *¹ 24 Vdc - 0,5 A, common powering for the inputs – 1 power supply for output independent powering– 6 outputs *¹ 24 Vdc - 0,5 A, independent power supply

Electric features – Refer to Prearranged solutions and technical specifications related to the digital and analog I/O (see par. 5.10.5.4 on page 135)

Size – 6 modules overall dimensione

Installation position – On the C5G-OPK inside panel with connector on CIP panel by box base

Usage restrictions – Depanding on the requirements, but in compliance with:• the instructions in Rules for the installation of I/O on X20

modules (see par. 5.10.5.2 on page 132) • the no. of free spaces for 42-pin connectors, according to the

instructions in par. 4.12 Connector Interface Panel (CIP) on page 80, item Preferred installation positions for optional connector.

Tab. 6.11 - C5G-EDI: technical features (Continued)

Item Description


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Options

6.3.12 C5G-ETHK: Ethernet kit

ScopeThe C5G-ETHK (ETHernet Kit) option makes available a Ethernet network connector on the Operator Panel Devices (OPD) remoting the ETH2 port pf the AMS-APC820 module, allowing the connection with a Personal Computer for maintenance programming and diagnostics purposes (non-continuous usage).

To obtain an Ethernet connection for continuous usage (e.g. connection to factory Host), we recommend to carry out a direct connection to the Ethernet ETH2 connector and to have the net cable exiting from the Connector Interface Panel (CIP) (see par. 4.12 on page 80).


Fig. 6.14 - C5G-ETHK: overall view

A: C5G-ETHK

Tab. 6.12 - C5G-ETHK: technical features

Item Description


Electrical features – Ethernet RJ45 port, 10/100/1000 Mbit/s– Protection category IP65 (with cap in closed position)– Remote connection for Ethernet port, obtained from ETH2

connector on the AMS-APC820 module


Installation position – On the Operator Panel Devices (OPD) only, right position A (see Fig. 6.14).

Usage restrictions – Only 1 option allowed– It is not possible to install the option if 2 C5G-USBK: USB kit options

are installed

A

ETH


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Options

6.3.13 C5G-HFK kit fastening hangers

FunctionThe C5G-HFK (Hangers Fixing Kit) option makes available a set of two hangers fasten the Control Unit to the floor.

Technical features and structureThe kit consists of a set of two hangers. To carry out the fastneing to the floor, suitable blocks are required, which are not part of the supply volume.

Fig. 6.15 - C5G-HFK: overall view

A: C5G-HFK

Tab. 6.13 - C5G-HFK: technical features

Item Description


Mecchanical features – Fastening hangers out of sheet painted in RAL 7024

Dimensioni e peso

Distance between hole centres : 730 x 605 mm (28.74 x 23.82 in)Hole diameter: 15 mm (0.59 in)

Installation position – Through the box supporting feet

Usage restrictions – It is not possible to install the C5G-HFK option together with the C5G-WHK: wheel kit (see par. 6.3.50 on page 213) one.

A

Front viewFront view

Side viewSide view

Top viewTop view

730 mm730 mm

60

5m

m

ø 15 mmø 15 mm

1,2 kg1,2 kg


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Options

6.3.14 C5G-HMK: Hour-meter kit

FunctionThe C5G-HMK (Hour Meter Kit) makes available a hour-meter recording the Robot working hours on the Operator Panel Devices (OPD) panel.

Technical features and structureThe hour-meter is connected to the X107/SDM connector on the SDM module. The output is enabled in Drive On only and therefore the hour-meter records the Robot operating hours only.

Fig. 6.16 - C5G-HMK: overall view

A: C5G-HMK

Tab. 6.14 - C5G-HMK: technical features

Item Description


Electrical features – Hour-meter, capacity up to 99999,99 hours, cannot be zeroed– 24 Vdc coming from X107/SDM connector on SDM module– Protection category IP54


Installation position – On the Operator Panel Devices (OPD) panel only

Usage restrictions – Only 1 option allowed

A


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Options

6.3.15 C5G-HSK5: High Speed Input Kit

FunctionThe C5G-HSK5 (High Speed Kit) option makes available two high-speed inputs for applications, commonly used to acquire a given technological item (e.g. welding line check).

Technical features and structureInside the C5G 2 inputs are available, one of which is shared with the Robot border area. The HSI3 is the shared input and cannot be used contemporaneously on the Robot border area and inside the C5G. The fast input signals converge on the first module AMS-IAM module.

The connection at the disposal of the user is available on X136 (by HSI1) and X137 (by HSI3) screw-in connectors (supplied together with the option). The connection by the Robot border area is available on dedicated connectors, depending on the Robot version (the signal travels from the X10 connector (Robot signals) by the C5G base to the X1 connector by the Robot base).

This module is to be installed on the omega guide inside the C5G, carrying out the suitable connections between the X138 and the X2 connector of the first AMS-IAM module as well as the X10 connector (Robot signals).

Fig. 6.17 - C5G-HSK5: overall view

A: C5G-HSK5

X136: signal for HSI1, including 24 Vdc power supply

X137: signal for HSI3, including 24 Vdc power supply

X138: sorting towards the first AMS-IAM module and X10 connector (Robot signals)

Tab. 6.15 - C5G-HSK5: technical features

Item Description


Electrical features – 2 high-speed inputs (HSI1 and HSI3)– shared HSI3, that can be accessed on the module or Robot border

area (contemporaneous usage not allowed) – Voltage: 24 Vdc (from 15 to 30 Vdc max)

(“1 logic” > 15 Vdc, “0 logic” < 5 Vdc)– Typical current: 10 mA– Connection with clean contact and/or digital signal

A


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Options

Usage modalities



For the usage modalities, refer to par. 7.5 HSI (High Speed Inputs) on page 65 in the “Transport and installation” manual

Tab. 6.15 - C5G-HSK5: technical features (Continued)

Item Description


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Options

6.3.16 C5G-OPK: Option Panel kit

FunctionThe C5G-OPK (Option Plate Kit) roption makes available an area to insall electric components on the omega guide.

A C5G-OPK plate is supplied as standard with the Control Unit basic version .

Technical features and structureThis option allows to install electric components on the omega guide, on two 220-mm (8.66 in) guide segments.

Fig. 6.18 - C5G-OPK: overall view

A: C5G-OPK

Tab. 6.16 - C5G-OPK: technical features

Item Description


Mechanical features – It can take an overall weight below 15 kg, equally divided between the 2 guides

Size and weight

Overall dimensions: 220 x 275 mm (8.66 x 10.83 in)

A

220 mm220 mm

275

mm

275

mm

1 kg1 kg


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Options

Installation position – on the box inside protrusion, in 3 prearranged positions, in compliance with the instructions in in Tab. 6.17 - Example of installation for the C5G-OPK plate on page 179

Usage restrictions – maximum 3 plates

Tab. 6.16 - C5G-OPK: technical features (Continued)

Item Description


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Options

General rules applying to the components installation on the C5G-OPK plateThe majority of options available on the C5G Control Unit require some installation space on the C5G-OPK plate. Based on logistics and functional analyses, we identified the suitable installation position, that a re recommended in Tab. 6.17.

Tab. 6.17 - Example of installation for the C5G-OPK plate

Items available Recommended position

Left: A230 / 400 V power

electromechanical items

Centre: BExtension position for:

Field bus I/O modules

Safety signal extension

Right: CMain position for:

Field busI/O modules

Safety signal extension

A B C A

A B

A B CB

B C

A B C

C

B C


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Options

6.3.17 C5G-OTK: Axis Over Travel kit

FunctionThe C5G-OTK (Over Travel Kit) option makes available the axis over-travel limit switch connection.

Technical features and structure2 inputs are available to identify the “axis +” and “axis -” over-travel positions. The option features terminal boards to connect up to 5 limit switches, connected in series to one another. The system software identifies only one “axis +” and only one “axis -” over-travel signal. The over-stroke signals converge on the second module AMS-IAM module.

The connection at the disposal of the user is available on screw-in connectors (supplied with the option), installed inside the C5G on the omega guide close to the X10 connector (Robot signals), carrying out the suitable connections between the X10 connector and the X2 one of the second AMS-IAM module.

Tab. 6.18 - C5G-OTK: technical features

Item Description


Electrical features – Voltage: 24 Vdc (from 15 to 30 Vdc max) (“1 logic” > 15 Vdc, “0 logic” < 5 Vdc)

– Typical current: 10 mA– Connection with not energized contact

Installation position – On the Connector Interface Panel (CIP), nearby the X10 connector.



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Options

Connection diagram

Fig. 6.19 - C5G-OTK: connection diagram

C5G


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Options

6.3.18 C5G-PFG-BCO: Bus Coupler module

FunctionThe C5G-PFG-BCO (Bus COupler) module makes possible the interfacing between the Ethernet POWERLINK Network (see par. 4.15 on page 84) and the X20 interface modules (see par. 5.10.1 on page 121), both field Bus and I/O modules.

Technical features and structureThis module consists of a mega-guide fastening base, an interface for the connection with the Ethernet POWERLINK network and a DC/DC powering device (identified as *¹ X20 PS 9400). The modules features 2 free slots to install field Bus modules on the X20 interface.

Minimum requirementsThe 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).*¹ Identification abbreviation posted on the component front side

Fig. 6.20 - C5G-PFG: overall view

A: C5G-PFG-BCO

Tab. 6.19 - C5G-PFG-BCO: main technical features

Item Description


Electrical features – Power supply: 24 Vdc (-15% to +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

Ethernet POWERLINK Cable 1,5 m (4.9 ft) Comau Code

– CR17231863 (ACC ETH POWERLINK 1,5 m)

A


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Options

Usage modalities

24 Vdc Power supply cable Comau Code

– CR17240260 (PFG supply cable)

For further details and the usage modalities, refer to par. 5.10.3 Bus Coupler PFG-BCO module on X20 interface on page 122.

Tab. 6.19 - C5G-PFG-BCO: main technical features

Item Description


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Options

6.3.19 C5G-PFM-PDPM: Profibus-DP Master Interface

FunctionThe C5G-PFM-PDPM (ProFibus Module - Profibus-DP Master) option makes available a Profibus-DP Master interface module inside the Control Unit.

Technical features and structureThe module is to be installed on the C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182). The corresponding connector is the C5G-PFPC: movable connector for Profibus-DP modules (see par. 6.3.21 on page 186), supplied as optional item.

Fig. 6.21 - C5G-PFM-PDPM: overall view

Usage modalities

A: C5G-PFM-PDPM

Tab. 6.20 - C5G-PFM-PDPM: technical features

Item Description






A


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Options

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

FunctionThe C5G-PFM-PDPS (ProFibus Module - Profibus-DP Slave) option makes available a Profibus-DP Slave interface module inside the Control Unit.

Technical features and structureThis module is to be installed on the C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182). The corresponding connector is the C5G-PFPC: movable connector for Profibus-DP modules (see par. 6.3.21 on page 186), supplied as optional item.

Fig. 6.22 - C5G-PFM-PDPS: overall view

Usage modalities

A: C5G-PFM-PDPS

Tab. 6.21 - C5G-PFM-PFMI: technical features

Item Description






A


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Options

6.3.21 C5G-PFPC: movable connector for Profibus-DP modules

FunctionThe C5G-PFPC (ProFibus Plug Connector) option makes available the connector suitable to connect the Profibus network cable on the C5G-PFM-PDPM: Profibus-DP Master Interface or C5G-PFM-PDPS: Profibus-DP Slave Interface module.


Fig. 6.23 - C5G-PFPC: overall view

A: C5G-PFPC

Tab. 6.22 - C5G-PFPC: technical features

Item Description


A


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Options

6.3.22 C5G-RSK100: 100-mm rising socket kit

FunctionThe option C5G-RSK100 (Rising Socket Kit 100) makes available an additional 100-mm base to support and lift the cabinet.

Technical features and structureThe rising socket supports and lifts the cabinet from the floor by additional 100 mm compared to the standard solution. Moreover serves as a three-side cover (front and sides) preventing the dirt from reaching the area under cabinet. It is supplied with a support that allows to keep the cables, that are connected by the cabinet base, 20-30 mm above the floor.

Fig. 6.24 - C5G-RSK100: overall view

A: C5G-RSK100

Tab. 6.23 - C5G-RSK100: technical features

Item Description

Codice Comau – CR17330880

Mechanical features – It increases the cabinet base height by 100-mm compared to the standard version

Size and weight – The same cabinet base size. Height is equal to 100 mm (3.94 in)– 12 kg (26.45 lb)

Installation position – Only by the base cabinet, positioned between the sockets/feet of the standard version.

Usage restrictions – Only 1 option allowed– It is compatible with the weight increase and barycentre change

caused by the Application Box installation– Check the installation restrictions with the option C5G-WHK: wheel

kit (see par. 6.3.50 on page 213).

A


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Options

6.3.23 C5G-SMK: Signal Machine Kit

FunctionThe C5G-SMK (Signal Machine Kit) option makes available two 24 Vdc alarm inputs, 4 24Vdc inputs and 4 24Vdc outputs by the Robot border area, to be used for minor applications by the user.

Technical features and structureThe two 24 Vdc alarm inputs are “Robot Allarm” (flange alarm) e Air Input (air fault). The signals are of the type normally closed (NC). If they are not used they shall be jumpered.The 4 24 Vdc inputs and 4 24 Vdc outputs are taken directly from the Safety Distribution Module (SDM), from the X311 and X310 connector respectively.The 10 I/O signal obtained that way travel from the X10 connector (Robot signals) by the box base to the Robot base (connector X1), from which they set out again to be available on specific connectors installed nearby the Robot axis 3.

The kit is to be installed inside the C5G performing the appropriate connections among the X2 connector of the third AMS-IAM module, the X311 and X310 connectors of the Safety Distribution Module (SDM) and the X10 connector (Robot signals).

The Robot already features the connections between the X1 connector by Robot base and the wrist (or axis 3, depending on the version). The Robot is not supplied with movable connector, that shall be purchased separately.

*¹ not available for series NJ4

Tab. 6.24 - Signal travelling path from C5G to Robot

C5G Robot Border Area

Signal Involved modules

By box baseBy robot

baseSiX / NS NM NJ *¹

Robot Alarm X2/IAM3

X10/CIP X1

X92

X92 X70Air input X2/IAM3 X91

4 Input X311/SDM X91/X92

4 Output X310/SDM X91

The pin structure and recommended connection diagram are to be found in the Robot manual “Technical specification”.

The description, pin structure and purchase code of the movable connector to be used for the connections by the robot border area are to be found in the Robot manual “Technical specification”.

Tab. 6.25 - C5G-SMK: technical features

Item Description



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Options

Alarm signal electric features (Robot Allarm, Air Input)

– 2 inputs – Voltage: 24 Vdc (from 15 to 30 Vdc max)

(“1 logic” > 15 Vdc, “0 logic” < 5 Vdc)– Typical current: 10 mA– Connection with clear contact and/or digital signal– Note: as it deals with inputs for faults, they shall be connected as

normally closed (NC). If not in use they are to be jumpered; if they are left open the associated alarm activates.

Input / Output signals electric features

– 4 inputs / 4 outputs– Voltage: 24 Vdc – Further details in par. 5.9.3 I/O electric features and pin structure of

the connectors on the Safety Distribution Module (SDM) on page 117

Installation position – By Robot border area

Usage restrictions – Only one option allowed.– This option cannot be installed together with the options

C5G-TDC400: 400V Tip Dresser Command kit (see par. 6.3.24 on page 191), C5G-TDC400-2: 400V Double Tip Dresser Command kit (see par. 6.3.25 on page 192) o C5G-TDS400: 400V Tip Dresser Supply kit (see par. 6.3.26 on page 193).

– A movable connector is required for the connection by the robot border area (refer to Robot manual “Technical specifications”).

Tab. 6.25 - C5G-SMK: technical features (Continued)

Item Description


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Options

Usage modalitiesThe alarm signals (Robot Allarm, Air Input) are already configured int eh system. If not in use they are to be jumpered; if they are left open the associated alarm activates.The 4 input signals and the 4 output ones of the SDM module shall be onfigured (refer to par. 5.9.5 Configuration of the I/O on the Safety Distribution Module (SDM) on page 120).

The I/O taken by the option and the ones still available for the user are specified in par. 5.9.6 Usage restrictions for the I/O on the Safety Distribution Module (SDM) on page 120. Also, refer to the option wiring diagram.

Usage modalities in the Robot manual “Transport and installation”.


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Options

6.3.24 C5G-TDC400: 400V Tip Dresser Command kit

FunctionThe C5G-TDC400 (Tip Dresser Command 400) option makes available a control system for an electrode dresser for spot welding applications, that is powered at the mains voltage.

Technical features and structureThi kit uses two digital inputs and one digital output of the Safety Distribution Module (SDM), to monitor the overload cutout and electromagnetic switch status and to control the electromagnetic switch respectively.

The kit consists of:

– an overload cutout and an electromagnetic switch installed on a C5G-OPK: Option Panel kit

– connection cables to take power down the main switch only and connection with SDM module

– a M25 cable gland to allow the cables intended for the motor to cross the CIP panel.

The C5G-TDC400 powering is taken down the Control Unit main switch. The motor connection is carried out directly on the electromagnetic switch output terminals.

Fig. 6.25 - C5G-TDC400: overall view

Usage modalitiesThe C5G-TDC400 option shall be supplemented by means of a suitable controlling software. The inputs and outputs associated to the option shall be suitably configured.

The motor powering cutoff is carried out through the power electromagnetic switch, following the opening of the Control Unit safety circuits (emergency, gates). The control circuit category is comparable to category b (according to norm EN ISO 13849-1), which can be improved by suitably managing the electromagnetic switch feedback signal. The integrator shall guarantee the appropriate integration and the assessment of the control circuit reliability degree.

A: C5G-TDC400

A


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Options


6.3.25 C5G-TDC400-2: 400V Double Tip Dresser Command kit

FunctionThe C5G-TDC400-2 (Tip Dresser Command 400-2) option makes available a control system for two electrode dressers for spot welding applications, that is powered at the mains voltage.

Technical features and structureThe kit uses two digital inputs and two digital outputs of the Safety Distribution Module (SDM), to monitor the overload cutouts and electromagnetic switches status and to control the electromagnetic switches respectively.

The kit consists:

– two overload cutouts and two electromagnetic switch installed on a C5G-OPK: Option Panel kit


– two M25 cable glands to allow the cables intended for the motor to cross the CIP panel.due passacavi .

The C5G-TDC400-2 powering is taken down the Control Unit main switch. The motors connection is carried out directly on the output terminals of the corresponding electromagnetic switch.

Set the current value in the overload cutout such as to guarantee the compliance with the current taken by the motor.

Further details about the configuration of the I/O on SDM module are to be found in par. 5.9.5 Configuration of the I/O on the Safety Distribution Module (SDM) on page 120.

The usage modalities and the wiring diagram are to be found in the manuals about:– the Spot welding application Low frequency, or– the Spot welding application Medium frequency.

The motors powering cutoff is carried out through the power electromagnetic switches, following the opening of the Control Unit safety circuits (emergency, gates). The control circuit category is comparable to category b (according to norm EN ISO 13849-1), which can be improved by suitably managing the electromagnetic switches feedback signal. The integrator shall guarantee the appropriate integration and the assessment of the control circuit reliability degree.


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Options

Fig. 6.26 - C5G-TDC400-2: overall view

Usage modalitiesThe C5G-TDC400 option shall be supplemented by means of a suitable controlling software. The inputs and outputs associated to the option shall be suitably configured.


6.3.26 C5G-TDS400: 400V Tip Dresser Supply kit

FunctionThe C5G-TDS400 (Tip Dresser Supply 400) option makes available the power supply at mains voltage for an electrode dresser for spot welding applications.

Technical features and structureThe kit uses one digital input of the Safety Distribution Module (SDM) to monitor the overload cutout status.

The kit consists of:

– an overload cutout installed on a C5G-OPK: Option Panel kit

A: C5G-TDC400-2

Set the current value in the overload cutout such as to guarantee the compliance with the current taken by the motors and run the PDL2 programme to guarantee the protection efficiency (e.g. preventing the output contemporaneous activation).


The usage modalities and the wiring diagram are to be found in the manuals about:– the Spot welding application Low frequency, or– the Spot welding application Medium frequency.

A


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Options


– a M25 cable gland to allow the cables intended for the motor to cross the CIP panel .

The C5G-TDS400 powering is taken down the Control Unit main switch. The motor connection is carried out directly on the overload cutout output terminals.

Fig. 6.27 - C5G-TDS400: overall view

Modalità d’usoThe C5G-TDS400 option shall be supplemented by means of a suitable controlling software. The input associated to the option shall be suitably configured.

The I/O taken by the option and the ones still available for the user are specified in par. 5.9.6 Usage restrictions for the I/O on the Safety Distribution Module (SDM) on page 120. Consultare inoltre lo schema elettrico dell’opzione.

The devices connected done the C5G-TDS400 option are powered even by open safety circuits (emergency, gates). Alternatively, use the C5G-TDC400: 400V Tip Dresser Command kit (see par. 6.3.24 on page 191) or the C5G-TDC400-2: 400V Double Tip Dresser Command kit (see par. 6.3.25 on page 192) that allow the load cutoff also in case of emergency stop.

A: C5G-TDS400

Set the current value in the overload cutout such as to guarantee the compliance with the current taken by the motor.


The usage modalities and the wiring diagram are to be found in the manuals about:– the Spot welding application Low frequency, or– the Spot welding application Medium frequency .

A


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Options

6.3.27 C5G-UCK: user connector kit, for SDM module

FunctionThe C5G-UCK (User Connector Kit) makes available 3 movable connectors allowing the wiring of the Digital Inputs / Output on the SDM module (see par. 5.9 on page 116).


Fig. 6.28 - C5G-UCK: overall view

Usage modalities

A: C5G-UCK

Tab. 6.26 - C5G-UCK: technical features

Item Description


Electrical features – plug connectors X106/SDM, X310/SDM, X311/SDM and X312/SDM for wires up to 1,5 mm², including identification labels


Installation position – On SDM module only


For further details and the usage modalities, refer to par. 5.9 Digital Inputs / Output on the SDM module on page 116.

A


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Options

6.3.28 C5G-USBK: USB kit

FunctionThe C5G-USBK (USB Kit) option makes available a USB type-A connector on the Operator Panel Devices (OPD) panel, allowing a convenient connection to compatible storage peripherals.


Fig. 6.29 - C5G-USBK: overall view

A: C5G-USBK (typical position)

B: C5G-USBK (position for second option installed)

Tab. 6.27 - C5G-USBK: technical features

Item Description


Electrical features – USB port type A– Protection category IP65 (with cap in closed position)– Remote connection of the USB port/s, directly connected to the

AMS-APC820 module USB ports (see Tab. 6.28)


Installation position – On the Operator Panel Devices (OPD) panel only

Usage restrictions – Only 2 options allowed contemporaneously– If the C5G-ETHK: Ethernet kit option is installed, only one option is

allowed.

Tab. 6.28 - C5G-USBK: installation position and USB port taken

Installed options Position (Fig. 6.29) Port on AMS-APC820 module

C5G-USBK(only one option installed)

A XD2:

C5G-USBK + C5G-USBK(two options installed)

A and B XD2: and XD3:

A B

USB


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COMAU Robotics servicesRepair: [email protected]: [email protected] parts: [email protected] service: [email protected]

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