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Robot Racer 999

Plus
Rel. 2.0

Technical Specifications

Description, available versions and technical


features of the Robot
Operating areas and Robot overall dimensions
Features of the Robot wrist
Robot integration principles and description of the
available options

CR00758095-en_00/2015.10
The information contained in this handbook 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 reserves the right to modify, without notice, the features of the product presented in this handbook.

Copyright 2008-2015 by COMAU - Published on 10/2015


Comau Robotics Product Instruction

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8


Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Fundamental Requirements Applied and Respected . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. ROBOT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17


Robot general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Robot axes identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Declaration of incorporation of partly completed machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Name and address of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. AVAILABLE VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . ...20


Available versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. OPERATING AREAS AND ROBOT OVERALL DIMENSIONS . . . . . . . . . . . . . . . . ...22


Racer 999 Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5. ROBOT WRIST FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25


Robot wrist flange diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Loads on wrist and additional loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Barycentre position and couplings for additional loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Determination of the max loads to the wrist flange (QF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Additional loads (QS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Comau Robotics Product Instruction

SUMMARY

6. FURTHER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..35


Description of the Robot mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Calibration principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7. COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION . . . . . . . . . . . ..37


Management and inspection through Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connections Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connections on Robot base (distribution panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connections for Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Solutions for Automations on Robot Series Racer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Solution with Digital Inputs / Outputs Deriving from SDM Module . . . . . . . . . . . . . . . . . . . . . 44
X70 connector pin-out on axis 3 Robot Racer Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
AIR fitting characteristics on axis 3 Robot Racer Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Kit I/O for Robot Racer Plus (CR18703160) (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
I/O Principle Electrical Diagram on SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Solutions with Inputs / Outputs through Fieldbus on X20 Interface modules . . . . . . . . . . . . . 54
Solutions with the Fieldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Multibus cable adapter (CR18223760). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Multibus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8. ROBOT INTEGRATION PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..60


Available solutions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Leveling Plate Unit for Robot Fixing (CR82222600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Bench for Robot Fixing (CR822218xx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Screws and Pins Kit for Robot Fixing (CR82226800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Solutions to integrate the Robot in production cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Axis 1 Adjustable Mechanical Limit Switch Unit (CR82226900) . . . . . . . . . . . . . . . . . . . . . . 75
Axis 2 Adjustable Mechanical Limit Switch Unit (CR82227000) . . . . . . . . . . . . . . . . . . . . . . 77
Axis 3 Adjustable Mechanical Limit Switch Unit (CR82227100) . . . . . . . . . . . . . . . . . . . . . . 80
Modes and stopping distance of the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stopping Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stopping time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stopping distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9. DEVICES FOR CALIBRATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . ..84


Options for calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Calibration Tool (82314100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Calibration Kit for Axis 5 and Axis 6 (CR82227200). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Calibrated Tool Unit - Tool Master L=117 mm (81783801) . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Options for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
C5G-SBR: Robot Axis Brake Releasing Module (CR17133882) . . . . . . . . . . . . . . . . . . . . . . 91

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Comau Robotics Product Instruction

SUMMARY

10. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...92


Options installation information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Options wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Available options for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

11. FURTHER INFORMATION ABOUT THE COMPONENTS . . . . . . . . . . . . . . . . . . . . ...94

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Comau Robotics Product Instruction

PREFACE

PREFACE
This chapter contains:
Reference documents
Documents storage
Limits on the handbook contents
Symbols used in the handbook.

Reference documents
This document refers to the Robots with standards outfitting listed below:
Racer 999 Plus Rel. 2.0

The structure of the complete set of handbooks describing the Robot and Control Unit
is detailed in the following table:

Manufacturer Robot Set of Handbooks


Technical Specifications
Robot Racer 999 Plus Transport and installation
Comau
Rel. 2.0 Maintenance
Wiring diagram

These handbooks must be integrated with the following documents:

Manufacturer Description Set of Handbooks


C5G Control Unit / C5Compact Technical Specifications
Transport and installation
Comau Maintenance
Use of the Control Unit
Wiring diagram
Programming PDL2 Programming
Language Manual
Comau
Motion Programming
VP2 Visual PDL2

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Comau Robotics Product Instruction

PREFACE

Documents storage
All the provided documents must be placed in close proximity to the area where is
installed the robotic system, maintained available for all people that work on it, and
preserved intact for the entire operational life of the robotic system.

Limits on the handbook contents


The figures included in the handbook have the purpose to represent the product
and can differ from what is actually visible on the robotic system.

Symbols used in the handbook


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

The symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed could cause injuries to the personnel.

The symbol indicates operating procedures, technical information and precautions, that
if are not observed and/or correctly performed may cause damages to the equipment.

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

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

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

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

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

This chapter deals with the following topics:


Responsibilities
Safety requirements.

1.1 Responsibilities

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

COMAU Robotics denies any responsibility for accidents caused by incorrect or


improper use of the Robotic system (Robot and Control Unit), 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 Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).

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

1.1.1 Safety Fundamental Requirements Applied and


Respected
The Robotic system composed by Control Unit and SMART 5 Robot series considers
as applied and respected the following Safety Fundamental Requirements, Annex I of
Machinery Directive 2006/42/CE: 1.1.3 1.1.5 1.2.1 1.2.2 1.2.3 1.2.4.3 1.2.5
1.2.6 1.3.2 1.3.4 1.3.8.1 1.5.1 1.5.2 1.5.4 1.5.6 1.5.8 1.5.9 1.5.10
1.5.11 1.5.13 1.6.3 1.6.4 1.6.5 1.7.1 1.7.1.1 1.7.2 1.7.4.

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1.2 Safety requirements

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

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

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

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

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

Installation and Startup


The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
Robot axes, in compliance with the safety requirements of the Country where the
System is installed.

Functioning in Programming Mode


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

Functioning in Auto / Remote Mode


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

Maintenance and Repair


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

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

Decommissioning and Dismantling


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

Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.

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

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

1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
Installation and Startup
Functioning in Programming Mode
Functioning in Auto / Remote Mode
Robot axes brake release
Maintenance and Repair
Decommissioning and Dismantling.

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1.2.4 Operating modes


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

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

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 may cause permanent damage to the
Control Unit components.
The Control Unit manages internally the main safety interlocks (gates, enabling
push-buttons, etc.). Connect the Control Unit safety interlocks to the line safety
circuits, taking care to connect them as required by the Safety Standards. The
safety of the interlock signals coming from the transfer line (emergency stop, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.

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

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


incomplete or missing execution.
The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic mode; in Programming mode the power is disabled
immediately. The procedure for the selection of the controlled stop time (that can
be set on SDM module) is indicated in the Transport and Installation Handbook of
the Control Unit.
When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.

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 module.

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

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

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

Functioning in Programming Mode


The programming of the Robot is exclusively the task of the authorized personnel.
Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
The programming should be controlled from outside the protected area whenever
possible.
Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Area.
If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
Activation of the motors (DRIVE ON) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on a inclined plane).
Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at low speed has been carried out. The
test must be controlled from a safe distance.
Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
Robot movement depends on the operator.
During the first running of a new program, the Robot may move along a path that
is not the one expected.
The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the Robot position
out of the path that links two steps of the program), could give rise to movements
not envisaged by the operator when testing the program.

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

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

Functioning in Auto / Remote Mode


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

Robot axes brake release


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

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

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

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

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

Maintenance and Repair


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

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.

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


possible, outside the protected area.
Trouble-shooting executed on the control is to be carried out, whenever possible
without power supply.
Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards must be observed
when operating in presence of dangerous voltages.
Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

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


check of the correct functioning of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics is to be used. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
Disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in any direction: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
It is strictly forbidden to remove the protective covering of the Robot springs.

Decommissioning and Dismantling


The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
Before decommissioning initiation, the mains voltage at the Control Unit inlet must
be powered off (switch off the circuit breaker on the power mains and lock it in open
position).
After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the power mains,
first disconnecting the power conductors, then the earth one. Disconnect the power
supply cable from the Control Unit and remove it.
First disconnect the connection cables between the Robot and the Control Unit,
then the ground cable.
If present, disconnect the Robot pneumatic system from the air distribution mains.
Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU 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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Comau Robotics Product Instruction

ROBOT DESCRIPTION

2. ROBOT DESCRIPTION
This chapter contains:
Robot general description
Robot axes identification
Declaration of incorporation of partly completed machinery
Name and address of the manufacturer.

2.1 Robot general description


The Robot is a machine specifically designed and constructed to be used in industrial
environments.
For the proper functioning, the Robot must be matched with the specific Control Unit.
The Control Unit features must be consistent with the connected Robot.
The Robot Racer 999 Plus is particularly suitable for application of
Assemblies
Handling
Machine tending
Packaging
Arc welding
To the Robot standard mechanics it is also combined a specific fitting + wiring unit,
depending on the Robot application.

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Comau Robotics Product Instruction

ROBOT DESCRIPTION

2.2 Robot axes identification


Hereinafter are identified the Robot axes:

Ax Robot axis
Mtr Motor axis

2.3 Declaration of incorporation of partly completed


machinery
The assembly composed of the SMART5 Robot series and by the Control Unit is
provided with a declaration of incorporation of partly completed machine, as stated
in the Annex II b. of the 2006/42/CE Directive.

It is forbidden to put into service of the assembly composed of the SMART5 Robot series
and the Control Unit before the machinery in which it is to be installed is declared to be
in compliance with the provisions of Directive 2006/42/EC.

The Declaration of incorporation of partly completed machine is provided in the


original with the assembly composed of the SMART5 Robot series and the Control Unit.
The identification plate (Fig. 2.1) is installed on the Robot body.

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Comau Robotics Product Instruction

ROBOT DESCRIPTION

Fig. 2.1 - Robot identification plate (example)

A xxxx REL. xxx

B CRxxxxxxxx

D xx lb / xx kg

A: Machine name and release


B: Product Part No.
C: The date of issue and the serial number
D: Weight

2.4 Name and address of the manufacturer


As defined by the Machinery Directive, the manufacturer is:

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

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Comau Robotics Product Instruction

AVAILABLE VERSIONS AND TECHNICAL FEATURES

3. AVAILABLE VERSIONS AND TECHNICAL


FEATURES
This chapter contains:
Available versions
Technical features.

3.1 Available versions


The versions of the available Robots are listed in the following Tab. 3.1 - Available
Versions Robot RACER 999 on pag. 20.

Tab. 3.1 - Available Versions Robot RACER 999

Wrist load Reach Assembling Part No.


Robot type Application type
(kg) (lb) (mm) (ft) position Robot
- Assemblies
- Handling
Racer 999 7 999 Floor / Ceiling
CR82388100 - Machine tending
Rel. 2.0 (15.43) (3.27) / Wall
- Packaging

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Comau Robotics Product Instruction

AVAILABLE VERSIONS AND TECHNICAL FEATURES

3.2 Technical features

Tab. 3.2 - Technical features Robot RACER 999 Plus

VERSION Racer 999 Plus


Structure / n axes Anthropomorphic / 6 axes
Wrist load 7 kg (15.43 lb) *
Nominal load at wrist 5 kg (11 lb) *
Additional maximum load 10 kg (22.04 lb) *
Axis 4 torque 13 Nm
Axis 5 torque 13 Nm
Axis 6 torque 7.5 Nm
Admissible inertia on axis 4 0,6 kg x m
Admissible inertia on axis 5 0,6 kg x m
Admissible inertia on axis 6 0,3 kg x m
Axis 1 +/- 165 (250/s)
Axis 2 - 65 / +150 (250 /s)
Axis 3 0 / -168 (300 /s)
Stroke /(Speed)
Axis 4 +/- 210 (600 /s)
Axis 5 +/- 135 (600 /s)
Axis 6 +/- 2700 (650 /s)
Max horizontal reach 999 mm (3.27 ft)
Repeatability +/- 0.05 mm
Robot weight 173 kg (382 lb)
Robot wrist features tools clamping ISO 9409 - 1 - A 40
Motors AC Brushless
Position measurement system Encoder
Protection degree IP65
Assembly position Floor / Ceiling / Wall
Operating environment temperature 0C to +45C
Storage temperature -25C to + 55C
Relative humidity 5% to 95% without condensation
Maximum temperature gradient 1,5 C/min
Pairing with Control Unit C5G ACC1 or C5Compact (see par. 7.1)

Notes:
*: See the par. 5.2.3 Determination of the max loads to the wrist flange (QF) on pag. 29 and the par. 5.2.4
Additional loads (QS) on pag. 32.
*: Other colours are available on request. The images contained in this handbook, are referred to standard
colours.

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Comau Robotics Product Instruction

OPERATING AREAS AND ROBOT OVERALL DIMENSIONS

4. OPERATING AREAS AND ROBOT OVERALL


DIMENSIONS
This chapter contains the operating areas drawings of the Robot available versions:
Racer 999 Plus

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Comau Robotics Product Instruction

OPERATING AREAS AND ROBOT OVERALL DIMENSIONS

Racer 999 Plus

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Comau Robotics Product Instruction

OPERATING AREAS AND ROBOT OVERALL DIMENSIONS

24
Comau Robotics Product Instruction

ROBOT WRIST FEATURES

5. ROBOT WRIST FEATURES


This chapter contains:
Robot wrist flange diagrams
Loads on wrist and additional loads

5.1 Robot wrist flange diagrams


This paragraph deals with technical drawings of the Robot wrist and with dimensions
and distance between hole centers used to attach the equipment.
In the drawing it is also given the calibrated tool used to calculate with high precision the
reference in the middle of the flange in case of equipment installation.

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Fig. 5.1 - Tool coupling flange ISO 9409 - 1 - A 40 (front view)

Dimensions in millimetres

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Fig. 5.2 - Clamping tool flange ISO 9409 - 1 - A 40 (side view)

Dimensions in millimetres

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

5.2 Loads on wrist and additional loads


This paragraph describes the procedures to define the maximum applicable load on the
Robot flange and the additional load applicable on the forearm. In detail:
Abbreviations
Barycentre position and couplings for additional loads
Determination of the max loads to the wrist flange (QF)
Additional loads (QS)

5.2.1 Abbreviations
The following abbreviations have been used throughout the chapter:
QF = Max load applied to the flange
QS = Additional load applied to the forearm
QT = Max. total load applicable on the Robot
LZ = Distance barycentre load P from the tool coupling flange
LXY = Distance barycentre load P from axis 6
M = Mass

5.2.2 Barycentre position and couplings for additional loads


The area in which it is admitted the barycentre position related to the additional load is
listed in Fig. 5.5 - Position of the additional loads barycentre on pag. 33.
Holes centres distances and sizes for coupling additional loads applied on the Robot
forearm are listed in the drawings in Fig. 5.6 - Tools fixing on pag. 34.

Fig. 5.3 - Barycentre coordinates of the load applied to the flange

Ly
Robot
Racer 999 Plus Lx Lxy

P Lz

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

5.2.3 Determination of the max loads to the wrist flange (QF)


The max load applicable to the flange is defined using the load graphs of load at wrist
where the maximum loading curves QF are traced depending on the coordinates LZ and
LY of the load barycentre.
The area defined by the loading curves defines the barycentre distances admitted for
load application specified on the area itself.
In the following Fig. 5.4 is shown the diagram of Maximum load capacity to the Robot
flange Racer 999 Plus.

The inertia specified in the graph curves refers to the centre of gravity of the load applied
on the flange.
When applying loads different from the values specified in the graphs, check the use
restrictions by means of the SMART Payload software function.

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Fig. 5.4 - Maximum load capacity to the Robot flange Racer 999 Plus

Load curves to the wrist with Standard positioning (horizontal axis 6)

D
E

(O)

A: M = 3 kg
B: M = 4 kg
C: M = 5 kg
D: M = 6 kg
E: M = 7 kg
(O)

M: weight

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Load curves to the wrist with Standard positioning vertical axis 6

(O)

E
D

C
B

A: M = 4 kg
B: M = 5 kg
C: M = 6 kg
D: M = 8 kg
E: M = 10 kg
(O)

M: weight

(O): Reference point for calculation load at wrist.

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

5.2.4 Additional loads (QS)


In addition to the load on the wrist QF, on the Robot forearm it can be applied an
additional load QS.
The maximum loads applicable are those listed in Tab. 5.1 - Maximum applicable loads
on pag. 32.
In each application the following conditions must be respected:
The barycentre of the load applied on the flange QF must be included in the area
defined by the curves of the specific graphics for each Robot, ad described in
paragraph Determination of the max loads to the wrist flange (QF) (see par. 5.2.3
on pag. 29)
The barycentre of the additional load QS must be included in the area of the graphic
specific for each Robot (see Fig. 5.5 - Position of the additional loads barycentre
on pag. 33)
To install special tooling on the Robot it is possible to use drillings on the Robot forearm
and measured in the specific drawings related to each Robot version (see Fig. 5.6
- Tools fixing on pag. 34.

Tab. 5.1 - Maximum applicable loads

QF QS QT
Robot type Max load applicable on Max additional load Total max applicable load
the flange applicable on the forearm on the Robot
5 > 7 kg (> 15.43 lb) 8 kg (17.64 lb)
Racer 999 Plus 15 kg (33 lb)
0 5 kg (11.02 lb)* 10 kg (22.05 lb)

*: Nominal load

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Fig. 5.5 - Position of the additional loads barycentre

Qs

Qf

Dimensions in millimetres

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Comau Robotics Product Instruction

ROBOT WRIST FEATURES

Fig. 5.6 - Tools fixing

Dimensions in millimeters

34
Comau Robotics Product Instruction

FURTHER INFORMATION

6. FURTHER INFORMATION
This chapter contains:
Description of the Robot mechanics
Calibration principles.

6.1 Description of the Robot mechanics

Degrees of freedom
The Robot is an anthropomorphic type with 6 degrees of freedom.

Robot configuration

A- Base
B- Column
C- Arm
D- Wrist
E- Flange

The fixed Robot base is anchored to a supporting structure (fixing plate or supporting
structure).
On the fixed Robot base, a column rotates with vertical rotating axis (axis 1); the column
supports the axis 2 motorizations.
One arm connects axis 2 to the wrist and includes the gear motors of the axes 3 and 4.
At the front end of the wrist there is the flange tool connection.
Inside the wrist are integrated gear motors for the axes 5 and 6.

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Comau Robotics Product Instruction

FURTHER INFORMATION

Robot axes motors


The Robot has got 6 axes, each one is controlled by a motor gear (detail on par. 2.2
Robot Axes Identification on pag. 14).
The motors are of AC type brushless and integrate inside them the brake and the
encoder.
The gearboxes are of the type with reduced clearance specific for robotic applications.

Robot Axes Stroke Restriction (Areas Restrictions)


Robot axes are provided with software limit switches (programmable).
In addition (optional) Robots can be provided with mechanical limit switches.

For all details on options useful for safety areas sectoring, see the par. 8.3 Solutions to
integrate the Robot in production cells on pag. 74.

6.2 Calibration principles


There are two calibration modes:
precision calibration: is carried out by means of use a specific tool that is the same
for all the axes and all models, it must be carried out after special maintenance
activity causing the decomposition of the kinematic chain between motor and
Robot axis or in case operation cycle requiring high precision are needed.
the calibration on reference notches: allows a quick calibration but improper and
scarce in precision that can not recover the Robot motion precision required in the
specific application. Calibration by means of reference notches consists in
positioning the Robot axes on the calibration notches aligning them precisely
without using any special tools and carry out the calibration of one axis at a time.

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

7. COUPLING WITH CONTROL UNIT AND


USER'S CUSTOMIZATION
This chapter contains:
Management and inspection through Control Unit
Connections Overview
Connections on Robot base (distribution panel)
Connections for Applications

7.1 Management and inspection through Control Unit


The Robot is inspected by the COMAU Control Unit and is not allowed another
combination.
The Robot is combined to a specific size of the Control Unit (see purchase part number
on the Control Unit "Technical Specifications" Manual).
The electrical connection between Robot and Control Unit is possible thanks specific
kits of connection cables.
In addition suitable options on Control Unit can solve integration requirements.
For this Robot version, is possible the combination with the following Control Unit:
C5Compact Control Unit
C5G Control Unit

Robot Racer Plus in configuration with C5Compact Control Unit

A Robot
B C5Compact Control
Unit
C Connection cables kit

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

Robot Racer Plus in configuration with C5G Control Unit

A Robot
B C5G Control Unit
C Connection cables kit

The Control Unit (B) and the connection cables (C) are described in the respective
instruction handbooks Technical Specifications of the Control Unit C5Compact e C5G.

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

7.2 Connections Overview


Integrator must connect the Robot to the Control Unit through specific cables (see
par. 7.1).
In addition he arranges on the Robot the settings to optimize the Robot integration in the
production process (air connection, electrical connection).

A Connections on Robot base


(distribution panel)
B Connections for Applications

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

7.3 Connections on Robot base (distribution panel)


In the following figure are shown all the connections available on the Robot base plate
(distribution panel)

Ref. Function Description


The Encoder signals connector X1 is directly connected on
the Control Unit through a specific cable.

X1 Encoder signals connector For further information on Encoder / Signals:


Control Unit: see the Control Unit Technical
Specifications" instructions handbook.

The motors signals connector X2 is directly connected on


the Control Unit through a specific cable.
Motor and Brake signals
X2 For further information on motor/brakes signals:
connector
Control Unit: see the Control Unit Technical
Specifications" instructions handbook.

Connection screw GND trough connection screw GND on


Control Unit with conductor.

Conductor connection of the For further information on the connection to the equalizer
GND
equalizer circuit circuit:
Control Unit: see the Control Unit Technical
Specifications" instructions handbook.

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

Ref. Function Description


Female screw thread fitting 1/4 The inner tube ends
without interruption on the plate Robot axis 3.

AIR AIR fitting for air input Depending on the function see:
Handling: see the par. 7.5 Solutions for Automations
on Robot Series Racer on pag. 43

The X50 connector is connected to the X70 connector in


the axis 3 area through a cable inside the Robot that
connects all the pins.
Connector for I/O / Multibus Depending on the function see:
X50
signals cable Handling: see the par. 7.5 Solutions for Automations
on Robot Series Racer on pag. 43
Arc Welding: see the Technical Specifications
handbook of the Welding applications
The connector SBR is connected to the connector SBR on
brake releasing module with multi-pin cable.
Brake releasing module
SBR
connector
For further details on the connector refer to the par. 9.2.1
referring to the SBR Brake Releasing Module.

In addition see the Instructions handbook of the application installed on the Robot
(Handling / Arc welding).

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Comau Robotics Product Instruction

COUPLING WITH CONTROL UNIT AND USER'S CUSTOMIZATION

7.4 Connections for Applications


In the following figure are shown all the connections available on the Robot axis 3.

Ref. Function Description


The connector X70 is connected to connector X50 on
Robot base with specific cable.

Depending on the function see:


X70 Signals connector I/O / Multibus Handling: see the par. 7.5 Solutions for Automations
on Robot Series Racer on pag. 43
Arc Welding: see the Technical Specifications
handbook of the Welding applications
Female feed-through panel thread diameter 1/4 The pipe
starts from the Robot base and reaches without
interruptions to the plate of axis 3.
Feed-through panel for air
AIR
passage Depending on the function see:
Handling: see the par. 7.5 Solutions for Automations
on Robot Series Racer on pag. 43

In addition see the Instructions handbook of the application installed on the Robot
(Handling / Arc welding).

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

7.5 Solutions for Automations on Robot Series Racer


In this chapter are described the following topics:
Solution with Digital Inputs / Outputs Deriving from SDM Module
I/O Principle Electrical Diagram on SDM (C5Compact Control Unit)
Structure of I/O Solution on SDM
I/O Principle Electrical Diagram on SDM (C5G Control Unit)
Structure of I/O Solution on SDM
X70 connector pin-out on axis 3 Robot Racer Plus
AIR fitting characteristics on axis 3 Robot Racer Plus
Kit I/O for Robot Racer Plus (CR18703160) (optional)
I/O Principle Electrical Diagram on SDM
Solutions with Inputs / Outputs through Fieldbus on X20 Interface modules
Solutions with the Fieldbus
Fieldbus principle diagram (C5G Control Unit)
Fieldbus principle diagram (C5Compact Control Unit)
Structure of the Solution with I/O signals through Fieldbus
Multibus cable adapter (CR18223760)
Multibus cable adapter principle diagram
Multibus cable
Multibus cable principle diagram

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

7.5.1 Solution with Digital Inputs / Outputs Deriving from SDM


Module
Below is shown the principle diagram of connection between Robot and Control Unit.

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

Fig. 7.1 - I/O Principle Electrical Diagram on SDM (C5Compact Control


Unit)

X310

X126

X311

C5G-SMKC*

C5G-SDM

X2B/CAB

X2
AIR X70

Service cable**

AMS-IAM

AIR INPUT

AIR
X50***

* Control Unit optional components (depending on the protocol)


** I/O signal cable and field bus for connection between C5Compact Control Unit and
Robot
*** Multibus cable adapter (optional, CR18223760)

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

Tab. 7.1 - Structure of I/O Solution on SDM

Item
Description For details see
Fig. 7.1
Optional components needed on the Control Unit
C5G-SMKC Signal Machine Kit Compact (CR17130282) Cap.11. on pag. 94
Standard components
AMS-IAM Axes control module Cap.11. on pag. 94
C5G-SDM Safety Distribution Module (SDM) Cap.11. on pag. 94
C5Compact Control
Connection cable between the C5Compact Control Unit and Unit Technical
Facility cable
Robot (CR1724446x) Specifications
Manual
X70 I/O signals connector and field bus installed on distribution panel par. 7.5.1.1
AIR Compressed air outlet installed on distribution panel par. 7.5.1.2

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

Fig. 7.2 - I/O Principle Electrical Diagram on SDM (C5G Control Unit)

X310

X126

X311

C5G-SMK*
C5G-SDM

X90
X3A/CAB

X2
AIR X70
Service cable**

AMS-IAM
AIR INPUT

AIR

X50***

* Control Unit optional components (depending on the protocol)


** I/O signal cable and field bus for connection between C5Compact Control Unit and
Robot
*** Multibus cable adapter (optional, CR18223760)

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

Tab. 7.2 - Structure of I/O Solution on SDM

Item
Description For details see
Fig. 7.2
Optional components needed on the Control Unit
C5G-SMK Signal Machine Kit (CR17130280) Cap.11. on pag. 94
Standard components
AMS-IAM Axes control module Cap.11. on pag. 94
C5G-SDM Safety Distribution Module (SDM) Cap.11. on pag. 94
C5G Control Unit
Connection cable between Control Unit C5G and Robot Technical
Facility cable
(CR1743328x) Specifications
Manual
C5G Control Unit
Technical
X90/CAB Cable gland connector on the cabinet base
Specifications
Manual
X70 I/O signals connector installed on a distribution panel par. 7.5.1.1
AIR Compressed air outlet installed on distribution panel par. 7.5.1.2

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Comau Robotics Product Instruction

SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

7.5.1.1 X70 connector pin-out on axis 3 Robot Racer Plus


Connector for:
I/O signals
Fieldbus signals
24 Vdc
female 19 crimping pin (on distribution panel axis 3)

Mating connectors to par. 7.5.1.3 Kit I/O for


Robot Racer Plus (CR18703160) (optional) on
pag. 51.
Front view - Female connector

Tab. 7.3 - X70 Connector Pin-Out Details

Pin Description Pin Description


1 +24Vdc SAFE 11 PFB B
2 0V (24Vdc) 12 0V (24Vdc)
3 TX- 13 available
4 TX+ 14 Ground
5 RX- 15 Not used
6 Not used 16 Not used
7 RX+ 17 Not used
8 CAN_H 18 Not used
9 CAN_L 19 Not used
10 PFB A

Tab. 7.4 - Example of movable connector suitable for X70


Connector for:
I/O signals
11
12
1 Fieldbus signals
10
17
18
13
2
24 Vdc
male 19 pins crimp mating
9 19 3
16 14
8 4
male contact HUMMEL 7.003.919.101
15

7 5
6

Front view - Male connector

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SOLUTIONS FOR AUTOMATIONS ON ROBOT SERIES RACER

7.5.1.2 AIR fitting characteristics on axis 3 Robot Racer Plus


Fitting to provide air to the devices installed on
machine
female threaded 1/4 GAS M22x1.5
entire tube Robot DN6
maximum pressure bore from the tube 2 MPa (20 Bar)

Fittings to be combined indicated at


par. 7.5.1.3 Kit I/O for Robot Racer Plus
(CR18703160) (optional) on pag. 51.

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7.5.1.3 Kit I/O for Robot Racer Plus (CR18703160) (optional)


The option consists of one multipolar connector to wire the related connector X70 (I/O
and field bus) located on Robot axis 3.
There is also a threaded adapter G 1/4 - M16x1.5 male / male and a hose pipe fitting
with nut M16x1.5, that can be used for the connection on fitting AIR present on the panel
axis 3.

The connectors pinout corresponds to the fixed connectors installed on the distribution
panel of Robot axis 3.

COMAU Part No.: CR18703160


X70 Connector
Connector for:
I/O signals
11
12
1 Fieldbus signals
10
17
18
13
2
24 Vdc
male 19 pins crimp mating
9 19 3
16 14
8 4
Male insert 19 pin HUMMEL 7.003.919.101
15

7 5
6

Front view - Male connector

AIR hose pipe fitting


Hose pipe fitting to supply air to the devices installed
on machine
For tube DN6
350-4B AEROQUIP

Straight pipe fitting


Fitting adapter Male-Male
1/4 Gas - M16x1.5
15-183-8-4B AEROQUIP

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7.5.1.4 I/O Principle Electrical Diagram on SDM


Fig. 7.3 - Wiring diagram on C5Compact Control Unit

C5Compact

IAM3 X2 X2B/CAB X50/DS X70


1 1 1 1

5 2 2 2

SDM
2
0V
1 +24 SAFE
+24int/ext
3 +24 I/O

8
0V

X311
1 3 3 3
INP 1
2 4 4 4
INP 2
3 5 5 5
INP 3
4 6 7 7
INP 4
5

X310
1

3 7 8 8
OUT 4
4 8 9 9
OUT 3
5 9 10 10
OUT 2
6 10 11 11
OUT 1
7

X2/CAB
1 24VR 6 6
+24int
6 0V 12 12
0V

15 15
HSI1+
+24V

HSI1-

0V
1

X136
2

IAM1 X2 X138
1 1 X50/DS X70
2 2

3 8
0V

+24/0.5A
4 3 X2C/CAB
5 4 9 HSI3+ 1 13 13

6 5 10 HSI3- 2 14 14

7 3
X138

8
HSM

X137
1

4
HSI3+
+24V

HSI3-

0V

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Fig. 7.4 - Wiring diagram on C5G Control Unit

C5G Robot
X50

Alarm
Input

Input

Output

*1
HSI3 *1

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7.5.2 Solutions with Inputs / Outputs through Fieldbus on X20


Interface modules
The following paragraphs represent the connection principle diagram between the
Robot and Control Unit that may vary depending on the protocol.

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7.5.2.1 Solutions with the Fieldbus

Fig. 7.5 - Fieldbus principle diagram (C5G Control Unit)

X124

C5G-PMI* X311

C5G-SDM

X93* or X94*

AIR X70
Multibus cable**

X20 Modules*

AIR
AIR INPUT

X50***

* Control Unit optional components (depending on the protocol)


** Optional Multibus cable
*** Multibus cable adapter (optional, CR18223760)

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Fig. 7.6 - Fieldbus principle diagram (C5Compact Control Unit)

X124

C5G-CPC* X311

C5G-SDM

X93*

AIR X70
Multibus cable**

X20 Modules*

AIR
AIR INPUT

X50***

* Control Unit optional components (depending on the protocol)


** Optional Multibus cable
*** Multibus cable adapter (optional, CR18223760)

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Tab. 7.5 - Structure of the Solution with I/O signals through Fieldbus

Item
Description For details see
Fig. 7.5, Fig. 7.6
Optional components needed on the C5G Control Unit
X20 Module Field bus module on interface X20 (depending on the protocol) Cap.11. on pag. 94
X93 or X94 Multibus connector on the cabinet base Cap.11. on pag. 94
Connection Multibus cable between the C5G Control Unit and
Multibus cable par. 7.5.4
Robot
Optional components needed on the C5Compact Control Unit
X20 Module Field bus module on interface X20 (depending on the protocol) Cap.11. on pag. 94
X93 Multibus connector on the cabinet base Cap.11. on pag. 94
Connection Multibus cable between the C5G Control Unit and
Multibus cable par. 7.5.4
Robot
Optional components needed on Robot
Adapter multibus
Multibus cable adapter par. 7.5.3
cable

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7.5.3 Multibus cable adapter (CR18223760)


The multibus adapter connects itself to Robot base on the connector X50 and makes
available in a single solution the I/O signals and fieldbus on the axis 3 distributor panel
on the connector X70.

Fig. 7.7 - Multibus cable adapter

X90 X50 /DS

Fig. 7.8 - Multibus cable adapter principle diagram

X90 X50 /DS

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7.5.4 Multibus cable


The multibus cable usually connects the Control Unit and Robot, transferring the
Fieldbus signals, 24 Vdc power supply and other process signals.
The cable on the side of Control Unit is provided with 17 multi-pin connector to be
connected to the CIP panel, to the X93 or X94 connector; the other outer end designed
on Robot base and is provided with 17 multi-pin X90 connector.

Tab. 7.6 - Multibus cable: available models

Description Comau Part No.


Multibus cable length 5 m (16.40 ft) 18567660
Multibus cable length 10 m (32.81 ft) 18567661
Multibus cable length 15 m (49.21 ft) 18567662
Multibus cable length 20 m (65.62 ft) 18567663
Multibus cable length 25 m (82.02 ft) 18567664
Multibus cable length 30 m (98.42 ft) 18567665
Multibus cable length 40 m (131.23 ft) CR18567666

Fig. 7.9 - Multibus cable principle diagram

KSR / HSI + *
KSR / HSI - *

TX-
TX+

RX-
RX+

* The conductor is defined HSI in case of HANDLING applications, and KSR in case of
SPOT WELDING application.

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8. ROBOT INTEGRATION PRINCIPLES


This chapter contains:
Available solutions for installation
Stresses on the supporting structure
Solutions to integrate the Robot in production cells
Modes and stopping distance of the Robot

8.1 Available solutions for installation

Because of the considerable stress discharged to the ground by the Robot, and the need
to have an appropriate supporting surface, direct fixing on the floor or ceiling is not
foreseen.

Depending on the application and operating requirements, the Robot can be installed on
the floor or on ceiling.
For all possible solutions, the Robot must always be installed on a supporting structure
interposed between the Robot base and the installation surface.

Available OPTIONS for installation


Robot type Installation type
Optional solutions Matched Robot fixing
(available alternatives) components
Leveling Plate Unit for Robot
Fixing (CR82222600) *
Bench for Robot Fixing Screws and Pins Kit for Robot
Ground
(CR822218xx) * Fixing (CR82226800)
Racer 999 Plus
Plate / Support made by the
integrator
Supporting structure made by the Screws and Pins Kit for Robot
Wall / Ceiling
integrator * Fixing (CR82226800)
* The units cannot be used simultaneously.
* It requires the support structure for installation (details on par. 5.1 Suggestions for
Robot Installations on ceiling / wall on pag. 32).

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8.1.1 Leveling Plate Unit for Robot Fixing (CR82222600)

Purpose
The level-adjustable plate option for Robot allows to fix properly the Robot on the floor.
The unit allows to meet the following requirements:
secure a good flatness of the resting surface, to avoid abnormal stresses on the
Robot base frame.
possibility for rigging Robot mounting to simplify the off-line programming
applications

Technical features and structure


The unit consists of:
four steel plates that are anchored to the floor by means of chemical sleeve
anchors (for a total of 8 sleeve anchors, not supplied).
a level-adjustable plate to be welded to the above mentioned ones, after reaching
the Robot optimum levelling position acting on the special levelling screws.

La Fig. 8.1 shows the optional fixing plate which can be provided by Comau.
Other solutions may be realized by the installer as long as the stresses produced by the
Robot and the resistance conditions of fixing surface are verified (see par. 8.2 Stresses
on the supporting structure on pag. 72)

To fix the Robot on the plate the Screws and Pins Kit for Robot Fixing
(CR82226800)option is available.

Restrictions
Use quantity 1 plate to fix of a Robot.

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To be used as an alternative to the Bench for Robot Fixing (CR822218xx) or the


supporting plate / frame provided by the integrator.

Fixing components
Completely threaded hex head screw M20x100 (8.8)
Hex nut M20-8 Fe/Zn
Chemical sleeve anchors (not provided)

Installation components
Self-leveling mortar

Weight
About 106 kg (233.68 lb)

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Fig. 8.1 - Diagram of Option Method Use

2
3

4
5

Dimensions in millimetres
1. Level-adjustable plate (q.ty = 1)
2. Plate (q.ty = 4)
3. Straight edge (q.ty = 8)
4. Hex head screw M20x100 (8.8) (q.ty = 4)
5. Hex nut M20-8 Fe/Zn (q.ty = 4)

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8.1.2 Bench for Robot Fixing (CR822218xx)

Purpose
The support helps to lift the Robot from floor level; the Robot is fixed on the upper base
of the support.
Different types of supports are available for Robots with different heights.

Tab. 8.1 - Option part no.

Description Comau Part No.


Supporting stand for Robot H=500 mm (1.64 ft) CR82221809
Supporting stand for Robot H=750 mm (2.46 ft) CR82221810
Supporting stand for Robot H=1000 mm (3.28 ft) CR82221811
Support for Robot H=1350 (4.26 ft) mm sloped 30 CR82221812

Technical features and structure


The assembly is made up of a steel structure with drillings for the chemical anchorages
specific for the fixing on the floor and with the Robot fixing drilling.

The following figures Fig. 8.2, Fig. 8.3, Fig. 8.4 and Fig. 8.5 show the optional fixing
benches that can be provided by Comau.
Other solutions may be realized by the installer as long as the stresses produced by the
Robot and the resistance conditions of fixing surface are verified (see par. 8.2 Stresses
on the supporting structure on pag. 72)

For fixing the Robot on the stand is available the option Screws and Pins Kit for Robot
Fixing (CR82226800).

Restrictions
Use quantity 1 stand for a Robot fixing.

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To be used as an alternative to the Leveling Plate Unit for Robot Fixing


(CR82222600) or the supporting plate / structure realized by the integrator.

Fixing components
Chemical sleeve anchors (not provided)

Installation components
Self-leveling mortar

Weight
Bench CR82221809: About 39 kg (85.98 lb)
Bench CR82221810: About 53 kg (116.84 lb)
Bench CR82221811: About 59 kg (130.07 lb)
Bench CR82221812: About 76 kg (167.55 lb)

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Fig. 8.2 - Method use diagram of the CR82221809 option

0.2

0.2

Dimensions in millimetres
1. Support (q.ty = 1)

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Fig. 8.3 - Method use diagram of the CR82221810 option

0.2

0.2

Dimensions in millimetres
1. Support (q.ty = 1)

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Fig. 8.4 - Method use diagram of the CR82221811 option

0.2

0.2

Dimensions in millimetres
1. Support (q.ty = 1)

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Fig. 8.5 - Method use diagram of the CR82221812 option

0.2

0.2

Dimensions in millimetres
1. Support (q.ty = 1)

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8.1.3 Screws and Pins Kit for Robot Fixing (CR82226800)

Purpose
The option for fixing screws and pins allows properly fix the Robot both on the floor or
ceiling.

Technical features and structure


The unit consists of the screws and pins needed to fix the Robot to a steel plate provided
with relevant holes.

Restrictions
Use quantity 1 unit to fix 1 Robot.

Fixing components
Socket hex head screw M16x50 (8.8) ISO 4762
Socket hex head screw M6x50 (8.8)
Socket hex head screw M6x60 (8.8)
Self locking washer 16x25.4x3.4

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Fig. 8.6 - Diagram of option method of use

3
5
6
2

3
6

4 3
1 6

Dimensions in millimetres
1. Centering device =16 mm L=53 mm (q.ty = 1)
2. Centering device =16 mm L=43 mm (q.ty = 1)
3. Socket hex head screw M16x50 (8.8) ISO 4762 (q.ty = 4)
4. Socket hex head screw M6x50 (8.8) (q.ty = 1)
5. Socket hex head screw M6x60 (8.8) (q.ty = 1)
6. Self locking washer 16x25.4x3,4 (q.ty = 4)

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8.2 Stresses on the supporting structure

Any possible vibrations transmitted by machines nearby the Robot installation area, may
reduce the precision and repeatability of the Robot movements.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.

Because of the considerable stresses discharged to the ground by the Robot and the
need to have appropriate backing plans, the direct fixing on the floor is not foreseen.

The values of stresses created by the Robot on the supporting structure are described
in he following Fig. 8.7 - Stresses on the supporting structure on pag. 73.

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Fig. 8.7 - Stresses on the supporting structure

The figure represents the Robot installed on the floor but it is valid for the Robot installed
on ceiling or sloped surface.

Robot Movement Type Fv (N) Fo (N) Mr (Nm) Mk (Nm)


Accelerating 2500 2300 800 2800
Racer 999 Plus
Emergency braking 3600 4500 1500 4500

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8.3 Solutions to integrate the Robot in production cells


To guarantee the safety minimum requirements in case of Robot fitting in production
cells, it is possible to limit Axes 1 and 2 stroke, depending on the cell structure and the
specific production needs.
The axis stroke limitation allows to avoid interferences with other machine parts and
assure a safe area, usually the one where the operator works, during the motion
trajectories of the Robot working cycle.
It is possible to install on the Robot different options to sector its axes in safety areas,
as shown in the following table.
Choose the most suitable solution considering the Modes and stopping distance of the
Robot (see par. 8.4 on pag. 82).

Type of
Available solutions for area restriction Supply Application
intervention
Axis 1
Axis 2
Axis 3
Software limit switch Standard Software *
Axis 4
Axis 5
Axis 6

Type of
Available solutions for safety areas sectorisation Supply Application
intervention
Axis 1 Adjustable Mechanical Limit Switch Unit (CR82226900) Axis 1
Axis 2 Adjustable Mechanical Limit Switch Unit (CR82227000) Optional Axis 2 Mechanical *
Axis 3 Adjustable Mechanical Limit Switch Unit (CR82227100) Axis 3
--- --- --- Electrical *

Mechanical *: Mechanical stop by means of buffer stop


Electrical *: Detection of the work areas
Software *: Detection of the work areas

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8.3.1 Axis 1 Adjustable Mechanical Limit Switch Unit


(CR82226900)

Purpose
The adjustable mechanical limit switch of axis 1 limits the stroke of axis 1 in both work
directions in steps of 15.

Technical features and structure


The Robot is equipped with a stop buffer to be fixed using the screws provided, in the
seats on the Robot column to limit the stroke of axis 1 in one direction only. If is
necessary limit the stroke in both directions, we will use a second buffer stop installable
as an option.
The axis 1 adjustable mechanical limit switch unit meets "man safety" requirements
since it is able to absorb all the axis kinetic energy.

Once the stop has been used (impact), the following parts must be replaced:
stopping buffer and fixing screws;
rubber dowel on Robot base and fixing screws.

Verify the integrity of the Robot parts involved in the impact, for example:
column in the fastening zone of the assembly;
the base in the fixing areas of the rubber blocks;
The equipment moved by the Robot.

In case of crush, failure in replacement replace any damaged parts will undermine
correct operation (and thus stopping) in future.

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Restrictions

Use maximum 2 stop buffers for each Robot base.

Fixing components
Socket hex head screw ISO 4762 - M10x20 (12.9)

Fig. 8.8 - Diagram of option method of use

2
Dimensions in millimetres
1. Stop buffer Ax.1 (q.ty: 1 already provided with the Robot + 1 optional)
2. Socket hex head screw M10x20 - 12.9 (q.ty: 4)

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8.3.2 Axis 2 Adjustable Mechanical Limit Switch Unit


(CR82227000)

Purpose
The option mechanical block (adjustable mechanical limit switch) of axis 2 allows to
reduce the stroke of axis 2 in both work directions in steps of 11.25.

Technical features and structure


The assembly consists of two stop buffers to be attached with the screws supplied, in
the specific seats on the Robot column to limit the stroke of axis 2 in both directions; if
the stroke is to be limited in only one direction, only one of the two stops will be used.
The axis 2 adjustable mechanical limit switch unit meets "man safety" requirements
since it is able to absorb all the axis kinetic energy.

Once the stop has been used (impact), the following parts must be replaced:
stopping blocks on column and rubber blocks on arm
fixing screws and blocks pins;

Verify the integrity of the Robot parts involved in the impact, for example:
the column in the area of stop buffers fixing
the arm in the area of rubber blocks fixing
the equipment moved by the Robot

In case of crush, failure in replacement replace any damaged parts will undermine
correct operation (and thus stopping) in future.

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Restrictions
Use maximum 2 stop buffers for each Robot.

Fixing components
Socket hex head screw M8x45 (12.9) - ISO 4762

Fig. 8.9 - Method use diagram of the front stopper option

Dimensions in millimetres
1. Stopper ax.2 (Q.ty 2)
2. Socket hex head screw M8x45 - 12.9 (Q.ty 8)

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Fig. 8.10 - Method use diagram of the rear stopper option

Dimensions in millimetres
1. Stopper ax.2 (Q.ty 2)
2. Socket hex head screw M8x45 - 12.9 (Q.ty 8)

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8.3.3 Axis 3 Adjustable Mechanical Limit Switch Unit


(CR82227100)

Purpose
The option mechanical block (adjustable mechanical limit switch) of axis 3 allows to
reduce the stroke of axis 3 in both work directions in steps of 15.

Technical features and structure


The assembly consists of two stop buffers to be attached with the screws supplied, in
the specific seats on the Robot column to limit the stroke of axis 3 in both directions; if
the stroke is to be limited in only one direction, only one of the two stops will be used.
The axis 3 adjustable mechanical limit switch unit meets "man safety" requirements
since it is able to absorb all the axis kinetic energy.

Once the stop has been used (impact), the following parts must be replaced:
stopping buffers on forearm and gum buffers on the arm
fixing screws and blocks pins;

Verify the integrity of the Robot parts involved in the impact, for example:
the arm in the fixing areas of the stopping buffers
the forearm in the fixing areas of the stopping buffers
the equipment moved by the Robot

In case of crush, failure in replacement replace any damaged parts will undermine
correct operation (and thus stopping) in future.

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Restrictions
Use maximum 2 stop buffers for each Robot.

Fixing components
Socket hex head screw M6x35 (12.9) - ISO 4762

Fig. 8.11 - Diagram of option method of use

Dimensions in millimetres
1. Stopper ax.3 (Q.ty 2)
2. Socket hex head screw M6x35 - 12.9 (Q.ty 6)

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8.4 Modes and stopping distance of the Robot

8.4.1 Stopping Modes


The Control Unit manages the Robot. Through line signals (typically given on X30
connector) it is possible to command the emergency stop, which operates in different
ways according to the following modes:
Local automatic mode (AUTO)
The stop is made in category 1 (one) according to the standard EN 60204-1, with
most effective and rapid accelerating ramp.
When the Robot is completely stopped, the parking brakes are automatically
inserted.
Programming (T1) mode
the stop is performed in category 0 (zero) according to the EN 60204-1 standard,
with the accelerating ramp almost null.
The parking brakes are immediately and automatically inserted.

8.4.2 Stopping time


The Control Unit is provided with a timer on the C5G-SDM module, active only in Local
Automatic mode (AUTO) and with selectable times. When the time is over, the enabling
on axes is removed.
The timer, even though with time that can be selected, does not influences on stopping
time (which always result the most rapid as possible), according to the Stopping Modes
(see par. 8.4.1 on pag. 82).
Consider the following minimum aspects:
With stop in Local Automatic mode (AUTO), stopping time are variable, according
to the Robot model, proportional to the inertia generated by the Robot speed and
the wrist load
With Programming mode stop (T1), time is almost null for the maximum limit speed
of 250 mm/s at wrist.
The selected time on the C5G-SDM module must be coherent both to the Robot
family and the featuring file loaded on the Control Unit. Any differences prevent the
Robot starting.
Assess carefully the stopping time set on the C5G-SDM module and adjust
consequently the installation of the fixed and movable guards of the machine.
The topic is widely discussed in the instructions handbook Transport and
Installation" of the Control Unit.

The stop in category 0 (zero) given with Robot in automatic mode with high speed
generates drift risks of the motion because of lack of trajectory control. Moreover the
Robot mechanics is solicited and can loose its efficiency.

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8.4.3 Stopping distances


The Robot requires stopping time depending on the model, proportional to the inertia
generates by the Robot speed and the wrist load.
Consider the following minimum aspects:
In local Automatic mode stop (AUTO), the stopping distances are variable.
In Programming mode stop (T1), the distances are almost null for the maximum
limit speed of 250 mm/s at wrist.
Assess carefully the stopping distances and adequate consequently the
installation of the fixed and movable guards of the machine.
In order to reduce the Robot operating area, several suitable options are available
(see par. 8.3 Solutions to integrate the Robot in production cells on pag. 74).

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9. DEVICES FOR CALIBRATION AND


MAINTENANCE
This chapter contains:
Options for calibration
Options for Maintenance.

9.1 Options for calibration


The Robot is provided with a series of necessary options to carry out the calibration
operations of the Robot axes, as described in the following table.

Tab. 9.1 - Available options

Robot type Option description Ref.

Calibration Tool (82314100) par. 9.1.1


Racer 999 Plus Calibration Kit for Axis 5 and Axis 6 (CR82227200) par. 9.1.2
Calibrated Tool Unit - Tool Master L=117 mm (81783801) par. 9.1.3

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9.1.1 Calibration Tool (82314100)

Purpose
The calibration kit with dial gauge is used to enable the correct manual calibration of
each Robot axis.

Technical features and structure


The kit consists of a dial gauge holder that is screwed into the specific seats on each of
the Robot axes and a centesimal dial gauge to find the correct calibration position.
When it is not used the dial gauge must be removed from the Robot and preserved for
further use.

Restrictions
None

Fig. 9.1 - Option diagram

1. Dial gauge holder


2. Conic ring nut
3. Probe
4. Dial gauge

For details on calibration procedure, see the Robot maintenance instructions handbook.

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9.1.2 Calibration Kit for Axis 5 and Axis 6 (CR82227200)

1. Dial gauge holder


2. Dial gauge

Purpose
This unit permits to use the Calibration Tool (82314100) assembly to carry out the
proper calibration of axes 5 and 6 in manual mode.

Technical features and structure


The unit is composed of a dial gauge holder tool to be screwed into the specific seats
on the axis 5 and 6.
When it is not used the equipment must be removed from the Robot and preserved for
further use.

Restrictions
None

Fig. 9.2 - Option diagram

1) Equipment to support the dial gauge


(CR82227211)

2) Q.ty 2 dowel pins ISO 8734 - 6x16 - B


- St

3) Q.ty 2 fixing screws (socket hex head


screws M5x20)

4) Q.ty 2 extraction dowel pins (socket hex


head screws M4x10)

5) Calibration Tool (82314100)

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For details on calibration procedure, see the Robot maintenance instructions handbook.

9.1.3 Calibrated Tool Unit - Tool Master L=117 mm (81783801)

Purpose
The calibrated tool unit is used to calculate the TCP (Tool Center Point) for the Robot
flange.

Technical features and structure


This unit consists of a cylindrical tip whose length is defined such as that the end is
positioned in a given point in relation to the wrist centre.
The tip is screwed directly on axis 6 exiting flange in radial position to it and does not
require the disassembly of the items possibly mounted on the flange itself.
When it is not used to calculate the TCP, the calibrated tool must be removed from the
Robot wrist.
The following Fig. 9.3 - Racer 999 Plus on pag. 88 and Fig. 9.4 - Racer 999 Plus on
pag. 89 shows the tip measures are referred to the Robot flange centre.

Restrictions
None

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Fig. 9.3 - Racer 999 Plus

Dimensions in millimetres

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Fig. 9.4 - Racer 999 Plus

Dimensions in millimetres

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9.2 Options for Maintenance


The Robot is provided with a series of necessary options to carry out the maintenance
operations on the Robot, as described in the following table.

Tab. 9.2 - Available options

Robot type Option description Ref.

Racer 999 Plus C5G-SBR: Robot Axis Brake Releasing Module (CR17133882) par. 9.2.1

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9.2.1 C5G-SBR: Robot Axis Brake Releasing Module


(CR17133882)

Purpose
The C5G-SBR (Small Brake Release) option makes available a transportable module
that must be connected to a Control Unit and that allows to brake release singularly the
Robot axes.

Technical features and structure


The brake releasing module takes the 24Vdc power supply directly from the Control Unit
and, through an internal protection for overload and short circuit, it allows to brake
release the Robot brakes.
The cable is 3 m long to allow the command operations only with suitable distance from
the Robot on which it is necessary to operate.
Is provided the brake release only one axis at a time. The brake releasing operation
is carried out pressing contemporaneously both the enabling push-button (keep it
pressed) and the pushbutton related to the desired axis. In order to obtain a soft brake,
release and press repeatedly the related pushbutton. In addition it is necessary to pay
attention, because a failure on a pushbutton can command the brake releasing
operation already by pressing the enabling pushbutton.

Restrictions
It is possible to use maximum 1 option for each Robot Control Unit.
It is required that the Control Unit is powered on.

Refer also to the Control Unit Technical Specification manual.

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OPTIONS

10. OPTIONS
This chapter contains:
Options installation information
Options wiring diagram
Available options for Robot

10.1 Options installation information


The options provided together with the Robot are quite always already installed.
The options installation instructions are fully described on the Transport and Installation
handbook.

The options listed below can be installed and used only on the Robots.

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10.2 Options wiring diagram


The option electrical diagrams (foreseen only where electrical connections are present)
are available in the complete electrical diagram of the Robot.
Because of the complexity of some options, it is possible that some electrical diagrams
are provided in a separated document.

All electrical diagrams are available in the Complete CD-ROM provided together with
the Robot.
In addition see par. Reference documents on pag. 6.

10.3 Available options for Robot


The Robot can be integrated with additional options to better adapt to the installation
requirement. These options, if not differently specified, can be chosen among the
available ones, combining them. All possible restrictions to the mutual incompatibility or
the maximum quantity that can be installed are clearly defined.

For a better finding, the options are listed below organised according to the topic and
application field, while the details are directly described in the related chapter.

Available options for installation


Screws and Pins Kit for Robot Fixing (CR82226800)
Leveling Plate Unit for Robot Fixing (CR82222600)
Bench for Robot Fixing (CR822218xx)

Available options for integration in production cells


Axis 1 Adjustable Mechanical Limit Switch Unit (CR82226900)
Axis 2 Adjustable Mechanical Limit Switch Unit (CR82227000)
Axis 3 Adjustable Mechanical Limit Switch Unit (CR82227100)
Available options for calibration
Calibration Tool (82314100)
Calibration Kit for Axis 5 and Axis 6 (CR82227200)
Calibrated Tool Unit - Tool Master L=117 mm (81783801)
Available options for maintenance
C5G-SBR: Robot Axis Brake Releasing Module (CR17133882)
Accessories
Kit I/O per Robot Racer Plus (CR18703160) (opzionale)

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11. FURTHER INFORMATION ABOUT THE


COMPONENTS

Tab. 11.1 - Generalities about the components

Reference
Component Description
manual
Components available only on C5Compact and C5G Control Unit
C5G /
AMS-IAM modules are axes control boards dedicated to the axes
C5Compact
management.
AMS-IAM Control Unit
Modules set to manage 1 axis or 2 axes are available; depending on
Technical
the power class, the modules take up from 1 to 2 slots.
Specifications
The SDM module is mechanically fastened on the ACC rack and
C5G /
occupies therefore the space of a slot. The 24 Vdc power supply of
C5Compact
the module and all the signals are connected by means of connectors;
C5G-SDM Control Unit
the bus on the rack is not displayed.
Technical
The module has an internal logic with double processor to manage the
Specifications
safety signals and the communication via CAN Bus with APC module.
The fieldbus module is available in the master and slave versions,
they can be chosen among Profibus-DP, Profinet and DeviceNet C5G /
protocols. C5Compact
Modulo X20 The fieldbus modules can be installed only on the slots 1 and 2 of the Control Unit
Bus Coupler PFG-BCO Module on X20 interface. Technical
It is possible to install contemporaneously the fieldbus modules and Specifications
I/O modules.
Components available only on C5G Control Unit
The C5G-DMI (Devicenet Multibus Interface cable) option provides
available a connector on the cabinet basis that includes 24 Vdc, C5G Control Unit
C5G-DMI Devicenet Master network and some I/O digital signals; able to Technical
connect slave external devices (e.g. Robot) by means of Multibus Specifications
Cable.
The C5G-PMI (Profibus-DP Multibus Interface cable) option sets
available a connector on the cabinet basis that includes 24 Vdc, C5G Control Unit
C5G-PMI Profibus-DP Master network and some I/O digital signals; able to Technical
connect slave external devices (e.g. Robot) by means of Multibus Specifications
Cable.
The C5G-PNMI (ProfiNet Multibus Interface cable) option provides
available a cable with connector on the cabinet basis that includes 24 C5G Control Unit
C5G-PNMI Vdc, ProfiNet I/O Controller (Master) network and some I/O digital Technical
signals; able to connect slave external devices (e.g. Robot) by means Specifications
of Multibus Cable.
The X10 connector is a multi-pin connector that collects all the
position management signals of the Robot (Encoders with EnDat 2.2
C5G Control Unit
interface), up to the configuration of 6 axis in total.
X10 Technical
The X10 connector is installed on Connector Interface Panel (CIP)
Specifications
and, it is connected to X1 connector on the Robot base, by means of
Connection cables between C5G and Robot.

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Tab. 11.1 - Generalities about the components (Continue)

Reference
Component Description
manual
The X60 connector is a multi-pin connector that collects all the Robot
axis power signals (motors) and brakes, up to the configuration of 6
C5G Control Unit
axis in total.
X60 Technical
The X60 connector is installed on Connector Interface Panel (CIP)
Specifications
and, it s connected to X2 connector on the Robot base, by means of
Connection cables between C5G and Robot.
The C5G-SMK option (Signal Machine Kit) sets available two alarm
inputs 24 Vdc, 4 inputs 24Vdc and 4 outputs 24Vdc on the Robot, to C5G Control Unit
C5G-SMK be used for small applications by user. The option uses some inputs Technical
and outputs already existing as standards on Safety Distribution Specifications
Module (SDM).
The (X93 / X94) connectors for the Master Fieldbus allows the
X93 connection of the Fieldbus between Control Unit master module and
the slave modules on tooling and / or on Robot.
C5G Control Unit
The connector is installed on the Control Unit base on the Connector
Technical
Interface Panel (CIP).
Specifications
X94 The X93 connector is combined with the first Fieldbus Master module
available on ARM1, while the X94 connector, if existing, with the
second master module available on ARM2.
Components available only on C5Compact Control Unit
The C5G-SMKC (Signal Machine Kit Compact) option sets available
C5Compact
two alarm inputs 24 Vdc, 4 inputs 24Vdc and 4 outputs 24Vdc on the
Control Unit
C5G-SMKC Robot, to be used for small applications by user. The option uses
Technical
some inputs and outputs already existing as standards on Safety
Specifications
Distribution Module (SDM).
The C5G-CDC (Cable Devicenet Compact) option provides available C5Compact
a connector on the cabinet basis that includes 24 Vdc, Devicenet Control Unit
C5G-CDC
Master network and some I/O digital signals; able to connect slave Technical
external devices (e.g. Robot) by means of Multibus Cable. Specifications
The C5G-PMI (Cable Profibus Compact) option provides available a C5Compact
connector on the cabinet basis that includes 24 Vdc, Profibus-DP Control Unit
C5G-PMI
Master network and some I/O digital signals; able to connect slave Technical
external devices (e.g. Robot) by means of Multibus Cable. Specifications
The X93 connector for the Master FieldBus allows the connection of
the Fieldbus between the master module inside the Control Unit and C5G Control Unit
X93 slave modules present on tooling and / or on Robot. Technical
The connector is installed in the back of the Control Unit on the Specifications
Connector Interface Panel (CIP).

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Original instructions

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