C5G Transport and Installation

Comau Robotics
Instruction Handbook
Control Unit
Standard version
Transport and installation
Information about the preparing activities and prearrangements required to install the C5G
Dimensions and weights, transport and lifting methods
Procedures to adapt the internal components and options for the powering network
Procedure to carry out the connections to the Robot and to the mains
Preliminary procedures to set the Control Unit at work
CR00757597_en-00/0411
The information contained in this manual is the property of COMAU S.p.A.
Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.
COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.
Copyright © 2008-2011 by COMAU - Date of publication 04/2011

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual content limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Staff for the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Storage requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Requirements for the installation area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Equipment and tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. MOUNTING PROCEDURE: DIMENSIONS, SPACE AND HANDLING . . . . . . . . . . ...21

Precautions before starting the procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Packing list check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Weight and size including package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C5G standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C5G featuring rising socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C5G featuring Application Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C5G featuring rising socket and Application Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overall dimensions and installation space required for the C5G (without conditioner) . . . . . . . 26
Overall dimensions and installation space required for the C5G (with conditioner). . . . . . . . . . 28
Lifting and handling procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lifting the C5G packaged in closed crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lifting the C5G on pallet without crate (Europallet 1200 x 800 mm) . . . . . . . . . . . . . . . . . . . 31
Lifting the C5G without package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Summary
Procedure to remove the crate, protection cloth and pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Placing in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4. POWERING SUPPLY FROM THE MAINS: FEATURES AND CONNECTION . . . . . ..36

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power supply features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Earth connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Selecting the powering voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
C5G-ACO / C5G-ACBO: Conditioner (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Procedure to install and connect the powering cable (on Main Circuit breaker) . . . . . . . . . . . . 40
5. TEACH PENDANT: CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

Connection typologies depending on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Terminal connection with cable (C5G-iTP) directly connected to the C5G . . . . . . . . . . . . . . 44
6. SAFETY CIRCUITS: MINIMUM REQUIREMENTS FOR INTEGRATION . . . . . . . . . ..46

List of minimum activities required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
List of suggested activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Safety stop: checking the stop circuit timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
E-Stop circuits: inputs and control procedure for stop circuits and mushroom-shaped push button
on Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
How to wire the X30 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Further details about the stop circuit signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X30/CIP connector: pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Safety signals: reference wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Troubleshooting for safety signals coming from unsuitably installed safety devices . . . . . . . 57
Safe cut-off for 24 Vdc power supply: using the internal or external power supplies. . . . . . . . . 58
Solution with power supply taken from the X106/SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7. CIRCUITS FOR MINOR AUTOMATION ROUTINES: MINIMUM REQUIREMENTS FOR

INTEGRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61
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Selecting the 24 Vdc power supply source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Digital I/O on SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
RS232 / RS422 serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8. START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...68
Precautions to be taken before starting the machine up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Staring up the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Errors caused by incorrect connections in the safety circuits or in the ystem inputs . . . . . . . . . 69
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Preface
PREFACE
This chapter deals with the following topics:
– Reference documents
– Content of the C5G Control Unit manuals
– Document preservation
– Manual content limits
– Symbols in the manual.
Reference documents
This document refers to the C5G Control Unit.
The complete set of manuals concerning the C5G control units consists of:
Comau C5G Control Unit – Technical Specification

– Transport and installation
– Maintenance
– Control Unit use
Circuit Diagram – Circuit Diagram (ver. ACC1 and ACC3)
– Circuit Diagram (ver. ACC5)
– Circuit Diagram (ver. PAL)
Those manuals are to be supplemented by the following documents:
Comau Robot – Technical Specifications *¹

– Transport and installation *¹
– Maintenance *¹
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion programming
Applications – According to the required application
type.
*¹ specific for the installed Robot type
The above mentioned manuals shall be preserved in good repair for the entire
Robot System operating life and shall always be available for the staff members
carrying out activities on the Robot System.
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Preface
Content of the C5G Control Unit manuals
Device Manuals Contents

C5G Control – Technical – Description and main features of the Control Unit
Unit Specification – Guide to Control Unit model selection
– General description about the expanding possibilities in
relation to I/O signals, communication networks and safety
devices
– Description and purchase codes for the Control Unit and its
optionals.
– Transport and – Information about the preparing activities and
installation prearrangements required to install the C5G
– Dimensions and weights, transport and lifting methods
– Procedures to adapt the internal components and options for
the powering network
– Procedure to perform the connection to the mains
– Preliminary procedure to set the Control Unit at work
– Maintenance – Help to problem-solving
– Preventive maintenance plan to guarantee the C5G
efficiency over time
– Preventive and special maintenance procedures
– Spare part list
– Wiring diagram
Document preservation
All documents forwarded shall be preserved nearby the Robot System and be at the
disposal of all staff members, who carry out activities on the Robot System. Moreover
the documents shall be preserved in good repair for the entire Robot System operating
life.
Manual content limits

The images in the instruction manuals are aimed at representing the product and may
differ from the items actually installed on the Robot System.
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Symbols in the manual
Find below the symbols highlighting WARNING, CAUTION and NOTES together with
their meaning
This symbol applies to operating procedures, technical information and

precautions that are to be complied with and/or properly performed to prevent
possible injuries.

precautions that are to be complied with and/or properly performed to prevent
possible equipment damages.

precautions that need necessarily to be highlighted.
This symbol concerns the material disposal procedures ruled by the RAEE
Directive.
This symbol reminds the user to avoid polluting the environment and stimulate a
sustainable attitude, i.e. disposing of the materials in the suitable waste collection
sites.
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General Safety Precautions
1. GENERAL SAFETY PRECAUTIONS
It deals with a general specification that apply to the whole Robot System. Due to
ist significance, this document is referred to unreservedly in any system
instruction manual.
This specification deals with the following topics:

– Responsibilities
– Safety Precautions.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robot System (Robot
and Control System) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any CE markings of the system are the responsibility of the
Integrator.
– COMAU Robotics & Service shall in no way be held liable for any accidents caused
by incorrect or improper use of the Robot System (Robot and Control System), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally
are to make sure that the Authorised Personnel is aware of and scrupulously follow
the precautions contained in this document as well as the Safety Standards in
addition to the Safety Standards in force in the country in which it is installed.
– The non-observance of the Safety Standards could cause injuries to the operators
and damage the Robot System (Robot and Control System).
The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.
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1.2 Safety Precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.
1.2.2 Definitions
Robot System (Robot and Control System)
The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.
Protected Area
The protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot
Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section.
Assigned Personnel
The persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.
Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Programming Mode
Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.
Auto / Remote Automatic Mode

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

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

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.
Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.
1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
– Installation and Putting into Service;
– Programming Mode;
– Auto / Remote Automatic Mode;
– Robot axes release;
– Maintenance and Repairs;
– Putting Out of Service and Dismantling
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1.2.4 Operating Modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
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– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.
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Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.
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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robot System (Robot and Control System) integrated inside
an area with safety barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the safety barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked;
• that the safety devices (emergency stop, safety barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Maintenance and Repairs

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

personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.
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 are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
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Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).
Stop distances
– With Robot in programming modality (T1), if you press the sttop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you
will obtain:
Tab. 1.1 - Stop spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Stopping
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.
– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
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Installation instructions
2. INSTALLATION INSTRUCTIONS
– Staff for the installation
– Storage requirements
– Requirements for the installation area
– Equipment and tools required.
2.1 Staff for the installation

The installation shall be carried out by staff suitably trained to use the lifting equipments.
Moreover the staff members shall be warned or trained (in electrics) and therefore aware
of the dangers associated with electricity as well as of the measures to be taken while
performing the electric connections to the powering network and the interconnection
signals (safety and control signals).
2.2 Storage requirements

To store the Control Unit the following conditions shall be complied with:
– do not place one case on another
– store in closed, dry and sheltered areas only, do not expose to the inclemency of
weather
– the permissible room storage temperatures is between -25 °C and +60 °C (-13 to
140 °F). Temperature up to 70° C (158 °F) are permissible for short periods (less
than an hour).
2.3 Requirements for the installation area

The working environment, where the C5G is to be installed, shall comply with the
following requirements:
1. The environment conditions (temperature, vibrations, etc.) shall fulfil the
requirements specified in chapter “Technical Specifications”. Moreover, it is
severely forbidden to install the robot and control unit in environments
featuring:
– explosion risk
– temperatures exceeding the maximum permissible one
– nuclear radiations.
2. The support surface, where the cabinet is to be installed shall feature a suitable
carrying capacity, provide a firm support for the 4 feet and do not be inclined.
3. The cabinet shall not be bound to any frame or machine.
4. The space around the cabinet shall be sufficient to allow a suitable ventilation and
comfortable maintenance activities (refer to par. 3.5 Overall dimensions and
installation space required for the C5G (without conditioner) on page 26). In case
of installation in narrow areas, we recommend to choose the wheeled option,
(wheels are not supplied as standard with the basic version).
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Installation instructions
5. Make sure the installation area features do not hinder the reachability of the control
devices on the cabinet and programming terminal.
6. Provide for the cableways according to the instructions in par. 4.3 Power supply
features on page 37.
7. In case more Control Units are to be installed close together, no special installation
requirements are to be complied with, except guaranteeing the required free space
around the Units.
8. The Control Units cannot be stacked. The possible installation of items over the
Control Unit shall be limited to the allowed options.
2.4 Equipment and tools required

To install the C5G the following equipment and tools are required:
– Lifting equipment suitable for the installation area (crane or lift truck)
– ordinary tools like screwdrivers, spanners, others.
– 8-mm and 13-mm socket wrenches.
– For crate removal:
• Iron lever (jemmy)
– Gloves
– Clips for lugs.
– For X30 connector:
• Clips for Harting contacts, code 09.99.000.0001
• Puller for Harting contacts, code 09.99.000.0012
• Harting contacts, code 09.15.000.6203.
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Mounting procedure: dimensions, space and handling
3. MOUNTING PROCEDURE:
DIMENSIONS, SPACE AND HANDLING
– Precautions before starting the procedure
– Equipment and tools required
– Packing list check
– Weight and size including package
– Overall dimensions and installation space required for the C5G (without
conditioner)
– Overall dimensions and installation space required for the C5G (with conditioner)
– Lifting and handling procedures
– Procedure to remove the crate, protection cloth and pallet
– Placing in position.
3.1 Precautions before starting the procedure

Before starting the handling procedure, please read carefully the notes in
Chap. Installation instructions on page 19.

– Lifting equipment suitable for the installation area (crane or lift truck)
– Eyebolts (supplied together with the Control Unit and already fastened on the
cover, featuring EC mark).
– 13-mm socket wrench
3.3 Packing list check

Inside the cabinet is a STANDARD PRODUCT LIST.
Make sure all components in the list are available.
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3.4 Weight and size including package

Depending on the version, check the following sections:
– C5G standard version
– C5G featuring rising socket
– C5G featuring Application Box
– C5G featuring rising socket and Application Box
3.4.1 C5G standard version
h A
d w
C D
Without conditioner (C) With conditioner (D)

Supply
modality On pallet In closed crate On pallet In closed crate
(A) (B) (A) (B)
145 kg 190 kg 180 kg 225 kg
Weight
320 lb 419 lb 397 lb 496 lb
1200x800x1330 mm 1000x800x1400 mm 1200x800x1670 mm 1000x800x1740 mm
Size *¹
47.2 x 31.5 x 52.4 in 39.4 x 31.5 x 55.1 in 47.2 x 31.5 x 65.7 in 39.4 x 31.5 x 68.5 in
*¹ approximate size (width x depth x height)
No package, without conditioner (C) No package, with conditioner (D)

125 kg 160 kg
Weight
275 lb 353 lb
Size
Installation see par. 3.5 see par. 3.6
position
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3.4.2 C5G featuring rising socket
h A
d w
C D

Supply
(A) (B) (A) (B)
157 kg 205 kg 192 kg 240 kg
Weight
346 lb 452 lb 423 lb 529 lb
Size *¹
*¹ approximate size (width x depth x height)

137 kg 172 kg
Weight
302 lb 379 lb
Size
position
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3.4.3 C5G featuring Application Box
B
A
h
d w
C D

Supply
(A) (B) (A) (B)
180 kg 225 kg 215 kg 260 kg
Weight *¹
397 lb 496 lb 474lb 573 lb
Size *²
*¹ typical weight. It may differ depending on the equipment installed inside. Refer to the identification plate posted on the Application Box.
*² approximate size (width x depth x height)

160 kg 195 kg
Weight *¹
363 lb 430 lb
Size
position
*¹ typical weight. It may differ depending on the equipment installed inside. Refer to the identification plate posted on the Application Box.
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3.4.4 C5G featuring rising socket and Application Box
B
A
h
d w
C D

Supply
(A) (B) (A) (B)
195 kg 240 kg 230 kg 275 kg
Weight *¹
430 lb 529 lb 507lb 606 lb
Size *²
*¹ typical weight. It may differ depending on the fitting-out installed inside. Refer to the identification plate posted on the Application Box.
*² approximate size (width x depth x height)

175 kg 210 kg
Weight *¹
386 lb 463 lb
Size
position
*¹ typical weight. It may differ depending on the fitting-out installed inside. Refer to the identification plate posted on the Application Box.
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3.5 Overall dimensions and installation space

required for the C5G (without conditioner)
1 2 3 4
B’’’ B’’ B’ B
C
A C’
C’’
E E
C5G Control Unit version (without conditioner)

With rising socket
Item Standard With rising socket With Application Box
and Application Box
(1) (2) (3) (4)
A 800 mm (31.49 in)
B 1110 mm (43.70 in) -- -- --
B’ -- 1210 mm (47.63 in) -- --
B’’ -- -- 1650 mm (64.96 in) --
B’’’ -- -- -- 1750 mm (68.90 in)
C 510 mm (20.08 in)
C’ 560 mm (22.05 in)
C’’ 590 mm (23.23 in)
D 70 mm (2.75 in)
E 400 mm (15.75 in) *¹
F 200 mm (7.87 in) *¹
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Note:
*¹ Minimum space to guarantee proper ventilation. The spaces mentioned in the table
do no allow to reach the rear wall for maintenance purposes, for which an ergonimic
analysis is requested to guarantee the access.
Moreover:
– Make sure not to hinder the warm air circulation and ensure the area above the
Control Unit is free.
– If necessary, it is possible to install wheels with the option C5G-WHK: wheel kit.
The Wheel Option do not modify the cabinet total height but cannot be installed
in case the version is supplied with Application Box.
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3.6 Overall dimensions and installation space

required for the C5G (with conditioner)
1 2 3 4
B’’’ B’’ B’ B
A C
C’
C’’
F
E E
C5G Control Unit version (with conditioner)

With rising socket
Item Standard With rising socket With Application Box
and Application Box
(1) (2) (3) (4)
A 800 mm (31.49 in)
B 1450 mm (57.09 in) -- -- --
B’ -- 1550 mm (61.02 in) -- --
B’’ -- -- 1990 mm (78.35 in) --
B’’’ -- -- -- 2090 mm (82.28 in)
C 510 mm (20.08 in)
C’ 560 mm (22.05 in)
C’’ 590 mm (23.23 in)
D 70 mm (2.75 in)
E 400 mm (15.75 in) *¹
F 200 mm (7.87 in) *¹
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Note:
*¹ Minimum space to guarantee proper ventilation. The spaces mentioned in the table
do no allow to reach the rear wall for maintenance purposes, for which an ergonimic
analysis is requested to guarantee the access.
Moreover:
– Make sure not to hinder the warm air circulation and ensure the area above the
Control Unit is free.
– If necessary, it is possible to install wheels with the option C5G-WHK: wheel kit.
The Wheel Option do not modify the cabinet total height but cannot be installed
in case the version is supplied with Application Box.
3.7 Lifting and handling procedures

The suitable procedure depend on the supply modality:
– Lifting the C5G packaged in closed crate
– Lifting the C5G on pallet without crate (Europallet 1200 x 800 mm)
– Lifting the C5G without package.
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3.7.1 Lifting the C5G packaged in closed crate
Lifting data
Weight to be lifted *¹: 190 to 270
kg
419 to 595
lb
*¹The weight may differ depending on the
version, in particular in case it deals with the
one supplied with Application Box. Always
refer to the plate posted on the Control Unit.
With crane or bridge crane (A)
Rope no.: 2
Rope length (approx.): 6000 mm*²
*²Adjust in case of version with Application
Box, keeping the 60° inclination angle
unaltered as shown in the picture
With lift truck (B)
Fork length: >1000 mm
Distance between fork 530 mm
centers:
Operating procedure with crane or bridge crane(A)

a. Place the 2 ropes underneath the crate as shown in the drawing.
b. Join the ends by the lifting hook.
c. Lift and move near the installation position.
d. After reaching the installation position, remove the ropes.
e. Carry out the procedure described in par. 3.8 Procedure to remove the crate,
protection cloth and pallet on page 33.
Operating procedure with lift truck (B)

a. Place the forks as required.
b. Make sure the fork ends jut out the crate opposite side.
c. Lift and move near the installation position.
d. Carry out the procedure described in par. 3.8 Procedure to remove the crate,
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3.7.2 Lifting the C5G on pallet without crate (Europallet 1200 x

800 mm)
Lifting data
A Weight to be lifted*¹: 145 to 260

A >=60°
kg
320 to573
lb
*¹ The weight may differ depending on the
Rope no.: 4
Rope lenght: 1000 mm
With lift truck (B)
Fork length: >1000 mm
Distance between forks 530 mm
centers:
Eyebolts
B
On Control Unit: 4 x M12
female
Operating procedure with crane or bridge crane (A)

a. Check the fastening of the 4 eyebolts already indtalled on the box upper part.
b. Fasten hooks and ropes to the 4 eyebolts on the cabinet, as shown in the
drawing, (also when the conditioner is installed).
c. Lift while keeping in balance and move near the installation position.
d. After reaching the installation position, it is not necessary to remove ropes and
hooks. Carry out the procedure described in par. 3.8 Procedure to remove the
crate, protection cloth and pallet on page 33.

a. Place the forks as required.
b. Make sure the fork ends jut out the crate opposite side.
c. Lift while keeping in balance and move near the installation position.
d. Carry out the procedure described in par. 3.8 Procedure to remove the crate,
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3.7.3 Lifting the C5G without package
Lifting data
Weight to be lifted *¹: 120 to 240
kg
265 to 529
lb
*¹ The weight may differ depending on the
Rope no.: 4
Rope length: 1000 mm
With lift truck (B)
Fork length: > 900 mm
Distance between fork 620 mm
centers:
Fork receiving hole: 175 mm
Do not use a hand
pallet truck, as it may
cause the item
overturning and the
cabinet damaging.
Eyebolts
On Control Unit: 4 x M12
female
Operating procedure with crane or bridge crane (A)

a. Check the fastening of the 4 eyebolts already installed on the box upper part.
b. Fasten hooks and ropes to the 4 eyebolts on the cabinet as shown in the drawing.
c. Lift keeping in balance and move near the installation position.

a. Place the forks as requested.
b. Make sure the fork ends jut out the crate oppite side.
c. Lift keeping in balance and keep it parallel to the floor then move near the
installation position.
While moving:
•Do not lift item over 50 cm.
•Keep it flat balanced and do not incline or overturn the Control Unit .
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3.8 Procedure to remove the crate, protection

cloth and pallet
Status: – Not applicable
Material: – Not necessary
Equipment: – For crate removal:
• iron lever (jemmy)
– Gloves
The package removal is carried out in three steps:

– Operating procedure for crate removal (if applicable)
– Operating procedure to remove the protection cloth
– Operating procedure to remove the pallet.
Operating procedure for crate removal

a. Using the jemmy prize the crate
sides and remove the crate
walls.
Wear protection
gloves, as nails and
wooden splinters may
cause lacerations.
b. Carry out the procedure described in Operating procedure to remove the

protection cloth below.
Operating procedure to remove the protection cloth

a. Remove the sellotape and protecting package.
b. Carry out the procedure described in Operating procedure to remove the pallet
below.
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Operating procedure to remove the pallet

a. Unscrew the 4 screws using the
13-mm socket wrench.
b. Remove the wooden boards

that cross the base or the
wooden items locking the
wheels (if applicable).
c. Lift the C5G from the pallet by

means of a crane / bridgecrane
or lift truck as described in
par. 3.7.3 Lifting the C5G
without package on page 32
and move near the installation
position.
Collect the wooden items, protection cloth and screws and

dispose of them in compliance with the environmental protection
directives.
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3.9 Placing in position

a. Place the cabinet on the floor
b. If the cabinet is not supplied with wheels go to step d.
c. If the cabinet is supplied with (optional) wheels:
c.1 move to position pushing carefully.
When moving the cabinet with wheels over long stretches, act
extremely carefully as small obstacles may cause the cabinet
overturning.
c.2 lock the wheels acting on the special lever on the wheels themselves.
d. Make sure the minimum space requested around the C5G fulfil the requirements
specified in par. 3.5 Overall dimensions and installation space required for the C5G
(without conditioner) on page 26.
e. Make sure not to hinder the warm air circulation and ensure the area above the
Control Unit is free
f. We do not recommend to remove the eyebolts. If they have to be removed:

– keep the eyebolts inside the cabinet. In case of later lifting, use only the
eyebolts supplied or anyway featuring the EC mark.
– Do not remove the plastic washer.
– To lock the Control Unit cover use 4 M12 nuts (not supplied) in the place of
the eyebolts. Tighten the nuts but do not force them. To keep the protection
class IP54 unaltered the nuts are to be installed properly.
g. Do not place any item over the Control Unit.
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Powering supply from the mains: features and connection
4. POWERING SUPPLY FROM THE MAINS:

FEATURES AND CONNECTION
– Precautions before starting
– Power supply features
– Earth connection diagram
– Selecting the powering voltage
– Procedure to install and connect the powering cable (on Main Circuit breaker)
4.1 Precautions before starting

Before carrying out the connection to the power supply, read carefully the notes in
Chap. Installation instructions on page 19.
Before performing the connection activities described in this chapter switch OFF (0
position) the main switch and cut off the source of power.
Operating procedure
a. Position the main switch Q100
lever (A) on OFF (0).
Before carrying out the connections, make sure the powering line is
not powered.

– 5.5 x 1 blade screwdriver
– Clip for lugs.
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4.3 Power supply features

Before connecting the power supply, read carefully the following information:
– Technical features
– Technical details
– Earth connection diagram.
Tab. 4.1 - Technical features

Powering and
C5G main
C5G Control Installed earth wires gG Fuse Required supply
circuit breaker
Unit Power minimum section up the C5G voltage
power interrupt
*²
2,5 mm²
3 kVA 10 A
(14 AWG)
C5G-ACC1
6 mm²
12 kVA 25 A 50 a 60 Hz (±2 Hz)
(10 AWG)
6 mm² 400 Vac -10%
8 kVA 25 A
(10 AWG) a 500 Vac +10% 6 kA a
C5G-ACC3
6 mm² 500 Vac
12 kVA 25 A optional *¹
(10 AWG)
400 Vac -10%
6 mm²
C5G-ACC3P 12 kVA 25 A a 575 Vac +10%
(10 AWG)
6 mm²
C5G-ACC5 12 kVA 25 A
(10 AWG)
*¹ with version supplied with transformer and voltage switching on terminal board
*² for length up to 20 m / 66 ft
*³ by the connection point is installed an automatic magneto-thermal switch,
Tab. 4.2 - Technical details

Component / function Description
The fuse shall be gG type, with features similar to the ones of the Siemens
Fuse up the C5G
3NAx-xxx series
When a differential switch type B is requested (AC/DC sensitive according to
norm IEC 60755), use a model featuring a fault current value >= 300 mA and
Differential switch up the adjustable triggering time > 100 ms.
C5G No automatic circuit breakers (fault current = 30 mA) are allowed.
Depending on the Customer supply specifications an armored quadripole (three

phases plus earth) cable in compliance with norm IEC 60332-1 or CEI 20/35 is
requested to carry out the connection to the mains.
Powering cable
On Main Circuit breaker On X120 connector
Max cable size: 10 mm² / 8 AWG Max cable size: 6 mm² / 10 AWG
Cable gland by cabinet The M25 type cable gland supplied is suitable for a cable featuring an outside
base diameter between 13 and 18 mm (between 0.5 and 0.71 in)
Additional recommend. Protect the cable using suitable casing (norm IEC 60204-1).
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4.4 Earth connection diagram
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4.5 Selecting the powering voltage

– Control Unit
– C5G-ACO / C5G-ACBO: Conditioner (if installed)
4.5.1 Control Unit

The Control Unit, powered with voltage from 400 Vac -15% to 500 Vac +10%, does not
require any voltage selection.
4.5.2 C5G-ACO / C5G-ACBO: Conditioner (if installed)
Status: – Power off

Material: – Not required
Equipment: – Bladeheaded screwdriver
Operating procedure
a. Select the voltage acting
directly on terminal board X13
(A) installed on the panel inside
the box.
b. Move the wire connected to the A

400 terminal to the 460 or 500
terminal, depending on the
powering voltage value.
Remeber that each value on the
terminal (400 / 460 / 500) allows
for a tolerance equal to +/- 10%.
The default value is 400 Vac.
c. Tighten the screws according to a torque between 2 and 4 Nm (18 and 44 lb-in).
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4.6 Procedure to install and connect the

powering cable (on Main Circuit breaker)
Status: – Power source off
Material: – Powering cable (not supplied)
– Plate with cable gland (supplied)
Equipment: – 5.5 x 1 blade screwdriver
Preliminary procedures / notes

– Open the cabinet door to reach the connection terminal board located on top, in
the fixed front section.
– The powering cable may be fitted in the cabinet comfortably without having to
remove walls or covers.
– In case the cable gland nut needs to be tighten to improve the retaining on the
plate, apply a suitable force not to damage the thread (especially if it deals with
a plastic cable gland).
Before carrying out the connection, make sure the powering line is
not powered.
If a different fitting point is required for the cable, refer to the

istructions in the section Follow-up procedure at the end of this
procedure.
Operating procedure
a. Fit the cable end from the
powering source in the cable
gland with plate (A), supplied
together with the Control Unit.
b. The cable shall enter from the

screw side and exit from the
opposite side.
c. Do not tighten the cable gland.
The cable gland version may be different from the one on

the box.
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Operating procedure (Continua)

d. Fit the cable end in the hole in
the cabinet base.
e. Push the cable in the hollow

space and have it coming out
from the upper hole.
f. Connect the R-S-T phases on

the terminal board (B) R, S and
T terminals respectively.
g. Connect the earth wire on the

GND terminal of the terminal
board (B).
h. Tighten the screws applying a

torque between 2 and 4 Nm (18
to 44 lb-in)
i. Push the cable gland and related plate (A) against the entry area by the cabinet
base.
j. Lock the cable in the cable gland thickening firmly.
k. Tighten the 4 screws to lock the cable gland plate.
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Follow-up procedure
Do not turn on the main switch to power the Control Unit until the
installation procedure is completed.
If a different fitting point is required for the cable, the in-fitting hole
shall not be left open.
To serve this puerpose, install anyway the plate with the cable gland.
Also, fit a plug (e.g. a plug Hummel code 1.296.2101.11, not part of the
supply volume) in the cable gland hole.
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Teach Pendant: connection
5. TEACH PENDANT: CONNECTION

– Connection typologies depending on the Teach Pendant
• Terminal connection with cable (C5G-iTP) directly connected to the C5G

Carry out all connection activities described in this chapter with main switch OFF
(position 0).
Operating procedure
a. Position the main switch Q100
lever (A) on OFF (position 0).

– No equipment required.
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5.3 Connection typologies depending on the

Teach Pendant
The Teach Pendant connection procedure varies depending on the terminal type and
the options available:
– Terminal connection with cable (C5G-iTP) directly connected to the C5G
5.3.1 Terminal connection with cable (C5G-iTP) directly

connected to the C5G
Status – Power supply off

Material: – C5G-iTP terminal
Equipment: – Not necessary
X124

Not necessary.
Operating procedure
a. The connection of the Teach Pendant X124 connector shall be accomplished on
the cabinet lower panel, right side.
b. The cable path has the cable
exiting from the front
underneath the electric panel
door.
X124
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Operating procedure (Continua)

c. Fit the movable connector (A)
and tighten the ring nut firmly.
d. Place the terminal on the

supporting surface (B) on the
door.
e. Wind the cable tidily on the

special support.
Act carefully while

closing the door to
avoid damaging the
cable:
make sure the cable is not stuck
between the feet and the door or
the rising socket and the door.
Flow-up procedure
– Not necessary.
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Safety circuits: minimum requirements for integration
6. SAFETY CIRCUITS: MINIMUM

REQUIREMENTS FOR INTEGRATION
– List of minimum activities required
– List of suggested activities
– Safety stop: checking the stop circuit timer
– E-Stop circuits: inputs and control procedure for stop circuits and
mushroom-shaped push button on Teach Pendant
– Safe cut-off for 24 Vdc power supply: using the internal or external power supplies.

The robot system (consisting of Robot and Control Unit) shall be operated in an
industrial environment by a qualified staff member that is acquainted with the
requirements related to the integration of a Robot in a complete machine, in compliance
with the basic safety prescriptions listed in the machine Directive.
For the sake of convenience, the qualified staff member that will carry out the activities
described here will be referred to as the “integrator”.
This chapter describes the minimum activities that the integrator shall perform to
upgrade the complete machine installing the Control Unit control devices and
emergency stop circuits.
Please remember that due to the Control Unit inherent features, a reduction of the
warranty cover may apply in case of multiple faults (see norm EN ISO 13849-1)..
In order to comply with the norm requirements, the integrator is responsible for
the correct integration of the safety circuits in the robot system.

– Ordinary electromechanical equipment
– Clip for lugs.
– For X30 connector:
• Clip for Harting contacts, code 09.99.000.0001
• Puller for Harting contacts, code 09.99.000.0012
• Harting contacts, code 09.15.000.6203.
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6.3 List of minimum activities required

– Safety stop: checking the stop circuit timer
– E-Stop circuits: inputs and control procedure for stop circuits and
mushroom-shaped push button on Teach Pendant.
6.4 List of suggested activities

– Safe cut-off for 24 Vdc power supply: using the internal or external power supplies
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6.5 Safety stop: checking the stop circuit timer

Material: – Not necessary
Equipment: – Small flat blade screwdriver

C5G stop circuit category
– The safety stop is accomplished according to the categories specified in norm EN
60204-1 par. 9.2.2. The Emergency Entries (E-Stop), Gate (Auto-Stop) and
General Stop (Gen-Stop) are subjected to a safety stop time (refer also to
par. 6.6.2 Further details about the stop circuit signals on page 52).
In particular:
• category 1 (controlled stop) in LOCAL or REMOTE mode
• category 0 (immediate power cut-off) in PROGRAMMING mode.
The time set in the stop circuit timer shall be consistent with the
Robot model.
Evaluate carefully the stop times and adjust accordingly the machine
movable and fixed guard installation.
Functionality
– The time set in the stop circuit timer does not influence the Robot stopping time,
that is accomplished in the shortest time possible, depending on the Robot
model.
– The timer function is enabled in LOCAL or REMOTE mode, while in programming
mode, the Robot stopping is performed always according to category 0.
Usage limits
– Please note that zeroing or reducing the controlled stopping time may result
in:
• deviations from the expected path, due to the untimely applying of the
engine waiting brake.
• risk of probable stress for the Robot, for the engine waiting brake as well as
impacts due to the deviations from the expected path.
Consistency check
– The SDM module controls and ensures that both rotating selector switches
feature the same setting.
– The system software controls consistency between the time set for the selector
switches and the one specified in the Robot characterization file.
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Operating procedure
If the time has to be adjusted:
a. Disconnect the power from the

mains.
b. Determine the time required

according to the data in
Tab. 6.1.
c. Check or possibly set both

rotating selector switches SW1
(A) and SW2 (B) on module
SDM according to Tab. 6.2.
Tab. 6.1 - Time to be set depending on Robot models

Time to be set for SDM module
Robot models (preferential according to Robot model and typical applications)
SMART 5 Six / NS
SMART 5 NM 1.5 seconds *¹
SMART 5 NJ
Square YZ-500 2 seconds
SMART NX1-600 2 seconds
SMART NX1-800 6 seconds
Tab. 6.2 - Time and position for the rotating selector switches on
SDM module
Time (seconds)
0 0,5 1 1,5 *¹ 2 2,5 3 4 5 6
Selector position
0 1 2 3 *¹ 4 5 6 7 8 9
SW1 / SW2
*¹ Value specified by manufacturer.
Follow-up procedure
Do not turn on the main switch to power the Control Unit until the
installation procedure is completed.
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6.6 E-Stop circuits: inputs and control procedure

for stop circuits and mushroom-shaped push
button on Teach Pendant
– How to wire the X30 connector
– Further details about the stop circuit signals
– X30/CIP connector: pins
– Safety signals: reference wiring diagram
– Troubleshooting for safety signals coming from unsuitably installed safety devices.
6.6.1 How to wire the X30 connector

Material: – Harting male contacts
no. 32 pins 09.15.000.6103 (0.5 mm² /
20 AWG),
no. 9 pins 09.15.000.6101 (1.5 mm² /
16 AWG),
no. 1 pin 09.15.000.6106 (2.5 mm² /
14 AWG)
connector and cap (supplied together
with the Control Unit)
Equipment: – Clip for Harting contacts, code
09.99.000.0001
– Puller for Harting contacts, code
09.99.000.0012

– The input/output signals for the stop circuits are available on the X30/CIP
connector located by the Control Unit base (details about the pins in Fig. 6.1
- X30/CIP connector: pinouts on page 54).
– Depending on the used wire section/current required, use the 0.5 mm², 1.5 or 2.5
mm² male pin for the powering lines, signals and/or jumpers.
The emergency stop push button on the Teach Pendant is not

controlled by the stop circuit inside the C5G.
The integrator shall connect the above mentioned contacts to the
machine emergency stop circuit by means of the connection
available on the X30 connector.
Failing to perform the connection will highly endanger the

programming as well as the machine operators.
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Operating procedure
a. Depending on the intervention modalities and the machine requirements, identify
the inputs to be connected (refer also to the par. 6.6.2 Further details about the
stop circuit signals on page 52).
b. Connect the signals as specified in par. 6.6.4 Safety signals: reference wiring
diagram on page 55.
c. In case the signal analysis is requested, check the status using the $SDIN
system variables listed in par. 6.6.2 Further details about the stop circuit signals
on page 52 or the suggestions in par. 6.6.5 Troubleshooting for safety signals
coming from unsuitably installed safety devices on page 57.
d. Crimp the male contacts on the
wires and assemble connector
and cap.
e. Fit in connector (A). The

connection of the Harting (male
and female) connectors shall be
accomplished without forcing to
prevent the pin damaging.
f. Lock connector (A) acting on

the lever.
g. Pull manually the cable,

(without overdoing), to check
whether the connection has
been properly accomplished.
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6.6.2 Further details about the stop circuit signals

The input/output signals for the stop circuits are available on the X30/CIP connector
located by the Control Unit base.
Tab. 6.3 - X30/CIP connector: safety signal definition

Signal Pin on X30 Definition and purpose Diagnosis
Status: it is always enabled and triggers the stopping mode (norm
$SDI[41]
EN60204-1) depending on the selected operating mode:
Channel 1
• category 1 in automatic mode
• category 0 in programming mode *¹
$SDI[42]
Signal: input used for the emergency stop function; connect a pair
Channel 2
of not-energized contacts of a safety device coming from the line.
C5G X30
Input +24V Int

4, 6
E-Stop
5, 7
Line External
E-Stop
Electric features:
– self-restoring fuse 1 A
– current on the contacts between 20 and 50 mA per each input
– voltage 24 Vdc
Status: it is enabled in automatic operating mode only and triggers

a stop according to category 1 (norm EN60204-1). By selecting the $SDI[47]
Programming mode, the C5G will be controlled by the Enabling Channel 1
Device (on Teach Pendant) and the Auto-Stop input will be
disabled. $SDI[48]
Signal: input used for the safety stop function; connect a pair of Channel 2
not-energized contacts of a safety device coming from the line.
C5G X30
Input
18, 20 +24V Int
Auto-Stop
19, 21
Line
Auto-Stop
(Fence)
Electric features:
– voltage 24 Vdc
*¹ For safety reasons, in Programming mode only category 0 stops are enabled (in compliance with EN
60204-1).
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Tab. 6.3 - X30/CIP connector: safety signal definition (Continued)

Signal Pin on X30 Definition and purpose Diagnosis
Status:it is always enabled and triggers the stopping mode (norm
EN60204-1) depending on the selected operating mode:
• category 1 in automatic mode
$SDI[43]
• category 0 in programming mode *¹
Channel 1
Signal: input used for the safety stop function; connect a pair of
not-energized contacts of a safety device coming from the line. It is
$SDI[44]
physically identical to the E-Stop input and can be used for Channel 2
functional purposes to trigger the Robot emergency stop without
acting on the E-Stop, that is typically enabled for wider geographic
areas.
Input C5G
25, 27 X30
Gen-Stop
26, 28
Line +24V Int
General
Stop
Electric features:
– voltage 24 Vdc
Status: it is always enabled. $SDI[120]

Signal: output for the (not-energized) contacts of the emergency Both
stop push button on the Teach Pendant. channels
The emergency push button on the Teach Pendant is not directly
connected to the Control Unit emergency stop circuit.
The integrator shall:
–properly interlock the push button contacts with the machine
(cell / plant) emergency stop circuit
– remember to include also the Teach Pendant E-Stop push button in the
procedure for the periodic inspection of the machine emergency
devices.
Output 11, 13 C5G X30
E-Stop PB 12, 14
Internal
E-Stop
iTP = Teach Pendant E-Stop
Inside contacts electric features:

– max current 1 A
– typ voltage 24 Vdc, max 50 V
Note: install quick-fit protection fuse 1 A on the 24 Vdc power supply input (to be
carried out by the integrator)
*¹ For safety reasons, in Programming mode only category 0 stops are enabled (in compliance with EN
60204-1).
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6.6.3 X30/CIP connector: pins

Fig. 6.1 - X30/CIP connector: pinouts
External View
Legend:
– Not Used / Not Available
– The 0V shown are connected together. The internal power supplies (0V INT, 0V
EXT and 0V Field Bus) are connected to one another, to the 0V inside the Control
Unit and to the earth.
The internal connections related to the X30 connector are shown in the Control
Unit wiring diagram.
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6.6.4 Safety signals: reference wiring diagram

– Stand-alone control reference diagram
– Centralized control reference diagram
.
The mushroom-shaped push button in the C5G shall be included in the

emergency safety circuit.
The wiring diagrams below are to be used only as guidelines to understand the
connections. The integrator shall assess the cell/line safety requirements and
carry out the connections accordingly.
Fig. 6.2 - Stand-alone control reference diagram
Stand Alone
Operations
X30
C5G
Internal
E-Stop
External
E-Stop
Auto-Stop
(Fence)
General
Stop
The signals electric features are to be found in Tab. 6.3 - X30/CIP connector:
safety signal definition on page 52.
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Fig. 6.3 - Centralized control reference diagram
Line
Operations
X30
C5G
Internal
E-Stop
External
E-Stop
Auto-Stop
(Fence)
General
Stop
The signals electric features are to be found in Tab. 6.3 - X30/CIP connector:
safety signal definition on page 52.
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6.6.5 Troubleshooting for safety signals coming from

unsuitably installed safety devices
In unusual cases, when the installation of safety devices (e.g. safety limit switch) is
carried out on major or precarious doors, it may happen that the door closing causes
irregular bounces on the contacts, that affect the electric signal. Such troubles on the
signals may lead to an inconsistent assessment of the signals by the SDM module and
therefore to a system jam.
The involved inputs are E-Stop, Auto-Stop and General-Stop (on the Auto-Stop is
usually connected the safety limit switch of the cell/line access door).
The diagnosis is possible checking the variables (bit) listed below: the 0 (zero) status
of the bit with both channels of the corresponding input closed identifies which signal
caused the jam.
Variable Function
E-Stop Input Status.
$SDI[1]
Values: 1 input closed, 0 input open
General-Stop Input Status
$SDI[2]
Auto-Stop Input Status (ignored in Programming mode)
$SDI[4]
To quit the diagnostic jam reopen both contacts of the corresponding signal or shut
down and then turn on again the Control Unit.
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6.7 Safe cut-off for 24 Vdc power supply: using

the internal or external power supplies
6.7.1 Solution with power supply taken from the X106/SDM
The solution described herein feature the following structure:
– the 24 Vdc power supply is delivered by the internal power supply AMS-ASM32 or
taken from outside source through the X30
– the 24 Vdc power supply for the I/O user’s modules (direct and cut power supply)
can be taken from the X106/SDM connector, at the disposal of the user.
For further information, refer to the Overview for 24 Vdc power supply in the
Control Unit (see par. 6.1 on page 115).

The electric wiring diagram described below are to be used only to
understand the connections. The integrator shall analyse the safety
requirements of the cell/line and carry out the connections according
to the needs.
Status: – Electric energy off

Material: – C5G-UCK: user connector kit, for
SDM module
Equipment: – Screwdriver set
Operating procedure
a. Carry out the circuit as shown in the outline wiring diagram in Fig. 6.4 - 24 Vdc
power supply cutoff circuit on X106/SDM: outline diagram on page 59.
b. If necessary, depending on the user choice for the circuitry, deliver the 24 Vdc
power supply through the X30 connector. In that case the JP200 position shall be
adjusted (refer to par. 7.3 Selecting the 24 Vdc power supply source on page 62).
c. Power the I/O modules taking the power supplies on the X106/SDM connector.
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Fig. 6.4 - 24 Vdc power supply cutoff circuit on X106/SDM:

outline diagram
SDM MODULE C5G

X30 X102
1A
24V INTP 24V INT.
1
8
24V EXT.
29
FIELD BUS
24V EXT.
15
22
X106
0V 24V I/O 1
2
INT./EXT. 2
0V 3
9 8A DRIVE ON
24V SAFE 4
16
23
30 SL2 P8A PSF
JP200 PIO
24V EXT.
24V INT.
X100
24V
ASM
AUX.
SUPPLY
MODULE 0V
Provide for suitable protections against overloads and short circuits down the X106/SDM connector.
Refer to the technical features in Tab. 6.4 - X106/SDM: pin structure and features on page 60
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Tab. 6.4 - X106/SDM: pin structure and features

Features:
– Voltage: 24 Vdc
– Max current: 8 A, shared between (V24 I/O) and (V24
X 106
SAFE)
1
– Corresponsing signals: V24 I/O, GND-V0, V24 SAFE
Pin structure:
X106/SDM Pin Signal
1 +24 Vdc I/O
1
2 0 Vdc I/O *
3 0 Vdc SAFE *1
4 +24 Vdc SAFE
* internally connected together. Also connected to the 0V shared with
GND-V0
Further details about the 24 Vdc power supplies and X106/SDM connector are to
be found in the manual “Technical specification” in par. 6.1 Overview for 24 Vdc
power supply in the Control Unit on page 115 and following ones.
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Circuits for minor automation routines: minimum requirements for integration
7. CIRCUITS FOR MINOR AUTOMATION

ROUTINES: MINIMUM REQUIREMENTS
FOR INTEGRATION
– Selecting the 24 Vdc power supply source
– Digital I/O on SDM module
– RS232 / RS422 serial communication

The robot system (consisting of Robot and Control Unit) shall be operated in an
industrial environment by a qualified staff member that is acquainted with the
requirements related to the integration of a Robot in a complete machine, in compliance
with the basic safety prescriptions listed in the machine Directive.
For the sake of convenience, the qualified staff member that will carry out the activities
described here will be referred to as the “integrator”.
This chapter describes the minimum activities that the integrator shall perform to
implement minor automation routines using the Control Unit.
For other applications (arc welding, spot welding, handling, etc.), please refer to
the specific instruction manuals.

– Ordinary electromechanical equipment
– In case of Digital I/O on SDM module, movable connectors for the SDM module
(purchase option C5G-UCK: user connector kit, for SDM module)
– In case of RS232 / RS422 serial communication, female 9-pin tray-type movable
connector, supplied with cap (to be purchased independently)
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7.3 Selecting the 24 Vdc power supply source

Before starting this procedure, read the specific section in the manual “Technical
Specifications”: Overview for 24 Vdc power supply in the Control Unit (see par. 6.1 on
page 115).
Preliminary procedures/ notes

The JP200 connector is supplied with earth connection by terminal 5
to connect the 0V to the equipotential circuit. The removal of this
connection neutralizes the solution for the faults towards earth (EN
60204-1 § 9.4.3.1)
Operating procedure
a. Select the 24 Vdc power supply source according to the reference wiring diagram
in Fig. 7.1 - Circuit to select the 24 Vdc source: power supply source selection
reference diagram on page 63.
b. Depending on the power supply source selected, consider the following aspects:
• an internal power supply source does not require any device and the
selection on the JP200/SDM connector is already correct (position A in
Fig. 7.1).
• an external power supply source requires an external powering device
(not supplied together with the Control Unit) that shall be connected through
the X30/CIP connector: pins (see par. 6.6.3 on page 54). The selection on
the JP200/SDM connector is requested (position B in Fig. 7.1).
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Fig. 7.1 - Circuit to select the 24 Vdc source: power supply

source selection reference diagram
24V
24V SDM MODULE
EXT. X30 X102
1A
24V INTP
SUPPLY 0V
1
8
24V EXT.
29
FIELD BUS
24V 24V EXT.
24V 15
22
EXT.
SUPPLY 0V
0V INT./EXT.
2
16
23
30
X122
JP200 JP200
24V EXT. 24V EXT. 8A DRIVE ON
24V INT. 24V INT.
SL2 P8A PSF

B A
X100
5A
24V
ASM PIO
AUX.
SUPPLY SL1 P5A
MODULE 0V
5A
1A 5A
Postion A: 24Vdc power internal source

Position B: 24 Vdc power external source, coming from X30
For further details about the 24 Vdc power supply source, please refer to par. 6.1
Overview for 24 Vdc power supply in the Control Unit on page 115 of the manual
“Technical specifications”.
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7.4 Digital I/O on SDM module

Before starting this procedure, read the specific section in the manual “Technical
Specifications”: Internal Digital Inputs / Output, on the SDM module (see par. 9.2 on
page 149).

To use digital I/O on the SDM module it is necessary to have the option C5G-UCK:
user connector kit, for SDM module
Operating procedure
a. Carry out the circuit as shown in the reference wiring diagram in Fig. 7.2 - Circuit
required to use digital I/O on SDM module: electric connection reference
diagrams on page 65.
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Fig. 7.2 - Circuit required to use digital I/O on SDM module:

electric connection reference diagrams
C5G SDM
Output
*1
Input
Input
For further details about the technical features and connectors, please refer to
par. 9.2 Internal Digital Inputs / Output, on the SDM module on page 149 of the
manual “Technical specifications”.
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7.5 RS232 / RS422 serial communication

– The user may use the COM2 port available on the AMS-APC820 module.
– The COM2 provides the RS232 / RS422 serial connection. The RS232 and RS422 ports cannot be used
contemporaneously.
– It is necessary a female 9-pin (tray type) DSUB movable connector (AMS-APC820 module side),
completed with cap (not supplied).
Features: Pins:
– RS232/RS422, non modem-capable,
electrically insulated
– UART 16550-compatible, 16-byte FIFO
– Speed: Max. 115 kbaud *¹
– Connection cable max length:
RS232: 15 m (49 ft)
RS422: 1200 m (3937 ft)
Operating procedure
a. Prepare the connection cable.
b. Connect the connector on the

COM2
COM2 to the.AMS-APC820
9
module.
c. The connection cable must exit 1
the Control Unit through the

X90 cable gland connector on
the Connector Interface Panel
(CIP).
d. Place the connection cable tidily inside the Control Unit, avoiding passages near
the powering cables.
e. If necessary, the communication may be tested using a simple programme and

a connection cable, as shown in Fig. 7.3. A standard Personal Computer,
supporting Hyper Terminal routine and configured to receive characters from a
serial unit at 9600 Baud/Rate, may be used as receiving unit. See also Fig. 7.4.
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Fig. 7.3 - Typical cable for RS232 serial connection between

COM2 on AMS-APC820 and Personal Computer
Features:
AMS-APC820
AMS-APC820 PersonalComputer
Personal Computer – RS232C
side
side side
side – Straight cable
– 2 movable
DSUB (tray
99 99 type) 9-pin
female
connectors by
the ends.
11 11 – No control
(female)
(female) (female)
(female) signal.
Pin2:2:RX
Pin RX Pin2:2:TX
Pin TX
Pin3:3:TX
Pin TX Pin3:3:RX
Pin RX
Pin5:5:GND
Pin GND Pin5:5:GND
Pin GND
Shield
Shield
Fig. 7.4 - Example of RS422 connection cable from COM2 on

AMS-APC820 and general device
Caratteristiche:
AMS-APC820 Serial Device
– RS422
side side
– Conduttori
twistati a
coppie (TX e
9 RX)
– 1 connettore
volante DSUB
(a vaschetta) 9
1
pin femmina
(female) lato APC820.
– Schermo
Pin 4: TXD Pin RX+
Pin 1: TXD Pin RX- (Shield)
Pin 9: RXD Pin TX+ connesso su
Pin 6: RXD Pin TX- entrambi i lati o
Pin 5: GND Pin GND un solo lato,
Shield Shield secondo
esigenza.
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Start up
8. START UP
– Precautions to be taken before starting the machine up
– Staring up the Control Unit
– Errors caused by incorrect connections in the safety circuits or in the ystem inputs.
8.1 Precautions to be taken before starting the

machine up
– The robot system (consisting of Robot and Control Unit) shall be integrated in a
complex system and suitably interfaced. If the safety signal interfacing circuits
are not connected, the user will be able to turn on the Control Unit but it will
not be possible to start the Robot engines. The reference diagrams for the
correct interfacing are to be found in the previous chapters.
– The UPS module battery shall be charged to ensure the controlled shut-down
functionality. The first complete charge takes about 3 hours. During such period the
Control Unit may not be able to guarantee the controlled shut-down functionality
triggering in case of power supply interruption.
8.2 Staring up the Control Unit

– To start up the Control Unit, turn the main switch on (position “I”).
– During the first seconds the system carries out the necessary self-tests to check
the modules functionality. This procedure is signalled by the LEDS lighiting up on
the modules.
– After performing the tests and loading the system, the Teach Pendant will be the
interface for any kind of activity to be carried out on the robot system (motion,
programming, diagnosis, ...).
– In case of errors due to open safety and control circuits, refer to par. 8.3 Errors
caused by incorrect connections in the safety circuits or in the ystem inputs on
page 69
Due to the extent of the topics related to the Control Unit startup, motion and
programming as well as any other required item, it is necessary to refer also to
Fo r a mo re d etail ed l ist, pl ea se refe r to th e
other manuals.
Depending on the needs, we suggest the following documents:
– as for the robot system start-up and usage: Usage of the Control Unit
– as for the specific applications: (the different application manuals).
For a more detailed list, please refer to par. Reference documents on page 6.
HS-RC-C5E-TIN_07.fm
68 00/0310
Start up
8.3 Errors caused by incorrect connections in

the safety circuits or in the ystem inputs
To start properly, the Control Unit requires some safety circuits and system diagnostic
inputs to be closed again.
Find below the minimum requirements to be complied with.
Tab. 8.1 - Circuits and signals to start the C5G

Circuit Description Minimum requirements / Notes
– The 2 safety channels shall be closed again
Notes:
– Signals available on X30 connector
– Refer to par. 6.6 E-Stop circuits: inputs and control
E-Stop Emergency stop from outside procedure for stop circuits and mushroom-shaped
push button on Teach Pendant on page 50
– Refer to par. 6.3 C5G-ISAK5: power supply kit for
applications on page 123 of Technical Specification
handbook.
Notes:
Auto-Stop Limit switch controlling the cell – Signals available on X30 connector
(Fence) access doors – Refer to par. 6.6 E-Stop circuits: inputs and control
procedure for stop circuits and mushroom-shaped
Notes:
– Signals available on X30 connector
General Stop Area stop
– Refer topar. 6.6 E-Stop circuits: inputs and control
procedure for stop circuits and mushroom-shaped
– The Robot Allarm input shall be closed again
Notses:
– Signals available on X2 connector of the third
AMS-IAM module (a connector serving as plug is
Robot alarm Flange alarm on Robot wrist
available to close the circuits)
– Alternatively, with C5G-SMK option installed, the
signals are available on connector by Robot border
area.
– Air Input input shall be closed again
Notes:
– Signals available on X2 connector of the third
Air input Air alarm by robot border area
– Alternatively, with C5G-SMK option installed, the
signals are available on connector by Robot border
area.
HS-RC-C5E-TIN_07.fm
00/0310 69
Start up
Tab. 8.1 - Circuits and signals to start the C5G

Circuit Description Minimum requirements / Notes
– The two OVT POS + and OVT POS - inputs shall be
closed again
– Or, with C5G-OTK option installed, the 5 over-stroke
inputs on X3 terminal board shall be closed
Note:
– Signals available on X2 connector of the second
OVT POS + Axes over-stroke alarm
OVT POS - (positive and negative stroke)
– Alternatively, with C5G-OTK option installed, the
signals that shall be closed agian are partly available
on connector by Robot border area and partly available
by the box base on the X3 terminal board close to the
X10 signals connector.
HS-RC-C5E-TIN_07.fm
70 00/0310
COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
comau.com/robotics Original instructions

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Comau Robotics

Transport and installation

Copyright © 2008-2011 by COMAU - Date of publication 04/2011

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

2. INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

3. MOUNTING PROCEDURE: DIMENSIONS, SPACE AND HANDLING . . . . . . . . . . ...21

Procedure to remove the crate, protection cloth and pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4. POWERING SUPPLY FROM THE MAINS: FEATURES AND CONNECTION . . . . . ..36

5. TEACH PENDANT: CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

6. SAFETY CIRCUITS: MINIMUM REQUIREMENTS FOR INTEGRATION . . . . . . . . . ..46

7. CIRCUITS FOR MINOR AUTOMATION ROUTINES: MINIMUM REQUIREMENTS FOR

Comau C5G Control Unit – Technical Specification

Those manuals are to be supplemented by the following documents:

Comau Robot – Technical Specifications *¹

Content of the C5G Control Unit manuals

Device Manuals Contents

Manual content limits

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– The application of these Safety Precautions is the responsibility of the persons

The installation shall be made by qualified installation Personnel and should

1.2 Safety Precautions

Installation and Putting into Service

Auto / Remote Automatic Mode

Maintenance and Repairs

Putting Out of Service and Dismantling

1.2.4 Operating Modes

Auto / Remote Automatic Mode

Robot axes release

Maintenance and Repairs

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

– Trouble-shooting and maintenance activities are to be executed, when possible,

Putting Out of Service and Dismantling

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

Tab. 1.2 - Safety electronics reaction time in programming

Mission time (typ. case)

2.1 Staff for the installation

2.2 Storage requirements

2.3 Requirements for the installation area

2.4 Equipment and tools required

3.1 Precautions before starting the procedure

3.2 Equipment and tools required

3.3 Packing list check

3.4 Weight and size including package

3.4.1 C5G standard version

Without conditioner (C) With conditioner (D)

No package, without conditioner (C) No package, with conditioner (D)

3.4.2 C5G featuring rising socket

Without conditioner (C) With conditioner (D)

No package, without conditioner (C) No package, with conditioner (D)

3.4.3 C5G featuring Application Box

Without conditioner (C) With conditioner (D)

No package, without conditioner (C) No package, with conditioner (D)

3.4.4 C5G featuring rising socket and Application Box

Without conditioner (C) With conditioner (D)

No package, without conditioner (C) No package, with conditioner (D)

3.5 Overall dimensions and installation space

C5G Control Unit version (without conditioner)

3.6 Overall dimensions and installation space

C5G Control Unit version (with conditioner)

3.7 Lifting and handling procedures