Professional Documents
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Comau Robotics
Instruction Handbook
CR00757737-en_00/2012.03
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.
SUMMARY
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Summary
5. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..37
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Generator connection to the main power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Generator connection to the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Type of cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Communication mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Generator order codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RS422 Serial cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Welding ground connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Transport trolley (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3x500V autotransformer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Remote control unit RCU 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51
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Preface
PREFACE
In this chapter are shown the following topics:
– Reference documents
– Documents preservation
– Limits on the manual content
– Symbols used in the manual
Reference documents
This document concerns the application Arc Welding System.
The complete set of Arc Welding System manuals consists of:
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Preface
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Preface
Documents preservation
All the documents provided should be stored near the
Robotic system and be available for all the people that work on it and it must
be preserved intact for all the operative life of the Robotic System.
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Symbols used in the manual
Below are listed the symbols that represent: WARNING, CAUTION and NOTES and
their meaning
The symbol calls the attention to the material disposal that is regulated by the
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Wire welding safety precautions
The safety precautions that follow integrate those for the robotic system,
contained in the Chapter SAFETY PRECAUTIONS of the Control Unit or Robot
manuals.
1.1 Responsibilities
Persons wearing a pace-maker are not allowed in any case to operate on arc
welding. Danger: high voltage!
– All the activities (installation, start-up, operation, maintenance, etc.) on arc welding
systems are only to be carried out by the authorised personnel.
– The integrator is to perform the correct integration of the arc welding system in the
cell. The integrator shall (without however limiting the activities to the indications
below):
• consider the correct installation spaces
• install the exhaust systems for the welding fumes
• install perimeter protections, access doors
• install protective shields for the eyes and against the sparks caused by the
welding process.
The Sistema di Saldatura a filo continuo is not to be started up before the machine
where it is incorporated has been declared in conformity with the provisions of
the applicable directives
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Wire welding safety precautions
– During welding operations an accident hazard exists caused by rubbing against the
metal edges of the parts to be welded or burns from contact with metal parts heated
by the welding. Wear protective gloves.
– The setting of wrong welding parameters can cause damage to the part to be
welded or to welding channel elements such as the welding torch. For this reason
the welding parameters are only to be set by qualified personnel.
Anti-reflection shields are to be mounted around the welding zone to avoid that
other persons, working in neighbouring zones, are hit by the radiation emitted by
the arc.
Never, for any reason whatsoever, look at an electric arc without adequate eye
protection.
The welded piece and the parts nearby (included the welding torch) can reach
high temperature that must be indicated in the appropriate sign (by the
integrator).
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Wire welding safety precautions
Make sure that in the immediate vicinity of the welding station there are no bins
containing petrol, diesel, solvents, rags or other inflammable materials.
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Wire welding safety precautions
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Wire welding safety precautions
The Control Unit and Generator electric circuits are supplied independently.
Always open both main switches.
The auxiliary 24 Vdc power supply may be supplied from an external source, or by
the robot control or by the line.
The input terminal blocks and the wiring elements up to the input terminals of the
main switch remain live when the main switch is open.
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Arc Welding System Description
The arc welding application cannot be installed on systems other than those
indicated above.
*¹ For information regarding the machine parts (C5GControl Unit, COMAU Robot,
Fronius Generator, ...) see the related instruction manuals indicated in par.
Reference documents on page 3.
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Arc Welding System Description
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Arc Welding System Description
2.2 Configuration
Fig. 2.2 - Connection principle diagram with Robot SMART5
Arc4
D
I H1 L F
A1
G1 Q
A M
G2
A4 H2 P
A1 C4 C E
A2 C5
A5 C1 B1
A3
B3
C6 C2 O
C3
B2
A6
A7 A8 N
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Arc Welding System Description
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C5G Control Unit
B - SMART5 RobotArc4
C - Generator
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C5G Control Unit
C- X90 connector
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C5G Control Unit
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C5G Control Unit
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C5G Control Unit
For further information please see the manual "Technical specifications" of the
C5GControl Unit .
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C5G Control Unit
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SMART5 RobotArc4
4. SMART5 ROBOTARC4
4.1 Robot
The Robot used for the Arc Welding System is a COMAU SMART5 RobotArc4 specific
for the welding applications.
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SMART5 RobotArc4
For all the details on the SMART5 RobotArc4, please refer to the specific
instruction manuals.
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SMART5 RobotArc4
The electric connection detail of the cables is contained in the application Circuit
Diagram.
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SMART5 RobotArc4
Wire puller assembly Wire puller assembly (with open side door)
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SMART5 RobotArc4
*: An example of slanting.
Tab. 4.3 - Order codes for cable pack and welding torch
Description Robot Comau Code
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SMART5 RobotArc4
Tab. 4.3 - Order codes for cable pack and welding torch
Robacta RA280 torch body kit angle 22° CR19072009
Robacta RA280 torch body kit angle 36° CR19072010
Robacta RA280 torch body kit angle 45° CR19072011
Robacta RA400 torch body kit angle 22° CR16655580
Robacta RA400 torch body kit angle 36° CR16655680
Arc4
Kit corpo torcia Robacta Drive CMT PAP CR19078038
Kit rulli diam. 1,0 mm (0.039 in) in Fe CR19078044
Kit rulli diam. 1,2 mm (0.047 in) in A / Mg / CuSi CR19078043
The anti-collision kit has to be enabled. See details in the Integration, Transport
and Installation manual in the chapter “Arc Welding Systemcomponents
installation”.
In order to work properly, the anti-collision kit must be equipped with the Torch
cleaner connection kit (internal Control Unit).
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SMART5 RobotArc4
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SMART5 RobotArc4
A A
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SMART5 RobotArc4
The A tool master, if necessary, must be installed on the on the threaded hole M6 B on
the anti-collision kit.
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SMART5 RobotArc4
The location point can be replaced with any type of reference point decided by the
user.
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SMART5 RobotArc4
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SMART5 RobotArc4
“TCP Check” Aluminium board dimensions TPC board Supporting Column dimensions
Plan view Frontal view
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SMART5 RobotArc4
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SMART5 RobotArc4
For further information please see the manuals ”Technical specifications” and
”Transport and Installation” of the robotArc4.
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SMART5 RobotArc4
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Generator
5. GENERATOR
In this chapter are shown the following topics:
– General information
– Generator connection to the main power supply
– Generator connection to the Control Unit
– Welding process
– Type of cooling
– Communication mode
– Generator order codes
– External RS422 Serial cable (From Control Unit to Generator)
– Welding ground connection cable for the Generator
– Transport trolley (optional)
– 3x500V autotransformer (optional)
– Remote control unit RCU 5000i
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Generator
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Generator
White
Brown
Green
Yellow
Grey
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Generator
For further information see the circuit diagram of Arc Welding System.
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Generator
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Generator
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Generator
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Generator
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Torch cleaning assembly and lubricator
Torch cleaning assembly and lubricator Torch cleaning assembly and lubricator
(rear view) (frontal view)
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Torch cleaning assembly and lubricator
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Torch cleaning assembly and lubricator
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Coil holder support or Marathon PAC Bell
The welding wire is usually available in coil or in a container depending on the welding
volumes and needed autonomy.
One of these alternatives can be installed:
– Coil holder support on robot on trolley (per filo in bobina), installato sul gruppo
trainafilo
– Marathon Pac kit (for wire in container), that can be positioned according to
installation requirements, considering a maximum distance between bell and wire
puller.
It is advised to support the cables pack and welding wire with the specific Balancer
assembly (optional).
Wire puller assembly Wire puller assembly (with open side door)
For more details refer to par. 4.3 Gruppo traina filo on page 27.
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Coil holder support or Marathon PAC Bell
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SmartArc Application Software
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Options
9. OPTIONS
In this chapter are listed the options available for the Arc Welding System:
In order to facilitate the search, the options are here listed and organised per
topic.
The related details are directly described in the pertaining chapter.
Available options
SMART5 RobotArc4
– TCP Check (optional)
– Location point (optional)
– Balancer assembly (optional)
Generator
– Transport trolley (optional)
– 3x500V autotransformer (optional)
– Remote control unit RCU 5000i
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Options
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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