LB Aw NM Man CMT en

SMA RT NS - E le nco ma nu al i
Comau Robotics
Instruction Handbook
Arc Welding System (CMT

Fronius generator)
Maintenance for System GaTeWayFRonius (GTWFR) serial

connection, with SMART5 NM 16-3.1Robot
CR00757745-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.
Copyright © 2011 by COMAU - Date of publication 07/2011

1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Precautions at the end of the maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Equipment necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14

General precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance operation sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Summary of intervention points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Preventive maintenance plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

Special maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32
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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:
Comau Arc Welding System – Technical specifications

– Integration, Transport and installation
– Maintenance
Programming, – Software application of the SmartArc Arc
specific for welding Welding System
Wiring diagram of Arc Welding System
These manual must be integrated with the following documents:
Comau C5GControl Unit – Technical specifications

– Transport and installation
– Maintenance
– Use of C5GControl Unit
– Wiring diagram
Robot – Technical Specifications
– Transport and installation
– Maintenance
– Wiring diagram
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion Programming
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Preface
Fronius – Transpulse Synergic 4000, 5000 (Generator use instruction)

– Transpulse Synergic 4000, 5000 (Additional information, I/O and
error signals)
– FK 4000 R (Use instructions for the generator cooling system)
– FK 4000 R (Flow meter and water filter installation)
– VR 7000 (Wire-feeder service installation)
– VR 7000 (Wire-feeder blowing assembly instructions)
– VR 7000 (Wire-feeder cover assembly instructions)
– VR 7000 (Wire guide sheath on wire-feeder unit assembly
instructions)
– BRG 97 N Mechanical Torch cleaning assembly (operating
instructions)
– Torch for Robot Robacta
– High Speed Touch Sensing (Installation and use of joint seam
track).
– Trolley
– Autotransformer
– RCU5000I teach pendant
The list above is complete in order to represent all
the possible configurations and expansion.
Typically it is enough to consult only the
specification of the purchased part.
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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.
Limits on the manual content

The figures inserted in the instruction manual have the purpose to represent the product
and can differ from what is actually visible on 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
This symbol indicates operating procedures, technical information and

precautions that if not observed and/or performed correctly could cause injuries
to the personnel.

precautions that if not observed and/or performed correctly could cause damage
to the equipment.

precautions that are to be underlined.
This symbol indicates that entry is forbidden to persons wearing a pace-maker.
The symbol calls the attention to the material disposal that is regulated by the
The symbol calls the attention on avoiding environmental contamination and

suggest to dismiss the materials on the appropriate collection facility.
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Wire welding safety precautions
1. WIRE WELDING SAFETY

PRECAUTIONS
– Responsibilities
– Information regarding the process
– Protection of the eyes and the body
– Protections against gas, fumes and fire
– 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!
Entry is forbidden to persons wearing a pace-maker.

Danger of death!
– 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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– 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.
1.2 Information regarding the process

The electric arc is identified by a very intense source of light and heat; in fact, the electric
current passing into the gaseous atmosphere existing between the electrode and the
part to be welded determines the emission of electromagnetic waves that are perceived
by humans as light and/or heat, according to the wave-length.
Beyond the limits perceptible by man, the arc emits also ultraviolet and infrared rays, but
ionised rays have never been detected.
1.3 Protection of the eyes and the body

The main danger present during the arc welding process is the emission of
electromagnetic waves, caused by the electric arc, having wave lengths that range from
infrared to ultraviolet.
These rays, if they hit the eye, can cause various pathologies: conjunctivitis, burning of
the retina, ‚”glass-blower cataract”, deterioration of visual capacity, etc., furthermore the
strong concentration of ultraviolet rays can cause burning of the skin.
Tab. 1.1 - DIN classes of standard adiactinic glass on page 8 indicates the tones of the
glass (always indicated on the glass conforming to relevant standards) to be used
according to the different types of welding executed; mirrored types are indicated to
reduce the action of the infrared rays.
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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Tab. 1.1 - DIN classes of standard adiactinic glass

CLASS FORESEEN USE CONDITIONS
Electrodes with diameters ranging from 3.25 to 5 mm.
9 For arc welding in protected atmosphere with current intensity up
to 75 A
Electrodes with diameters over 5 mm.
10 For arc welding in protected environment with current intensity
up to 200 A
Electrodes with diameters over 5 mm.
up to 250 A
Electrodes that have a very strong luminous effect.
up to 300 A
To weld parts with very thick walls.
over 300 A and up to 500 A
1.4 Protections against gas, fumes and fire

In arc welding considerable quantities of fumes and gas are released, the quality of
which depends on the type of weld material and the quantity of power used.
When welding with covering gas (CO2 and Argon) it happens that, due to the effect of
the high temperatures, the CO2 separates into O+CO recomposing again in CO2 after
cooling. Therefore, close to the operator‚Äôs respiratory organs there is a considerable
quantity of oxygen and carbon oxide, as well as small quantities of ozone.
Owing to the effect of the base metal (steel) during the welding a development of Iron
Oxide fumes also takes place, but usually the quantity does not exceed the allowed
limits of 10 mg/cu m of air. The welding of galvanised or painted parts is particularly
hazardous.
During welding, vapours are also formed by microscopic particles produced by the
combustion and in part by metal volatilization. At a certain distance from the arc these
vapours condense into very fine particles that in their turn coagulate in larger particles
reaching dimensions that however never exceed 1 micron (1 thousandth of a millimetre).
It has been ascertained that these powders are usually inert, i.e. they do not contain
silica, so they do not cause silicosis risks. These powders, because of their dimensions,
are not treated by natural human filtering devices, determining the risk of
PNEUMOCONIOSIS.
It is important to install appropriate fume exhausts near the point where the operations
take place.
Avoid welding on parts that are painted, galvanised or soiled by grease, oil or other.
It is also necessary to be vary careful when handling freshly welded parts because of
obvious burning hazards caused by the heat of the part.
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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1.5 Safety precautions

1.5.1 Applicability
These precautions are to be applied when carrying out the following activities:
– Installation and Start-up on page 9;
– Operation in programming mode on page 9;
– Maintenance and Repairs on page 10;
– Putting out of service and dismantling on page 10
1.5.2 Operating modes

Installation and Start-up
– When foreseen, connect the robot pneumatic system to the air distribution line and
carefully check that the setting of the system is the specified pressure value: a
wrong setting of the system pressure influences the correct robot motion.
– Install filters on the pneumatic system to collect any condensation.
– The automated welding system is to be installed in the specific areas prepared for
this purpose.
– Electrical connections are to be made on the system with power cut-out, after the
connection has been made, restore all the protective coverings against accidental
contacts.
– The welding system supply voltage and cable cross sections are to be those
specified in the technical documentation of the product.
– Electrical connections to the welding system are to be performed to avoid all
negative effects on the functioning of the system devices caused by inductive or
capacitive interferences.
– Connection between the plant mains and the generator are to be by means of the
power plug provided on the generator.
– The welding system components are not to be modified during installation.
Unforeseen drilling or cutting operations on the system components could
deteriorate the safety level foreseen by the manufacturer.
– Before starting welding activities, make sure that there is no inflammable material
close to the welding protection.
– The system is only to be used for ARC WELDING. Improper use of the system
could cause damage to persons, the user, the fixtures or an environment hazard
risk.
Operation in programming mode

– The torch (integral to the robot wrist) moves with continual motion at a speed of
less than 250 mm/s if the controller is in programming mode and faster than 250
mm/s in automatic mode. Therefore consult the safety precautions regarding robot
handling in the different machine states. These are contained in the chapter
“GENERAL SAFETY PRECAUTIONS" of the Robot.
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Maintenance and Repairs

– Only qualified and authorised persons are allowed to carry out maintenance
operations.
– Maintenance operations on the welding system are only to be carried out with the
system power off. Always check that any interconnected voltages have been
deactivated and if necessary wait before starting to operate for sufficient time for
the discharging of the capacitors present in some system circuits.
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.
– If the protections are removed to replace components, they are to be carefully

reinstalled so as to ensure the safety level foreseen by the manufacturer.
– If components are replaced, the spare parts used are to have the same safety class
and use as those installed (see the spare parts recommended by COMAU
Robotics & Final Assembly).
– After any type of component has been replaced, check the serviceability
(especially for safety devices) before resuming system automatic operation.
– After replacement, any discharged batteries are not to be opened, recharged,
thrown in the fire or other. For the disposal, abide by the current laws in force.
Putting out of service and dismantling

– If present, disconnect the robot pneumatic system from the air distribution mains.
– Disconnect the welding channel pneumatic system from the air distribution mains.
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General maintenance procedures
2. GENERAL MAINTENANCE
PROCEDURES
– Precautions before starting
– Precautions before starting
– Precautions at the end of the maintenance activities
– Maintenance staff
– Equipment necessary
– Torque wrench settings.
The maintenance activities that are not described in this manual are not allowed.
If necessary, require the manufacturer intervention.
2.1 Precautions before starting

– Before performing any maintenance operation, please read carefully the chapter
Wire welding safety precautions, and in particular the paragraph describing the
maintenance operations.
– Any maintenance operation on the Arc Welding System is to be carried out only by
qualified and suitably trained staff.
– Before starting with any maintenance activity, be sure that there are no external
voltages interconnected to the electronic modules and to the Control Unit
components.
– The circuit breaker and the fuses are dimensioned for the foreseen use of the
circuits and, in case of damage, they can be replaced only with equivalent parts
foreseen in the spare parts catalogue. The use of not foreseen protection can
cause danger for the staff and malfunctioning of Arc Welding System.
– Use original spare parts only.
2.2 Precautions before starting

– Any removal or installation of electromechanics components, electronic modules,
connectors, cables or any other component must be performed only with main
switch opened. Disconnect the C5G Control Unit power supply (interconnected
voltage)
– In case of cable replacement re-set the connection of screens previously
disconnected.
– The replaced cable must have the corresponding COMAU code of the
dismissed one.
– Before connection any cable, please refer to the electrical diagrams of the Arc
Welding System.
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– During the installation of new cables, please avoid anomalous bending

radiuses on behalf of the previous ones. Respect possible fastening points
and determined paths already existing.
– If the cable has a cable clamp, check its proper functioning.
2.3 Precautions at the end of the maintenance

activities
– After any maintenance operation, re-set the protection devices previously
removed.
– After any maintenance operation, before to start the normal working cycle, perform
functional checks of the Arc Welding System and in particular of the replaced
component.
– In case of partial or complete Arc Welding System dismantling, different materials
shall be dismantled separately. The Control Unit shall be dismantled in compliance
with the environmental prescriptions in force in the Land where it is installed.
– After the maintenance operations have been terminated, check the correct
functioning of the Arc Welding System. Check the correct execution of some robot
working cycles and the correct functioning of security devices before leaving the
station.
At the end of each maintenance session, the first machine start-up shall
be regarded as a test for the whole plant. During such phase the operator
shall stand outside the Robot range of action but in an position that
allows to check its movements. Moreover, he/she shall have the Teach
Pendant at disposal nearby.
2.4 Maintenance staff

The maintenance staff of the Arc Welding System shall be suitably trained, in order to
be able to use the lifting means properly.
Moreover, the staff shall be warned or trained (in electrics, mechanics and fluidic field)
and therefore aware of the risks associated with electric energy and of the measures to
be taken to safely reach the Arc Welding System.
2.5 Equipment necessary

The component securing systems (screws, nuts) have been standardised, using as few
variations as possible.
The table below indicates the minimum equipment needed for maintenance
interventions of the Arc Welding System.
Tab. 2.1 - Equipment necessary

Preliminary Maintenance Special Maintenance
Suction type cleaner Set of flat tip screwdrivers
Brush with soft bristles Set of cross-tip screwdrivers
Set of cross-tip screwdrivers Set of Allen wrenches (size in mm)
Set of Allen wrenches (size in mm) Set of socket wrenches (size in mm)
Set of socket wrenches (size in mm)
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2.6 Torque wrench settings

While disassembling and re-assembling the components comply with the screw torque
wrench settings. If not otherwise specified, apply the torque corresponding to the screw
typology used.
Do not over tight, as you may damage the thread and therefore the item position
in its seat.
Do not under tight, as it may cause the item falling and/or overheating (and
consequent breaking) due to an incorrect adherence to the dissipating frame.
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3. GENERAL MAINTENANCE
PROCEDURES
This chapter describes the general procedures for maintenance:
– General precautions
– Maintenance operation sheets
– Switching off the power supply
The maintenance activities that are not described in this manual are not allowed.
If necessary require the manufacturer's intervention.
3.1 General precautions

Most maintenance activities for the Arc Welding System are to be performed with power
supplies cut out:
In those cases the wording "Main switch open" is specified in the maintenance sheet.
The procedure is described in par. 3.3 Switching off the power supply on page 16.
If the type of fault allows robot repositioning, it is advised to set it in idle position before
starting the maintenance operations.
After the maintenance operations have been terminated, check the correct functioning
of the Arc Welding System. Check the correct execution of some robot working cycles
before leaving the station.
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3.2 Maintenance operation sheets

The following maintenance sheets describe the maintenance procedures to perform on
the Arc Welding System.
Each sheet contains the following information:
Saying Information description

Status: It underlines the condition that the Arc Welding System has
to assume before performing the maintenance operations.
Material Necessary material for the activity. This represents both the
spare parts and the consumable material.
Equipment Equipment needed for the maintenance operations.
Preliminary procedures It describes the activities to be performed before the
/ notes operating procedure. It explains also the notes that give
deeper information on the activity.
Operating procedure It describes the operating procedure step by step, with
explanation figures, if necessary.
Follow-up procedure It describes the activities to carry out after the operating
procedure. Usually the opposite activity of the preliminary
procedure is shown.
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Preventive Maintenance - Switching off the power supply
3.3 Switching off the power supply

Status: – Not significant
X3A/CAB
Material: – Not required
Equipment: – Not required
X2/IAM3
X310/SDM
X311/SDM
X312/SDM SDM
COMx
X126/SDM
X8 X82
Air from External
X19
X8 X82
Preliminary procedures/ notes

– Most maintenance activities are to be performed with power supplies cut out. In
those cases the wording "Main switch open" is specified in the maintenance
sheet. In order to obtain a complete and secure power sectioning, it is
necessary to section the C5G Control Unit power supply too
(interconnected sections 24V).
– The maintenance activities to be carried out on the cabinet main powering
section shall be performed only after disconnecting the power from the mains. In
those cases the wording "Input voltage off" is specified in the maintenance sheet.
Before switching off the Control Unit, perform the shutdown software
procedure. For a detailed switching off procedure of the C5G Control
Unit, please refer to the related manual.
Operating procedure
Main switch open
a. Disconnect the C5G Control
Unit power supply. With closed
cabinet door, set the Q100 main
switch lever (A) in 0 (OFF)
position.
b. Push the lever to access the

n
eyelet.
c. Insert the padlock in eyelet of

main switch lever.
d. Remove the padlock only at the

end of the maintenance activity.
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Preventive Maintenance - Switching off the power supply
Operating procedure (Continue)

e. Remove the padlock only at the end of the maintenance activity.
f. The padlock is not provided with the electrical cabinet.
When the main switch is open, the X120 connector and the related
cable on the main switch are energized.
n
Input voltage off

a. Cut the electric power as shown in the previous points at the section Main switch
open.
b. Open and lock the main switch on the C5G Control Unit (power supply from
busbar). The padlock is not provided with the Control Unit
c. Remove the padlock only at the end of the maintenance activity.
Follow-up procedure
– Not necessary.
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Maintenance Plan
4. MAINTENANCE PLAN
4.1 Overview
Arc Welding System maintenance is divided in:
– Preliminary Maintenance
– Special Maintenance.
Arc Welding System maintenance is:

– detailed with specific procedures described in Maintenance operation sheets
– graphically summarised in Summary of intervention points.
It is recommended to carry out preventive maintenance activities periodically, to

preserve the Arc Welding System functional features longer.
In case of poor or missing preventive maintenance activities during the warranty
period, this will be regarded as prejudicial to the warranty itself.
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Maintenance Plan
4.2 Summary of intervention points
P4 - S4 P8 - S8
P7 - S7 P6 - S6
P1 - S1 P5 - S5
X3A/CAB
X2/IAM3
X310/SDM
X311/SDM
SDM
P3 - S3
X312/SDM
COMx
X126/SDM
X8 X82
Air from External
P2 - S2
X19
X8 X82
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Preliminary Maintenance
5. PRELIMINARY MAINTENANCE
To guarantee the Arc Welding System proper operating, it is necessary to carry out
preventive maintenance activities periodically, to reduce the amount of faults caused by
the ordinary deterioration over time.
The preliminary maintenance operations shall be performed by qualified staff.

Chap. General maintenance procedures at page 14 describes the preparative
operations on theArc Welding System that are to be performed prior to starting
preliminary maintenance activities.
The maintenance activities that are not described in the following chapters shall
be performed by Comau qualified staff.
.
It is recommended to carry out preventive maintenance activities periodically, to

preserve the Arc Welding System functional features longer.
In case of poor or missing preventive maintenance activities during the warranty
period, this will be regarded as prejudicial to the warranty itself.
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5.1 Preventive maintenance plan

Find in Tab. 5.1 the preventive maintenance plan based on the frequency.
Tab. 5.1 - Preventive maintenance plan

Frequency Activity Ref. ¹
Control Unit
P1
For a detailed description of the operations, see the specific COMAU maintenance
manual.
Robot
P2
manual.
Generator
Before each shaft Generator: coolant level check P3
Once a week Generator: check activation of cooling fan
Once a month Generator: blowing air input filter
For a detailed description of the operations, see the specific Manufacturer's maintenance
manual.
Torch cleaning assembly and lubricator

Torch cleaning assembly and lubricator: Level check of anti-splatter P4
Before each shaft coolant
Torch cleaning assembly and lubricator: Milling check
Group cleaning torch and lubrication : liquid level check
Once a week
Torch cleaning assembly and lubricator: alignment check
manual.
Welding torch
Welding torch: wire-guide head replacement P5
Welding torch: insulator check
Before each shaft
Welding torch: sheath check
Welding torch: check gas nozzle
Once a week Welding torch: check the proper tightening
manual.
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Tab. 5.1 - Preventive maintenance plan

Cable pack
Cable pack: wire-guide nozzle check P6
Cable pack: check feeding rollers (Push Pull)
Once a week Cable pack: sheath check
Cable pack: cable pack check
Cable pack: wire-guide nozzle check
Cable pack: compressed air blowing
Cable pack: tightening of wire feeding rollers
Once a month Cable pack: check of coolant leakage
Marathon Pack bell
Once a week Marathon Pack bell: check and cleaning the internal sheath P7
For a detailed description of the operations, see the specific Manufacturer's manual.
Wire puller
Wire puller: puller rollers check P8
Once a week Wire puller: wire feeding rollers tightening
Wire puller: blowing with compressed air
Wire puller: sheath cleaning
Once a month
Wire puller: wire guide nozzles check
For a detailed description of the operations, see the specific Manufacturer's manual.
¹ The reference is to be found in par. 4.2 Summary of intervention points a pag. 19
AP-AW-C5E-MAN_02.fm
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Preventive Maintenance - Generator
5.2 Generator: coolant level check
X3A/CAB
Material: – Coolant
X310/SDM
X311/SDM
X2/IAM3
(see Spare parts list).

X312/SDM SDM
COMx
Equipment: – Cleaning cloth

X126/SDM
X8 X82
Air from External
X19
X8 X82

– Not necessary
Operating procedure
a. Check visually the coolant level
present, by means of the
indicator (A).
b. If the level is less than or similar

to the minimum level (min), fill
up the coolant as described in
the following points.
c. Open the load cover (B).
d. Fill the coolant, verify the level

on the measurement instrument
(A) and pay attention not to
exceed the maximum level.
e. Close the load cover (B).
f. Remove the coolant on the dirty

parts.
Follow-up procedure
– Not necessary.
For a detailed description of the operations, see the specific Manufacturer's

maintenance manual.
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Preventive Maintenance - Group cleaning torch and lubrication
5.3 Group cleaning torch and lubrication : liquid

level check

Material: – Liquid
X3A/CAB (see Spare parts list).
X2/IAM3
Equipment: – Cleaning cloth

X310/SDM
X311/SDM
X312/SDM SDM
COMx
X126/SDM
X8 X82
Air from External
X19
X8 X82

– Not necessary
Operating procedure
a. Check visually the liquid level
present in the tank, by means of
the indicator (A).
b. If necessary fill up the liquid as

described in the following
points.
c. Unscrew and remove the tank

(A).
d. Fill the liquid in the tank (A) and

pay attention not to exceed the
maximum level.
e. Screw again the tank(A) on the

cleaning and lubricator
assembly (B).
f. Remove the liquid on the dirty

parts.
Follow-up procedure
– Not necessary.
For a detailed description of the operations, see the specific Manufacturer's

maintenance manual.
AP-AW-C5E-MAN_05b.fm
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Special Maintenance
6. SPECIAL MAINTENANCE
To replace damaged items, follow the procedures described in the maintenance sheets.
The special maintenance operations shall be performed by qualified staff.

Chap. General maintenance procedures at page 14 describes the preparative
operations on the Arc Welding System that are to be performed prior to starting
special maintenance activities.
The maintenance activities that are not described in the following chapters shall
be performed by Comau qualified staff.
AP-AW-C5E-MAN_03.fm
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Special Maintenance
6.1 Special maintenance plan

Find in Tab. 6.1 the special maintenance plan based on the frequency.
Tab. 6.1 - Special maintenance plan

Frequency Activity Ref. ¹
Control Unit
S1
manual.
Robot
S2
manual.
Generator
S3
manual.

Once a month Mill replacement S4
manual.

Once a week Welding torch: gas nozzle replacement S5
After failure Welding torch: replacement
manual.
Cable pack
After failure Outfitting cable package replacement S6
Marathon Pack bell
After every bulk drum Marathon Pack bell: sostituzione anima interno guaina P7
replacement
manual.
Wire puller
AP-AW-C5E-MAN_03.fm
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Special Maintenance
Tab. 6.1 - Special maintenance plan

After failure Wire puller: rollers replacement P8
manual.
¹ The reference is to be found in par. 4.2 Summary of intervention points a pag. 19
AP-AW-C5E-MAN_03.fm
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Special Maintenance - Welding torch
6.2 Welding torch: replacement

Status: – Power off
Material: – Removable welding torch
X3A/CAB
X2/IAM3
X310/SDM
Equipment: – -
X311/SDM
X312/SDM SDM
COMx
X126/SDM
X8 X82
Air from External
X19
X8 X82

– Enter the unit of the Arc Welding System in a secure manner.
See the complete machine manual (welding unit) for details on the
access procedure due to maintenance.
Operating procedure
a. Disconnect the three
connectors B present on the
torch body A.
a. Screw the cover C.
b. Unscrew the ring nut D that

fasten the cable pack to the
welding torch.
AP-AW-C5E-MAN_07.fm
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Operating procedure (Continue)
c. Unscrew the fixing screw E of
the torch to the anticollision
assembly F.
d. Remove the Centering device

G and the sleeve bushing H.
e. Remove the torch body A

anticollision assembly F.
f. Unscrew the two fixing screws I

and remove the blocking device
J.
g. Unscrew the blocking screw K

and remove the blocking device
L.
h. Disconnect the tube M from the

hole N on the torch.
i. Remove the torch from the

wiring end.
j. Carry out the assemblying of a

new torch A following the
procedure from the last step to
the first one.
k. Before carrying out the

reassemblying, check the
presence of OR gaskets on the
torch body A.
For more details see also the FRONIUS manufacturer’s manual

FRONIUS.
AP-AW-C5E-MAN_07.fm
00/0312 29
Follow-up procedure
– Check the correct functioning of the welding torch, controlling that the first
working cycles are performed properly.
AP-AW-C5E-MAN_07.fm
30 00/0312
Special Maintenance - Outfitting
6.3 Outfitting cable package replacement

Material: – Outfitting
X3A/CAB
X2/IAM3
X310/SDM

X311/SDM
X312/SDM SDM
COMx
X126/SDM
X8 X82
Air from External
X19
X8 X82

– Enter the cell of the Arc Welding System in a secure manner.
See the complete machine manual (welding cell) for details on the
access procedure due to maintenance.
Operating procedure
a. Carry out hte replacement
procedure of the welding torch
(see paragraph Welding torch:
replacement).
b. Remove the cable pack

connections A from the wire
puller assembly
Follow-up procedure
– Not necessary
AP-AW-C5E-MAN_09.fm
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Spare parts list
7. SPARE PARTS LIST

This chapter contains the spare parts list divided according to the machine part:
– COMAU C5G Control Unit
– SMART5 RobotNM 16-3.1COMAU
– Generator
– 3x500V Autotransformer for generator
– Wire feeder assembly
– Weld torch
– Anti-collision assembly
– Tool Master
– Location point
– TCP Check
– Mechanical torch cleaning assembly
– Marathon Pack bell assembly
AP-AW-C5E-MAN_17.fm
32 00/0312
Spare parts list
Tab. 7.1 - COMAU C5G Control Unit
Position Comau code Description
A CR17132680 HSK5 C5G option for Control Unit
For a complete spare parts list of the Control Unit, see the C5G Control Unit maintenance
manual.
AP-AW-C5E-MAN_17.fm
00/0312 33
Spare parts list
Tab. 7.2 - SMART5 RobotNM 16-3.1COMAU
CR16660580 Cable pack 8,25 m (27.06 ft)
B CR19078048 Wire buffer set CMT
For a complete spare parts list of the Control Unit, see the Robot SMART5 NM 16-3.1
maintenance manual.
AP-AW-C5E-MAN_17.fm
34 00/0312
Spare parts list
Tab. 7.3 - Generator

FRONIUS TPS4000 SER CMT Generator assembly - Comau Code CR16659280
A CR19070002 TPS 4000 CMT Synergic Fronius Generator
B CR19078046 FK 4000-R cooling assembly with flow switch

C CR19078033 i-kit local net passive distributor
D CR19060573 Gateway interface

RCU 5000i Terminal kit - Comau Code CR16657680
E CR19076014 Distance control RCU5000i with cable 5m
Cables for FRONIUS generator
CR16041460 Serial cable, length 7 m (23 ft)
CR16041461 Serial cable, length 12 m (39.4 ft)

F
CR16041464 Serial cable, length a 27 m (88.6 ft)
CR16041465 Serial cable, length 32 m (105 ft)
G 19060484 Ground cable 95 mm², 10 m (32.8 ft)
AP-AW-C5E-MAN_17.fm
00/0312 35
Spare parts list
Tab. 7.4 - 3x500V Autotransformer for generator
A CR19061436 3x500V Autotransformer
AP-AW-C5E-MAN_17.fm
36 00/0312
Spare parts list
Tab. 7.5 - Wire feeder assembly
A CR19076011 VR7000 KIT Wire puller assembly

CR16655380 Rollers kit for wire with diameter 1 mm (0.039 in) in AL/CUSI3
B CR16655480 Rollers kit for wire with diameter 1 mm (0.039 in) in Fe
AP-AW-C5E-MAN_17.fm
00/0312 37
Spare parts list
Tab. 7.6 - Weld torch

Torch body kit
CR19072009 Robacta torch body kit RA280 angle22°
CR19072010 Robacta torch body kit RA280 angle 36°

A
CR19078049 Robacta torch body kit Drive CMT PAP
Tab. 7.7 - Anti-collision assembly
AP-AW-C5E-MAN_17.fm
38 00/0312
Spare parts list
Tab. 7.8 - Tool Master
A 81783801 Tool Master (Calibrated tool assembly) L=117
Tab. 7.9 - Location point
A 166542200400 Location point
AP-AW-C5E-MAN_17.fm
00/0312 39
Spare parts list
Tab. 7.10 - TCP Check

TCP Check Code 16654480
A 16654360 TCP Check cable, length 10 m (32.8 ft)
B 19061423 Optical sensor
C CR19061439 T splitter
AP-AW-C5E-MAN_17.fm
40 00/0312
Spare parts list
Tab. 7.11 - Mechanical torch cleaning assembly
A
C

Robacta Reammer Torch Cleaner with 00 mm (27.56 in) column Code 16689494
A 19060480 Robacta Reamer Torch Cleaner device
B 19060481 Support column, height 700 mm (27.56 in)
C CR19074003 Electrolyte fluid (0.5 litres (16.90 oz container)

CR19074019 Milling for RA280 Torch with nozzle diam. 12 mm
D
CR16654180 Digital I/Os cable, length 8 meters (26.25 ft)
CR16654280 Digital I/Os cable, length 15 meters (49.21 ft)

E
CR16655980 Digital I/Os cable, length 8 meters (26.25 ft) (Double Robot)
CR16656080 Digital I/Os cable, length 15 meters (49.21 ft) (Double Robot)
AP-AW-C5E-MAN_17.fm
00/0312 41
Spare parts list
Tab. 7.12 - Marathon Pack bell assembly

Circular cover Marathon pack
19060479 Marathon Pac sheath length (11.48 ft)
CR19076017 Marathon Pac sheath length 5 m (16.4 ft)
A
CR19076009 Marathon Pac sheath length 6,35 m (20.83 ft)

Octagonal cover Marathon pack
19060479 Marathon Pac sheath length 3,5 m (11.48 ft)

A CR19076017 Marathon Pac sheath length 5 m (16.4 ft)
AP-AW-C5E-MAN_17.fm
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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

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SMA RT NS - E le nco ma nu al i

Arc Welding System (CMT

Maintenance for System GaTeWayFRonius (GTWFR) serial

Copyright © 2011 by COMAU - Date of publication 07/2011

2. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

3. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14

4. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

5. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

6. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

7. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32

Comau Arc Welding System – Technical specifications

These manual must be integrated with the following documents:

Comau C5GControl Unit – Technical specifications

Fronius – Transpulse Synergic 4000, 5000 (Generator use instruction)

Limits on the manual content

This symbol indicates operating procedures, technical information and

This symbol indicates operating procedures, technical information and

This symbol indicates operating procedures, technical information and

This symbol indicates that entry is forbidden to persons wearing a pace-maker.

The symbol calls the attention on avoiding environmental contamination and

1. WIRE WELDING SAFETY

Entry is forbidden to persons wearing a pace-maker.

1.2 Information regarding the process

1.3 Protection of the eyes and the body

Tab. 1.1 - DIN classes of standard adiactinic glass

1.4 Protections against gas, fumes and fire

1.5 Safety precautions

1.5.2 Operating modes

Operation in programming mode

Maintenance and Repairs

– If the protections are removed to replace components, they are to be carefully

Putting out of service and dismantling

2.1 Precautions before starting

2.2 Precautions before starting

– During the installation of new cables, please avoid anomalous bending

2.3 Precautions at the end of the maintenance

2.4 Maintenance staff

2.5 Equipment necessary

Tab. 2.1 - Equipment necessary

2.6 Torque wrench settings

3.1 General precautions

3.2 Maintenance operation sheets

Saying Information description

3.3 Switching off the power supply

Preliminary procedures/ notes

b. Push the lever to access the

c. Insert the padlock in eyelet of

d. Remove the padlock only at the

Operating procedure (Continue)

f. The padlock is not provided with the electrical cabinet.

Input voltage off

c. Remove the padlock only at the end of the maintenance activity.

Arc Welding System maintenance is:

It is recommended to carry out preventive maintenance activities periodically, to

4.2 Summary of intervention points

The preliminary maintenance operations shall be performed by qualified staff.

It is recommended to carry out preventive maintenance activities periodically, to

5.1 Preventive maintenance plan

Tab. 5.1 - Preventive maintenance plan

Torch cleaning assembly and lubricator

Tab. 5.1 - Preventive maintenance plan

¹ The reference is to be found in par. 4.2 Summary of intervention points a pag. 19

5.2 Generator: coolant level check