SMART NS - Elenco manuali

Comau Robotics
Instruction Handbook

Arc Welding System (TPS Fronius

generator)

Integration, Transport and Installation for System

GaTeWayFRonius (GTWFR) serial connection, with
SMART5 Six Robot

CR00757673-en_00/2014.01
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 © 201-20141 by COMAU - Date of publication 01/2014

 Summary

SUMMARY

1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. INSTALLATION SUMMARIZING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15

3. INSTALLATION SUGGESTIONS, LIFTING AND HANDLING PROCEDURE . . . . . ...17

Staff in charge for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation environment requirements and suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Network power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C5G Installation dimensions and spaces (without air conditioner). . . . . . . . . . . . . . . . . . . . . 20
Installation dimensions and spaces C5G (with Air conditioner) . . . . . . . . . . . . . . . . . . . . . . . 21
Control Unit handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C5G lifting overview with packing in closed container . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Lifting overview C5G without packaging, on pallet (europallet 1200 x 800 mm) . . . . . . . . .23
Lifting overview C5G without packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Robot support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Torch cleaning assembly and lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. ARC WELDING SYSTEM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . ...26

Control Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Robot holder (optional) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Robot installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Generator installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Outfitting installation on Robot SMART5 Arc4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preparation of the Robot wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SupAnti-collision kit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Summary

Superior cable package installation (from torch to wire feeder) . . . . . . . . . . . . . . . . . . . . . . . 31

Torch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wire feeder installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
connection pack kit installation (from wire feeder to robot base) . . . . . . . . . . . . . . . . . . . . . . 35
Mechanical milled torch cleaning assembly installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Tool Master installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Balancer installation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TCP Check installation (optional) for alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TCP Check installation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Location point installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5. CONNECTION OF ARC WELDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..46

Cables installation hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connection between Control Unit and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connection between Control Unit and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
C5GSerial cable - welding generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connection between Control Unit and torch cleaning assembly . . . . . . . . . . . . . . . . . . . . . . . . 53
Digital I/O cableC5G - torch cleaning assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connection between generator and wire feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Connection between Control Unit and safeties, line Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connection between C5G and TCP Check (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connections to the power supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Control Unit connection to the electric power supply line. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Generator connection to the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Robot and torch cleaning assembly connection to the compressed air distribution line . . . . 68
Robot connection to the welding gas distribution network . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
RS422 Serial cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6. CONTINUOUS WIRE WELDING SYSTEM ACTIVATION . . . . . . . . . . . . . . . . . . . . . ..73

Precautions to be taken before activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connectors pin-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Welding wire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Installation of the holder on the Robot (Aspo) and coil insertion . . . . . . . . . . . . . . . . . . . . . . 75
Marathon Pac and cover positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Wire insertion in the wire feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Bleeding the water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SMART-ARC and optional software modules activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Robot motions programming hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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 Summary

7. CONTINUOUS WIRE WELDING SYSTEM DEACTIVATION . . . . . . . . . . . . . . . . . ...80

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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 1500 (Wire-feeder service installation)
– VR 1500 (Wire-feeder blowing assembly instructions)
– VR 1500 (Wire-feeder cover assembly instructions)
– VR 1500 (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 seam
search).
– Trolley
– Autotransformer
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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 Preface

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.

This symbol indicates operating procedures, technical information and precautions that
if not observed and/or performed correctly could cause damage to the equipment.

This symbol indicates operating procedures, technical information and 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

In this chapter are shown the following topics:
– 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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 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.

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 12 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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Wire welding safety precautions

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.
11 For arc welding in protected environment with current intensity
up to 250 A
Electrodes that have a very strong luminous effect.
12 For arc welding in protected environment with current intensity
up to 300 A
To weld parts with very thick walls.
13 For arc welding in protected environment with current intensity
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’s 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.

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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.

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 13;
– Operation in programming mode on page 14;
– Maintenance and Repairs on page 14;
– Putting out of service and dismantling on page 14

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.

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Wire welding safety precautions

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.

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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 Installation summarizing table

2. INSTALLATION SUMMARIZING TABLE

The table below summarises the installation sequence for the Arc Welding System.
The table can be used as a check list for the progress of the installation activities.
In this case it is advised to copy the table below and fill in the‚ ”Done"column at the end
of each operation.

Tab. 2.1 - Installation summarizing table

Step Operation Done

Installation environment requirements and suggestions
1 Staff in charge for the installation
2 Equipment required
3 Installation environment requirements and
suggestions
4 Network power supply
Handling and transport procedures
5 Control Unit
6 Robot
7 Robot support
8 Generator
9 Torch cleaning assembly and lubricator
Installation procedure
10 Control Unit Installation
11 Robot holder (optional) installation
12 Robot installation
13 Generator installation
14 Outfitting installation on Robot SMART5 Arc4
15 Mechanical milled torch cleaning assembly
installation
16 Tool Master installation
17 Balancer installation (optional)
18 TCP Check installation (optional) for alignment
check
19 Location point installation
Components connection
20 Connection between Control Unit and Robot
21 Connection between Control Unit and Generator
22 Connection between generator and wire feeder
23 Connection between Control Unit and safeties, line
Ethernet
24 Connection between C5G and TCP Check (optional)
25 Control Unit connection to the electric power supply
line

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Installation summarizing table

Tab. 2.1 - Installation summarizing table (Continue)

Step Operation Done

26 Generator connection to the mains power supply
27 Robot and torch cleaning assembly connection to
the compressed air distribution line
Activation procedure
28 Precautions to be taken before activation
29 Power-on
30 Welding wire installation
31 Bleeding the water circuit
32 SMART-ARC and optional software modules
activation

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 Installation suggestions, lifting and handling procedure

3. INSTALLATION SUGGESTIONS, LIFTING

AND HANDLING PROCEDURE
This chapter contains:

– Staff in charge for the installation

– Equipment required.
– Installation environment requirements and suggestions
– Network power supply
– Control Unit
– Robot
– Robot support
– Generator
– Torch cleaning assembly and lubricator.

3.1 Staff in charge for the installation

Staff in charge for the installation should be instructed to operate correctly with lifting
devices.
Furthermore the staff must be a person educated (in electrical, mechanical and fluidic
fields) and therefore must know the dangers deriving from electric power and the
precaution to be adopted to perform connection on the power supply and the
interconnection signals (security signals and control signals)

3.2 Equipment required

The following equipment is required for the installation of the Arc Welding System:
– Lifting system (crane)
– Forklift
– Standard workshop equipment such as screwdrivers, wrenches, etc.

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Installation suggestions, lifting and handling procedure

3.3 Installation environment requirements and

suggestions
The integrator is to provide and install the following systems and structures:
– welding fumes exhaust system
– install perimeter protections, access doors
– install protective shields for the eyes (see Tab. 1.1 - DIN classes of standard
adiactinic glass on page 12) and against sparks caused by the welding process.
Furthermore, the integrator shall comply to the requirements of current directives and
standards so as to install the Arc Welding System correctly and safely in a cell.

The Arc Welding System 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

The power supply cable connection on the main switch of the C5G Control Unit can be
upstream or downstream.

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3.4 Network power supply

Tab. 3.1 - Summary of network power supply required for Arc

application

Device Electric power Compressed air Gas Notes

See Control Unit
C5GControl
3 kVA / 4.5 A --- --- “Transport and
Unit
Installation" manual
See details in Tab. 5.1
12.2 kVA [TPS4000] - Conductor section
Generator --- ---
13.1 kVA [TPS5000] and protections on
page 65.
Torch Cleaning See details in Tab. 5.2
assembly and --- 7 l / second --- - Splitter Compressed
lubricator air supply
Welding torch characteristics on
--- 1800 Nl / minute --- page 68.
production
procedure --- --- According to need ---

3.5 Control Unit

The Robot and Control Unit customising for theArc Welding System does not change
the standard lifting procedure.

The Robot and Control Unit lifting and handling procedures are contained in the related
manuals. The instruction manuals are indicated in paragraph Reference documents.

In the following chapter are described:

– C5G Installation dimensions and spaces (without air conditioner)
– Installation dimensions and spaces C5G (with Air conditioner)
– Control Unit handling

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3.5.1 C5G Installation dimensions and spaces (without air

conditioner)

Tab. 3.2 - Overall dimensions

C5G + rising
Quote C5G standard Notes
socket
A 800 mm (31.49 in) ---
B 1110 mm (43.70 in) --- ---
B’ --- 1210 mm (47.63 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) Minimum dimension to guarantee the ventilation.
F 200 mm (7.87 in) Minimum dimension to guarantee the ventilation.

Tab. 3.3 - Weight

Weight
In closed container 240 kg (529 lb)
On pallet 195 kg (430 lb)
Without packaging 175 kg (386 lb)

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3.5.2 Installation dimensions and spaces C5G (with Air

conditioner)

Tab. 3.4 - Overall dimensions

C5G + rising
Quote C5G standard Notes
socket
A 800 mm (31.49 in) ---
B 1450 mm (57.09 in) --- ---
B’ --- 1550 mm (61.02 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) Minimum dimension to guarantee the ventilation.
F 200 mm (7.87 in) Minimum dimension to guarantee the ventilation.

Tab. 3.5 - Weight

Weight
In closed container 275 kg (606 lb)
On pallet 230 kg (507 lb)
Without packaging 210 kg (463 lb)

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3.5.3 Control Unit handling

In order to move the system packed on a pallet use a forklift or a crane.

Arrange ropes with breaking loading and slope adequate to the weight to be lifted. The
forklift track and the crane must be adequate to the weight to be lifted.
In order to guarantee the correct balance during the operation, use only the suggested
anchor points.

Different lifting methods are described:

– C5G lifting overview with packing in closed container
– Lifting overview C5G without packaging, on pallet (europallet 1200 x 800 mm)
– Lifting overview C5G without packaging

3.5.3.1 C5G lifting overview with packing in closed container

Information for lifting

Weight to be lifted 240 kg (529 lb) / 275 kg (606 lb)

Lifting with crane (A)

Ropes quantity 2
Ropes length (approximate): 6000 mm

Lifting with forklift (B)

Forks length: >1000 mm
Pitch forks: 530 mm

Operating procedure
See the operations detail on the specific
manual of the Control Unit.

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3.5.3.2 Lifting overview C5G without packaging, on pallet (europallet 1200

x 800 mm)
Information for lifting
Weight to be lifted 195 kg (430 lb) / 230 kg (507 lb)

Lifting with crane (A)

Ropes quantity 4
Ropes length (approximate): 1000 mm
Eyebolts on C5G: 4 x M12 female

Lifting with forklift (B)

Forks length: >1000 mm
Pitch forks: 530 mm

Operating procedure
See the operations detail on the specific
manual of the Control Unit.

3.5.3.3 Lifting overview C5G without packaging

Information for lifting
Weight to be lifted 175 kg (386 lb) / 210 kg (463 lb)

Lifting with crane (A)

Ropes quantity 4
Ropes length (approximate): 1000 mm
Eyebolts on C5G: 4 x M12 female

Lifting with forklift (B)

Forks length: >900 mm
Pitch forks: 620 mm
Forks inlet holes: 175 mm
Danger: Do not use the transpallet because it
generates overturning risk and damage the cabinet.

Operating procedure
See the operations detail on the specific
manual of the Control Unit.

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3.6 Robot
Dimensions and Robot weight outfitted with the Arc Welding System differ from the
standard robot as shown in the following Tab. 3.6.
The motion procedures do not change from the not outfitted model. Pay attention not to
damage the outfitting with the lifting ropes.

The overall dimensions, the motion procedures and robot transport are described in the
Robot installation manual (see paragraph Reference documents).

Tab. 3.6 - Dimensions and weight increase

Outfitting dimension increase 0 mm.

The outfitting is included in the superior overall (A)
Weight increase + 20 kg (44.01lb)

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3.7 Robot support

Robot support bench lifting and handling procedures are contained in the Robot manual.
The instruction manuals are indicated in paragraph Reference documents

3.8 Generator

Generator lifting and handling procedures are contained in the related manuals. The
instruction manuals are indicated in paragraph Reference documents

3.9 Torch cleaning assembly and lubricator

The torch cleaning assembly and lubricator lifting and handling procedures are
contained in the related manuals. The instruction manuals are indicated in paragraph
Reference documents

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4. ARC WELDING SYSTEM COMPONENTS

INSTALLATION
This chapter contains:

– Control Unit Installation

– Robot holder (optional) installation
– Robot installation
– Generator installation
– Outfitting installation on Robot SMART5 Arc4
– Mechanical milled torch cleaning assembly installation
– Tool Master installation
– Balancer installation (optional)
– TCP Check installation (optional) for alignment check
– TCP Check installation (optional)
– Location point installation.

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4.1 Control Unit Installation

Information for the proper installation of the Control Unit (type of fastening to perform,
material to be used, clamping couples, ...), are described in the C5G Control Unit
manual. See the relevant instructions manual indicated in Reference documents.

4.2 Robot holder (optional) installation

Information for the proper installation of the Robot holder (type of fastening to perform,
material to be used, clamping couples, ...), are described in the Robot SMART5
Arc4manual. See the relevant instructions manual indicated in Reference documents.

4.3 Robot installation

Information for the proper installation of the Control Unit (type of fastening to perform,
material to be used, clamping couples, ...), are described in the in the Robot SMART5
Arc4manual. See the relevant instructions manual indicated in Reference documents.

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4.4 Generator installation

Operating procedure
a. The bearing surface where the generator is to be installed is to be able to support
the weight and must not be sloped.

The generator weight is about 37 kg (81.56 lb) and must be handled

with care, by using the big upper handle.

b. The generator may be supplied

with the optional trolley.
In this case, the generator is
already positioned on the
trolley.

c. If the generator does not have

the trolley, place the generator
directly on the floor.
Be sure that the power
generator is electrically
insulated from the welding
ground.

d. Check the level of the coolant in the pump.

The information for the checking and topping up of the coolant level is contained in the
Generator manual. See the relevant instructions manual indicated in Reference
documents.

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4.5 Outfitting installation on Robot SMART5 Arc4

In the following paragraphs are shown the installation procedures:
– Preparation of the Robot wrench
– SupAnti-collision kit installation
– Superior cable package installation (from torch to wire feeder)
– Torch installation
– Wire feeder installation
– connection pack kit installation (from wire feeder to robot base)

4.5.1 Preparation of the Robot wrench

Operating procedure
a. Attach the ring (A) on the rear
part of the robot wrist (C) using
the 2 provided screws.

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Operating procedure (Continue)

a. Attach the flange adaptor to the
wrist robot flange with the 4
available screws and a Loctite
242 weak strength threadlocks

4.5.2 SupAnti-collision kit installation

Operating procedure
a. Position manually the
anticollision assembly (A) on
the flange adaptor (B)

b. Fasten the anticollision

assembly (C) using the
supplied screws.

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Operating procedure (Continue)

c. Set the seal (D) on the
anticollision assembly (A).

4.5.3 Superior cable package installation (from torch to wire

feeder)

Operating procedure
a. Position the cable package (A)
passing it in sequence inside.
the:

a.1 Anticollision robot wrist (B).

a.2 Guide ring (C) on the robot

wrist.

a.3 Hole (D) to put the outfitting in

the installation zone of the wire
puller.

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4.5.4 Torch installation

Operating procedure
a. Position the Torch (A) on the
anticollision (B).

b. Insert the threaded bushing (C)

on the Torch.

c. Screw the bushing with the

adequate wrench (D).

d. Insert the bushing (E) and

screw it manually.

4.5.5 Wire feeder installation

Operating procedure
a. Position the holder (A) nearby
the fastening holes (B) on the
robot.

b. Hold with one hand the holder

and screw the anterior two
fixing screws (C) using a Loctite
242 weak strength threadlocks .

c. Screw the two fixing rear

screws (D) using a Loctite 242
weak strength threadlocks.

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Operating procedure (Continue)

d. On the working bench, position
the wire puller assembly (E)
with the inferior part upward.

e. Position the plate (E) on the

wirepuller assembly.

f. Screw the 2 rear fixing screws

(G).

g. Position the wirepuller unit (E)

on the holder (A).

h. Screw the 4 rear fixing screws

(H).

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Operating procedure (Continue)

i. Insert the washer (J) and screw
the reducer (I) on the s "AIR IN"
joint present on the wirepuller
assembly (E)

j. screw the reducer (I).

k. Position the X92 robot

connector (K) in the foreseen
seats of the holder (A).

l. Screw the 4 connector fixing

screws (L).

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4.5.6 connection pack kit installation (from wire feeder to robot

base)

Operating procedure
a. Position the holder (A) on the
robot body.

a. Attach the flange adaptor to the

wrist robot flange with the 4
available screws and a Loctite
242 weak strength threadlocks

b. Screw the two holder fixing

screws (B) using a Loctite 242
weak strength threadlocks.
c. Position the signal exchange
assembly (C) on the holder (A).

d. Screw the 3 fixing screws.(A) of

the holder.

e. Position the holder (E) on the

inferior collar (F) .

f. Screw the 2 fixing screws of the

holder (G).

g. Insert the wiring corrugated (H)

in the two semicollars (I).

h. Join the two semicollars

components (I) and position it
on the holder (E).

i. Screw the 2 fixing screws (J).

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Operating procedure (Continue)

j. Unscrew the 2 screws and
remove the holder (K).

k. Set the wiring corrugated (H) as

shown in the figure, in order to
eject it from the robot base.

l. Insert the corrugated (H) in the

two semicollars (L).

m. Join the two components of the

semicollar (L) and position it on
the robot axis 1.

n. Screw the two fixing screws

(M).

o. Position the cover (N).

p. Screw the 4 fixing screws (O)

using using a Loctite 242 weak
strength threadlocks.
q. Position the two plates (P) and
(Q) on the robot base.

r. Screw the 4 fixing screws (R)

using using a Loctite 242 weak
strength threadlock.

s. Insert the corrugated (H) in the

semicollars (S).

t. Join the two components of the

semicollar (S) and position it on
the holder on the Robot base.

u. Screw the 2 fixing screws (T).

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4.6 Mechanical milled torch cleaning assembly

installation

Fig. 4.1 - Overall dimensions (Bottom view and front view)

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Operating procedure
a. If the column is present, lock it
on the pavement with adequate
brackets, using the passing
holes (A) (diam. 14 mm) as
shown in the figure.

For the type of blocks to

be used and the
tightening torque values,
see the manual of the
manufacturer.

b. Attach the torch cleaning and

lubricator assembly on the
column, passing holes (A)
(diam. 8 mm) as shown in the
figure.

If there is no column it is
necessary to fix the torch
cleaning and lubricator
assembly on an adequate
holder.

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Operating procedure (Continue)

c. Unscrew the ring nut (B) and fill
the tank (B) with the electrolytic
liquid provided with the option.
For the typology of
electrolytic fluid, please
see the manufacturer
manual

d. Re-screw the ring nut (B)

e. To adjust the electrolytic fluid

quantity:

e.1 remove the cover (D)

e.2 screw the regulation screw (E)

clockwise to increase, and
counterclockwise to reduce,

e.3 re-locate the cover (D).

Check that the mill on the torch cleaning assembly, is coherent with the torch type
installed on the Robot.

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4.7 Tool Master installation

Operating procedure
a. Insert the Tool Master in the threaded hole on robot axis 6 as indicated in figure
(A).

b. Perform the TPC (Tool Centre Point) calculation / check procedure

To calculate the user TCP see SmartArc manual.

c.Once the check / calibration operations has been carried out, remove the
Tool Master from the robot wrist.

If the robot is SMART5 Arc4, the Tool Master values to assign for the
Tool calculation are:
X = 154 Y=0 Z=7

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4.8 Balancer installation (optional)

Operating procedure
a. Fasten the cradle in an intermediate point of the bundle to allow the robot
maximum freedom of movement.
b. The balancer is to be fastened
to a stable point, sufficiently
robust to support the weight of
the balancer and the bundle,
and higher than the cradle
coupling point. Maximum reach:
4-6 kg.

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4.9 TCP Check installation (optional) for alignment

check

The functioning of the TCP Check could be impaired if the support it is secured to is
electrically connected with the welding ground. If necessary, install commercial isolators
between the TCP Check plate and the support column.

The following paragraphs describe the TCP Check system (optional) installation
procedures to perform the alignment check.
Depending on the adopted solution, perform one of the following procedures:
– TCP Check installation (optional)
– Location point installation.

4.9.1 TCP Check installation (optional)

Operating procedure
a. To attach the TCP Check there
are 4 holes for TCEI M8x25
screws.

P1 P2

Plan view

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Operating procedure (Continue)

b. If the holder column is present
the TCP Check can be directly
attached on the available plate
with 4 M8 threaded holes.

Plan view
a. To attach the column on the
pavement there are 4 passing
holes with diameter 13 mm.

For the type of blocks to

be used and the
tightening torque values,
see the manual of the
manufacturer.

Plan view

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Arc Welding System components installation

Operating procedure (Continue)

b. In the figure the maximum
dimensions of the column.

If the column is not

present, it is necessary to
attach the TCP Check on
the appropriate holder.

Frontal view
c. Attach the TCP check on the
column. Screw the fixing
screws clamping them to the
right tightening torque.

For the type of screws to

be used and the
tightening torque values,
see the manual of the
manufacturer.

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4.9.2 Location point installation

Operating procedure
a. Fasten the location point in an
appropriate place (on fixture or
on column).

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5. CONNECTION OF ARC WELDING SYSTEM

This chapter contains:
– Cables installation hints
– Connection between Control Unit and Robot
– Connection between Control Unit and Generator:
• C5GSerial cable - welding generator
• Ground cable.
– Connection between Control Unit and torch cleaning assembly:
• Digital I/O cableC5G - torch cleaning assembly
– Connection between generator and wire feeder
– Connection between Control Unit and safeties, line Ethernet
– Connection between C5G and TCP Check (optional)
– Connections to the power supply networks:
• Control Unit connection to the electric power supply line
• Generator connection to the mains power supply
• Robot and torch cleaning assembly connection to the compressed air
distribution line.
– RS422 Serial cable

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5.1 Cables installation hints

The connection cables used in the Arc application are to be installed with special care,
paying attention to the following advice:
– protect the cables with appropriate coverings (standard IEC 60204-1)
– arrange the cables in a tidy manner and do not make coils to recover the excessive
length
– avoid power cables and communication cables being too close to each other
– do not use cables that are not foreseen in the Arc application.

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5.2 Connection between Control Unit and Robot

Status: – Power off

Material: – Motor cable
– Encoder cable
– Ground cable
– 8 mm (0.314 in)spark plug wrench
ASM

Equipment:
– Medium / big flat-head screwdriver

Preliminary procedures / notes

Details of the connections are contained in the relevant Control Unit and
Robot Installation manuals.

Operating procedure
Connections overview (representative image)

C5G ROBOT CONTROLLER CIP ROBOT PANEL

X93 X124

Ax1
X60

X10

X30
X62

X90
Ax2
X1

X2

Ax3
Ax4
AIR
Ax5
Ax6
X90

ENCODER/BRAKE CABLE

GROUND CABLE
MOTOR CABLE

Follow-up procedure
– Not necessary.

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5.3 Connection between Control Unit and Generator

Status: – Power off

Material: – Ground cable
– The described cables are provided
with the application kit.
– Wrench, depending on the screw type
ASM

Equipment:
used for the locking of the ground
cable eyelet.

Preliminary procedures / notes

– The cables indicated are supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
– The following procedures and connections are required:
• C5GSerial cable - welding generator
• Ground cable.

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5.3.1 C5GSerial cable - welding generator

Operative procedure - Serial cable

COM2
AMS-APC820
Rs422

C5G ROBOT CONTROLLER CIP

X93 X124
X60

X10

X30
X62

X90

SERIAL CABLE

a. The serial cable must exit from the Control Unit through the X90 cable entry
connector on the CIP panel.
b. The cable ends inside the
cabinet is provided with a
connector linked on the COM2
of the AMS-APC820 (A)
module.

c. The other cable end is provided

with a SUB-D 9 pin connector
(B) that must be connected to
the RS422 connector on the
generator.

d. Screw the connector screws

(B).

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Operative procedure - Serial cable (Continua)

For a multi machine:

e. connect the end of the second serial cable to the RS422 connector on the
generator.

f. connect the end of the second serial cable on the CG5-SL module on the Control
Unit.

SERIAL CABLE

Rs422
C5G-SL COM2
AMS-APC820
Rs422

C5G ROBOT CONTROLLER CIP

X93 X124
X60

X10

X30
X62

X90

SERIAL CABLE

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5.3.2 Ground cable

Operative procedure - Welding ground cable

a. The cable must be connected to nearest the metal point to the welding zone.
b. Connect the TCP Check cable
on connector (A) of the splitter.
Position the ground cable
avoiding overlaying of
spires.

c. Connect the other ground cable end to the point previously defined on the
equipment, using the provided eyelet insulated cable lugs (hole diameter 12mm).
d. Carry on the system impedance calibration.
The procedure is described in the Power generator manual. See the
relevant instructions manual indicated in Reference documents.

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5.4 Connection between Control Unit and torch

cleaning assembly

Status: – Power off

Material: – Digital I/O cable
– The described cables are provided
with the application kit.
– Wrench, depending on the screw type
ASM

Equipment:
used for the locking of the ground
cable eyelet.

Preliminary procedures / notes

– The cables indicated are supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
– The following procedures and connections are required:
• Digital I/O cableC5G - torch cleaning assembly.

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5.4.1 Digital I/O cableC5G - torch cleaning assembly

Operative procedure - Digital I/O cable

C5G ROBOT CONTROLLER CIP

X93 X124
X60

X10

X30
X62

X90
X8

a. The digital I/O cable electrically

connects the torch cleaning and
lubricator assembly to the C5G
Control Unit.

b. Connect the digital I/O cable to

the X8 (A) connector of the
C5G Control Unit.

c. Connect the other digital I/O

cable end to the connector (B)

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5.5 Connection between generator and wire feeder

Status: – Power off

Material: – Cables pack 95 mm² (AWG 3/0)
Equipment: – Pincer.
ASM

Preliminary procedures / notes

– The cable indicated is supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
The section of the cables pack that is not overhead is to be positioned
inside metal cable trays to protect against impacts and crushing. Position
the cable pack avoiding overlaying of spires.

Operating procedure

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Operating procedure (Continua)

a. Connect the cable pack on the
wire puller installed on board
the robot.
– A = gas inlet
– B = gas outlet
– C = air outlet
– D = power cable/ signals
– E = welding wire tube

b. Connect the inlet gas tube to

the connector (A). The tube is
without identification (collar).

c. Connect the outlet gas tube to

the connector (B). The is
identified with a red collar.

d. Check that the air inlet tube is

connected to connector (C).
The tube is blue identified by a
yellow collar.

e. Connect the power / signal

cable to the connector (D).

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Operating procedure (Continua)

f. Connect the anticollision cable
of the welding wire passage
cable pack to the connector (E).

g. Connect the anticollision cable

to the connector (F).

h. Connect the ends of the cable pack deriving from the robot with the ends of the
cable pack deriving from the generator. .
i. Connect directly the gas tube
(G) to the gas bottle or to the
supply coming from the plant.
– The fitting on the tube is 1/4” G
Fronius code 44.0450.0281.

j. Connect the water inlet tube to

connector (A). The tube is
identified by a blue collar.

k. Connect the water outlet tube to

connector (B). The tube is
identified by a red collar.

l. Connect the power cable to the

generator connector (K).

m. Connect the signals cable to

connector (L).

Follow-up procedure
– Not necessary.

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5.6 Connection between Control Unit and safeties, line

Ethernet

Status: – Power off

Material: – According to the type of installation
required.
Equipment: – Standard maintenance equipment.
ASM

Preliminary procedures / notes

– Not necessary.

Operating procedure

C5G ROBOT CONTROLLER CIP

X93 X124
X60

X10

X30
X62

X90

ETHERNET
PLC Interface

SAFETY

a. Safety signals:
– connect the safety signals through connector X30 on the CIP panel at the cabinet
base.
Details of the connections are contained in the Guide to Control Unit
integration manual.

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Operating procedure (Continua)

b. Ethernet network:
– updating though the Ethernet
network, connect the Control
Unit to the line Ethernet. The
connection is to be performed
on ETH2 connector of the
AMS-APC820 module.

Ethernet network connection details are contained in the Guide to Control

Unit integration manual.

Follow-up procedure
– Not necessary.

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5.7 Connection between C5G and TCP Check

(optional)

Status: – Power off

Material: – TCP Check cable
Equipment: – Not necessary.
ASM

Preliminary procedures / notes

– This procedure is only necessary for the installation of the TCP Check (optional).

Operating procedure

C5G ROBOT CONTROLLER CIP

X93 X124
X60

X10

X30
X62

X90

X80

a. Connect the TCP Check cable

on connector (A) of the splitter.
Note in case of multi machine
version, connect the cable on one of
the connectors (B) of the splitter (C).

b. Connectors (D) are the

connectors of the two optical
sensors used in the TCP
Check.

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Operating procedure (Continua)

c. Connect TCP Check cable
connector X80 on connector
X8A (E) on the Control Unit CIP
panel.

Note: connector X8A (E)

is positioned on the arc
outfitting plate.

d. Make sure that the internal

cable connected on connector
X80/CIP is connected to
connector X136 HSI1,
X136/C5G HSK5
For a multi machine:

e. Repeat the procedure,

connecting the second TCP
Check cable on the second
connector of the splitter.

f. Connect TCP Check cable

connector X80 on connector
X8B (G) on the Control Unit CIP
panel.

Follow-up procedure
– Not necessary.

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Operating procedure - Welding ground cable

a. The cable must be connected to the nearest metallic point in the welding area.
b. Connect the ground cable on
the connector (E) of the
generator.
Position the ground cable
in order not to overlap it or
generate curves.

c. Open the cover of the extern

box (F) unscrewing the 6 fixing
screws.

d. Check the direction of the arrow

on the current sensor Hall effect
(H).

e. The yellow arrow represented

in the figure determines the
current direction: it starts from
the equipment and ends on the
generator (from (J) to (G)).

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Operating procedure - Welding ground cable (Continua)

Respect the direction shown by the arrow on the sensor Hall effect: the
direction represents the current flow deriving from the ground floor on the
equipment to reach the generator.

f. Insert the ground cable in the cable gland (G).

g. Pass the ground cable inside the current sensor Hall effect (H).

h. The ground cable must go out from the cable gland (J).

i. Close the cover of the extern box.

j. Tighten the cable glands (G) (J).

k. Connect the other end of the ground cable on the on the point previously defined
on the equipment.
l. Carry out the system impedance calibration procedure.
The procedure is described in the Generator instructions handbook.

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5.8 Connections to the power supply networks

The Arc Welding System requires the following connection to the power supply lines:
– Control Unit connection to the electric power supply line
– Generator connection to the mains power supply
– Robot and torch cleaning assembly connection to the compressed air distribution
line
– Robot connection to the welding gas distribution network

5.8.1 Control Unit connection to the electric power supply line

The information for connection to the electric power supply line is contained in the C5G
installation manual (see Reference documents).

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5.8.2 Generator connection to the mains power supply

The power supply of the generator is provided through a loose cable with three phase
16A, 400V standard plug. If there is a transformer, power is supplied through a loop
cable without end.
Depending on the socket installation type and the power supply provided, please
consider the need to install a differential circuit breaker.
Connect the generator power supply plug to an appropriate socket.
Upstream of the generator there may be a switch/protection fuse connection of the
power supply cable with appropriate characteristics.
Tab. 5.1 contains the electrical connection characteristics.

Before connecting the power supply cable, verify the mains power supply voltage
coherence with those of the power generator / transformer (if present).

Tab. 5.1 - Conductor section and protections

Power supply
Power supply Network protection
Type of generator Power conductor cross
voltage characteristics
section
Fronius Primary continuous 35 A delayed
(TPS4000 SER 3x400V +/- 15% power (100% of
PAP) 3x500V +/- 10% *1 insertion time): 12.2
50 / 60 Hz kVA 4 mm¬ð
cos ϕ 0.99 (for long sections
Fronius Primary continuous 32 A delayed provide an adequate
(TPS5000 SER 3x400V +/- 15% power (100% of cross section)
PAP) 3x500V +/- 10% *1 insertion time): 13.1
50 / 60 Hz kVA
cos ϕ 0.99
*1: If the Autotransformer 3x500V (optional) is present

Status: – Power cut-out directly from the supply

(busbar)
Material: – Not necessary.
Equipment: – Not necessary.
ASM

Preliminary procedures / notes

– Not necessary.

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Operating procedure
400 V
a. Set the main switch lever (A) to
0 (OFF).

b. Connect the plug (B) to the

mains power supply socket or, if
there is a Transformer, in the
provided socket in the rear side
of the Transformer.

Before connecting, make sure that there is no power in the power supply
line.

500 V (Transformer)
a. Set the main switch lever (A) to
0 (OFF).

b. Connect the generator output

cable to the transformer.

c. Adjust the internal connection

on the transformer according to
the provided voltage.

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Operating procedure (Continua)

d. Wire the black plug (B) to the
transformer output cable (The
socket must have connection to
ground).

e. Connect the plug (B) to the

mains power supply socket.

Before connecting, make sure that there is no power in the power supply
line.

Follow-up procedure
Do not close the main switch to supply the Generator until the installation
procedure has terminated.

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5.8.3 Robot and torch cleaning assembly connection to the

compressed air distribution line
Tab. 5.2 contains the pneumatic connection characteristics.

Tab. 5.2 - Splitter Compressed air supply characteristics

Required air pressure

Device Supply fitting /tube
and flow rate
7 l / second
Torch cleaning 1.53 gallon / second
1/4“ G fitting
assembly and lubricator 0.6 MPa
6 bar
1800 Nl / minute
395.94 gallon / minute
Robot 3/8” G fitting
0.6 MPa, 0.7 MPa (max)
6 bar, 7 bar (max)

Status: – Pneumatic supply cut out directly from

mains
Material: – Not necessary.
Equipment: – Standard maintenance equipment.
ASM

Preliminary procedures / notes

– The procedure gives information on the compressed air connection points.
– The air is to be suitably filtered, adjusted to the pressure indicated and provided
with gate to cut out for maintenance purposes.
– The connection is made directly on the inlet fitting of the devices.

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Operating procedure
a. Supply compressed air to the
fitting (A) installed at the robot
base.

b. Supply compressed air to the

fitting (B) installed on the Torch
Cleaning Assembly and
lubricator.

Before connecting, make sure that there is no pneumatic power in the

power supply line.

Follow-up procedure
Do not open the manual valve to supply the devices until the installation
procedure has terminated.

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5.8.4 Robot connection to the welding gas distribution network

Tab. 5.3 contains the pneumatic connection characteristics.

Tab. 5.3 - Welding gas supply characteristics

Required air pressure

Device Supply fitting /tube
and flow rate
1800 Nl / minute
395.94 gallon / minute
Robot 3/8” G fitting
0.6 MPa, 0.7 MPa (max)
6 bar, 7 bar (max)

Status: – Power off

Material: – Not necessary
Equipment: – Standard maintenance equipment.
ASM

Preliminary procedures / notes

– The procedure gives information on the compressed air connection points.
– The connection is made with the provided piping (A) on the cable package.
–

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Operating procedure
a. Connect the welding gas supply
tubing to the fitting (A) of the
gas tube on the cable package
coming out from the robot base.

Follow-up procedure
– Not necessary.

5.9 RS422 Serial cable

Here follows the serial cable diagram used to connect the C5G Control Unit and the
Fronius generator.

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C5G side Generator side

CONNECTION SCHEME
COM2 COLOR AWG SIGNAL RS422/TS-TPS

White

Brown

Green

Yellow

Grey

For further information about connections and wires section please refer to the Robot
electric diagram.

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6. CONTINUOUS WIRE WELDING SYSTEM

ACTIVATION
This chapter contains:

– Precautions to be taken before activation

– Connectors pin-out
– Power-on
– Welding wire installation
– SMART-ARC and optional software modules activation
– Robot motions programming hints

6.1 Precautions to be taken before activation

a. Check presence and efficiency of the installation environment requirements as

described in par. 3.3 Installation environment requirements and suggestions on
page 18

b. Wear the individual protection devices as indicated in par. 1.3 Protection of the
eyes and the body on page 11.

6.2 Connectors pin-out

For information regarding the arrangement and the pin-out of the connectors, see the
Robot manual (see Reference documents).

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6.3 Power-on
Proceed as follows:

If the Generator has been stored at a temperature different to that for use, power-on and
wait for it to acclimatise

a. Power on the C5G Control Unit, as indicated in the Instructions for use manual.

For information regarding faults that could occur on the C5G Control Unit, see the
Instructions for Use manual (see Reference documents).

b. Put the main switch on the Generator / Transformer to ON

c. Open the pneumatic system cut-out ball valve. Supply the robot and the Torch
Cleaning assembly and lubricator with compressed air.

d. Open the gas system flow regulator.

For information regarding faults that could occur on the generator, see the Instructions
for Use manual (see Reference documents).

6.4 Welding wire installation

In the following paragraphs the welding wire installation procedures are described.
Depending on the the adopted solution, perform one of the following procedures:
– Set the main switch lever of the Generator and Transformer (if present) to 0 (OFF).
– Installation of the holder on the Robot (Aspo) and coil insertion
– Marathon Pac and cover positioning.
Then continue the installation with the procedure of Wire insertion in the wire feeder.

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6.4.1 Installation of the holder on the Robot (Aspo) and coil

insertion

Operating procedure
a. Set the coil holder (A) (ASPO) on the Robot installation base.

b. Fasten the coil holder screwing the fixing screws.

c. Insert manually the coil (B) on the coil holder (Aspo) installed on the Robot. The
coil weight is 15-18 kg (33.07-39.68 lb).
If correctly inserted, the coil is automatically fastened to the coil holder.

d. Insert the wire sheath (C) on the

holder (D) and screw the
locking knob (E).

e. Insert the wire on the sheath

f. Push the wire until it comes out

from the opposite side of the
sheath.

g. Fix the end of the sheath to the

wire feeder (see Wire insertion
in the wire feeder).
Representative image

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6.4.2 Marathon Pac and cover positioning

Operating procedure
a. Set in the right position the
Marathon Pac containers
The Marathon Pac bulk
drum weight is about
250 kg and must be
handled with care,
using an adequate
lifting means.

b.Set and fasten the

Marathon Pack kit (cover) on
the welding wire container, the
circular cover or the octagonal
cover can be used.

c. Insert the welding wire in the

sheath (point A)

d. Push the wire until it comes out

from the opposite side of the
sheath (point B).

e. Fix the sheath ends (B) to the

wire feeder (see Wire insertion
in the wire feeder)

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6.4.3 Wire insertion in the wire feeder

Operating procedure
a. Set the main switch lever of the
!

Generator and Transformer (if

present) to 0 (OFF).

b. Open the wire feeder cover (A).

c. Pull down the two small rolls

locking levers (B) (as the left
lever) in order to unlock the rolls

d. Set the sheath with the wire on

the taper hole (C).

e. Push the wire in order to put it in

the exit zone (E).

f. Pull up the two small rolls

locking levers (B) (as the right
lever) in order to lock the rolls
and adjust the wire closing
pressure.

a. Close the wire feeder cover (A)

b. Set the main switch lever of the

Generator and Transformer (if
present) to 1 (ON).

c. Use the impulse pushbutton (D)

i, until the wire does not come
out from the welding torch.

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Continuous wire welding system activation

6.5 Bleeding the water circuit

For information regarding the water bleeding procedure, see the Generator manual (see
Reference documents).

6.6 SMART-ARC and optional software modules

activation

For information regarding the activation and use of the software:

• SMART-ARC *
• SMART-ARC SCRATCH START
• SMART-ARC OVERLAP
• SMART-SEARCH
see the related manual (see Reference documents).

* Software provided with the application.

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6.7 Robot motions programming hints

During the welding cycle programming the maximum range of axis 1 has to be checked.
An amplitude of more than 140° could cause excessive wear and damage the outfitting
on board the robot.
Therefore the amplitude is to be limited within a range of 140°.

If the robot axis 1 amplitude is excessive, it could cause damage to the outfitting. It is
recommended to limit the range of axis 1 to -70°/+70° from a hypothetical central work
point (140° maximum range).

-70

+70

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7. CONTINUOUS WIRE WELDING SYSTEM

DEACTIVATION

Operating procedure

a. Perform the C5G Control Unit shut-down and set the main switch to OFF

For detailed information on the C5G shut-down procedure, see the related instructions
manual (see Reference documents).

b. Set the Generator main switch to OFF

c. Bring the compressed air cut-out ball valve to closed position

d. Close the gas system cut-out ball valve.

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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