SMA RT NS - E le nco ma nu al i

Comau Robotics
Instruction Handbook

Arc Welding System (CMT

Fronius generator)

Technical Specification for System GaTeWayFRonius

(GTWFR) serial connection, with SMART5 NS12 Robot

CR00757740-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 03/2012

 SUMMARY

1. WIRE WELDING SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. ARC WELDING SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..12

General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. C5G CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..16

Customization of the C5GControl Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Torch cleaner connection kit (internal Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Arc outfitting board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
High speed inputs Kit C5G-HSK5 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Serial port RS422 COM2 on AMS-APC820 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
X90 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. SMART5 ROBOTNS12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..22

Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Robot outfitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fastening kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connection pack kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wire puller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Weld torch push-pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Anti-collision kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wire buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TCP (Tool Center Point) calculation/check devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tool Master (Calibrated tool assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Location point (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TCP Check (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TCP Check for second Robot (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Robot support (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Balancer assembly (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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5. GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Generator connection to the main power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Generator connection to the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Type of cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Communication mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Generator order codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RS422 Serial cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Welding ground connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Transport trolley (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3x500V autotransformer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Remote control unit RCU 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6. TORCH CLEANING ASSEMBLY AND LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . ...45

Mechanical milled torch cleaning assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Digital I/Os cable from mechanical torch cleaning assembly to C5G . . . . . . . . . . . . . . . . . . . . 46
Wire-cutter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7. COIL HOLDER SUPPORT OR MARATHON PAC BELL . . . . . . . . . . . . . . . . . . . . . ...48

Coil holder support on robot on trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Marathon Pac kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8. SMARTARC APPLICATION SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

9. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...51

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 Preface

PREFACE
In this chapter are shown the following topics:
– Reference documents
– Documents preservation
– Limits on the manual content
– Symbols used in the manual

Reference documents
This document concerns the application Arc Welding System.
The complete set of Arc Welding System manuals consists of:

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.

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 9 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.

Make sure that in the immediate vicinity of the welding station there are no bins
containing petrol, diesel, solvents, rags or other inflammable materials.

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 Wire welding safety precautions

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 10;
– Operation in programming mode on page 10;
– Maintenance and Repairs on page 11;
– Putting out of service and dismantling on page 11

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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Wire welding safety precautions

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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 Arc Welding System Description

2. ARC WELDING SYSTEM DESCRIPTION

In this chapter are shown the following topics:

– General overview
– Configuration

2.1 General overview

Arc Welding System performs the welding with the following processes (according to the
generator used)
– MIG/MAG synergic
– MIG/MAG pulsed synergic
– MIG/MAG Brazing pulsed synergic.
The Arc Welding System is an application composed of

– C5G Control Unit *¹ integrated by:

• Customization of the C5GControl Unit *¹
– SMART5 RobotNS12 *¹
• Robot outfitting
• Weld torch push-pull *¹
• Anti-collision kit
• Tool Master (Calibrated tool assembly)
• Robot support (optional)
– Generator *² with:
• System GTWFR (GaTeWayFRonius) connected to Control Unit SMP through
serial port via module APC820 (in mode RS422)
• RS422 Serial cable
• Welding ground connection cable
– Wire puller assembly *¹
– Torch cleaning assembly and lubricator *¹
– Coil holder support or Marathon PAC Bell
– SmartArc Application Software; the information on software are available on the
manual "Software application of Wire Welding System SmartArc"
– Options.

The arc welding application cannot be installed on systems other than those
indicated above.

*¹ For information regarding the machine parts (C5GControl Unit, COMAU Robot,
Fronius Generator, ...) see the related instruction manuals indicated in par.
Reference documents on page 3.

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Arc Welding System Description

Fig. 2.1 - Connection principle

A C5G Control Unit

B SMART5 RobotNS12
C Generator
D Torch cleaning assembly and lubricator
E Weld torch push-pull

The Arc Welding System is available in several configurations distinguished by:

– welding process used
– communication mode between C5G Control Unit and Generator
– type of cooling used.

Tab. 2.1 - Arc Welding Systemconfiguration

Communication
Process Cooling Generator Robot Control Unit Layout
mode
MIG/MAG sinergico
MIG/MAG sinergico Fig. 2.2
TPS4000
pulsato Serial GTWFR Water NS12 C5G - ACC1 and
SER CMT
MIG/MAG sinergico Tab. 2.2
pulsato Brazing

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 Arc Welding System Description

2.2 Configuration
Fig. 2.2 - Connection principle diagram with Robot SMART5
NS12

D I H1 L F
Q
A1 G1
A G2 M

A4 H2 P
A1 C E
C4
A2 C5
A5 C1 B1
A3
B3 O
C6 C2
C3
A6 B2

A7 A8
N

Tab. 2.2 - Composition

Item Choice of
Description
Fig. 2.2 configuration
C5G Control Unit
A ACC1 C5G Control Unit *¹
Torch cleaner connection kit (internal Control Unit) e and connection cable to
A1 *¹
the torch cleaner
A2 High speed inputs Kit C5G-HSK5 (optional) *³
A3 Arc outfitting board *¹
A4 Serial port RS422 COM2 on AMS-APC820 module *¹
A5 X90 connector *¹
A6 Serial interface cable to Generator *¹
A7 Joint detector wiring assembly (optional) *³
A8 Seam Track (optional) *³
SMART5 RobotNS12
B1 SMART5 RobotNS12 *¹
B2 Robot support (optional) *³
B3 Robot outfitting *¹

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Arc Welding System Description

Tab. 2.2 - Composition (Continue)

Item Choice of
Description
Fig. 2.2 configuration
Generator
C Generator *¹
C1 Connection pack kit *²
C2 Transport trolley (optional) *³
C3 Welding ground connection cable *¹
C4 Wire joint seam track (optional) *³
C5 3x500V autotransformer (optional) *³
Remote control unit RCU 5000i *¹
C6
Connecting cable *³
Torch cleaning assembly and lubricator
D Torch cleaning assembly and lubricator *¹
Complete configuration components
E Weld torch push-pull body kit *²
F Balancer assembly (optional) *³
G1 OctagonalMarathon Pac kit
*²
G2 CircularMarathon Pac kit
H1 Coil holder support *¹
H2 Wire guide cable *²
I Rollers kit diameter 1,2 mm *²
L Wire puller assembly *¹
M Anti-collision kit *¹
TCP Check (optional) *³
N Holder column (Optional) *³
TCP Check for second Robot (optional) *³
O Location point (optional) *³
P Tool Master (Calibrated tool assembly) *¹
Q Wire Buffer *¹
component is obligatory in the configuration
component is obligatory with alternatives available
optional component

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3. C5G CONTROL UNIT

In this chapter are shown the following topics:

– Customization of the C5GControl Unit

A - C5G Control Unit

B - SMART5 RobotNS12

C - Generator

D - Torch cleaning assembly and lubricator

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C5G Control Unit

3.1 Customization of the C5GControl Unit

In the Arc Welding System, the C5G Control Unit is configured starting from the base
version integrates with the following customizations:
– Torch cleaner connection kit (internal Control Unit)
– Arc outfitting board
– High speed inputs Kit C5G-HSK5 (optional),it is necessary only in some
configurations.
Furthermore the following services already available in the base version of the Control
Unit have been used:
– Serial port RS422 COM2 on AMS-APC820 module
– X90 connector.

A - Serial port RS422 COM2 on AMS-APC820

module

Serial Cable RS422

C- X90 connector

D- Torch cleaner connection kit (internal Control

Unit)

E- Arc outfitting board

F- High speed inputs Kit C5G-HSK5 (optional)

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3.1.1 Torch cleaner connection kit (internal Control Unit)

The command and control signals directed to the torch cleaner device, and the
anti-collision kit on the Robot are collected and divided in the Control Unit thanks to the
"Torch cleaner connection kit"
Four different solutions are available (only one among those available can be installed),
they are characterized by cable length from the cabinet base to the torch cleaner and
for the configuration with one or 2 Robots.
Each kit is supplied with cabinet internal connectors and cables that merge to the
connector X8 (labelled X8A e X8B if the configuration foresees 2 Robots) and the
external cable designed to the torch cleaner-

Comau Code Description

Torch cleaner connection kit,
CR16654180 external cable length 8 m single
Robot
Torch cleaner connection kit,
CR16654280 external cable length 15 m single
Robot
Torch cleaner connection kit,
CR16655980 external cable length 8 m double
Robot
Torch cleaner connection kit,
CR16656080 external cable length 15 m double
Robot

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C5G Control Unit

3.1.2 Arc outfitting board

The outfitting arc board is the board on which are fixed all the connectors which connect
the direct cables to the devices foreseen in the Arc Welding System and for which is
foreseen the interruption on the cabinet base (typical the connector X8 of the Torch
cleaner connection kit (internal Control Unit) (see par. 3.1.1 on page 18)).
For the RS422 serial cable passing the solution X90 connector (see par. 3.1.5 on
page 21)is used.
The outfitting board is installed on the CIP panel on the bases of the C5GControl Unit.
The following elements can be added:
– Torch cleaning assembly and lubricator
– TCP Check (optional)

Comau Code Description

CR16101280 Arc outfitting board

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3.1.3 High speed inputs Kit C5G-HSK5 (optional)

The option C5G-HSK5 is used if the configuration includes the option orTCP Check
(optional) (see par. 4.7.3 on page 32).
Through this option, the signal deriving from the TCP Check (optional) is read by the
Control Unit and processed by the application software in order to correct the position.

Comau Code Description

CR17132680 High Speed Input Kit

The option is the same available in the Control Unit.

For further information please see the manual "Technical specifications" of the
C5GControl Unit .

3.1.4 Serial port RS422 COM2 on AMS-APC820 module

The management programs are sent to the generator through the serial protocol RS422
on the homonyms port COM2, available as standard on the module AMS-APC820 of the
Control Unit.
The connection is carried on through RS422 Serial cable (see par. 5.8 on page 39) and
the connectors on the ends are directly connected to the ports.
If the Arc Welding System configuration foresees a second generator, this is connected
to a further RS422 serial port, optional on the Control Unit.

For further information please see the manual "Technical specifications" of the
C5GControl Unit .

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C5G Control Unit

3.1.5 X90 connector

The cables deriving from the internal modules of the Control Unit, which are designed
for the external devices and travel without interruptions, pass through the X90 cable
gland connector available as standard in the Control Unit.
The RS422 Serial cable (see par. 5.8 on page 39) is one of the cables that exploit this
opportunity.

The X90 connector is already available in the Control Unit.

For further information please see the manual "Technical specifications" of the
C5G Control Unit .

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4. SMART5 ROBOTNS12

This chapter contains:

– Robot
– Robot outfitting
– Wire puller assembly, composed of:
– Fastening kit
– Connection pack kit
– Weld torch push-pull
– Anti-collision kit
– Wire buffer
– TCP (Tool Center Point) calculation/check devices, composed of:
– Tool Master (Calibrated tool assembly)
– Location point (optional)
– TCP Check (optional)
– TCP Check for second Robot (optional)
– Robot support (optional)
– Balancer assembly (optional)

4.1 Robot
The Robot used for the Arc Welding System is a standard COMAU SMART5
RobotNS12 opportunely fit for the Application Arc.

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SMART5 RobotNS12

For all the details on the SMART5 RobotNS12, please refer to the specific
instruction manuals.

4.2 Robot outfitting

The robot outfitting is composed of:
– Fastening kit
– Connection pack kit

4.2.1 Fastening kit

The outfitting assembly consists of brackets and screws to fasten the outfitting on board
the Robot.

Tab. 4.1 - Fastening kit order code

Description Comau Code
Fastening kit assembly CR19078050

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4.2.2 Connection pack kit

The connection pack kit is composed by cables (signal cables, power cables, gas and
air tubes) connecting the Generator and the Robot

Description Cooling type Comau Code

Cables pack 6,25 m (20.50 ft) Water CR16660580

The electric connection detail of the cables is contained in the application Circuit
Diagram.

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SMART5 RobotNS12

4.3 Wire puller assembly

The wire puller assembly is controlled by the generator. It is installed on the generator
trolley and the connections between the wire puller assembly and the generator are
made by a cable pack.
The internal rollers of the wire puller assembly are provided for iron wire with diam. 1.2
mm (0.047 in). Roller with different diameters are available on demand, as shown in the
following table.
The Weld torch push-pull is connected to the wire puller assebly by means of a wire
guide cable.

Wire puller assembly Wire puller assembly (with open side door)

Tab. 4.2 - Wire puller assembly order codes

Description Comau Code
FRONIUS VR7000 KIT Wire puller assembly CR16657480
Connecting cable generator/wire puller 1,2 m (3.93 ft) 70 mm² CR19076012
Connecting cable generator/wire puller 4 m (13.12 ft) 95 mm² CR19076013
Rollers kit for AL/CUSI3 wire Ø 1 mm (0.039 in) CR16655380
Rollers kit for iron wire Ø 1 mm (0.039 in) CR16655480

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4.4 Weld torch push-pull

The welding torch is available with different amperage ranges and different slanting
angles.
The welding torch can be fitted, regardless of the slant angle, with contact tip diameter
0.8 mm (0.031 in), 1.0 mm (0.039 in) and 1.2mm (0.047 in).
The welding torch requires periodical cleaning to be carried out with the Torch cleaning
assembly and lubricator.
The weld torch is provided with a servo-motor in AC with high dynamics for wire power
supply.

Robacta RA280 * Robacta RA400 *

*: An example of slanting.

Tab. 4.3 - Order codes for cable pack and welding torch
Description Robot Comau Code
Robacta RA280 torch body kit angle 22° CR19072009
Robacta RA280 torch body kit angle 36° CR19072010
Robacta RA280 torch body kit angle 45° CR19072011
Robacta RA400 torch body kit angle 22° CR16655580
Robacta RA400 torch body kit angle 36° CR16655680
NS12
Kit corpo torcia Robacta Drive CMT PAP CR19078048
Kit rulli diam. 1,0 mm (0.039 in) in Fe CR19078044
Kit rulli diam. 1,2 mm (0.047 in) in A / Mg / CuSi CR19078043

4.5 Anti-collision kit

The anti-collision kit signals the impact of the torch with parts of fixtures or welded parts
and stops the robot. It is located between the robot wrist and the welding torch.

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SMART5 RobotNS12

Tab. 4.4 - Anti-collision kit order codes

Description Comau Code
Anti-collision kit CR16660680

The anti-collision kit has to be enabled. See details in the Integration, Transport
and Installation manual in the chapter “Arc Welding Systemcomponents
installation”.

In order to work properly, the anti-collision kit must be equipped with the Torch
cleaner connection kit (internal Control Unit).

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4.6 Wire buffer

Il Wire buffer garantisce una perfetta sincronizzazione tra il carrello traina filo e la torcia
di saldatura.
Il dispositivo funge da volano e disaccoppia il motore di traino e di spinta assicurando un
movimento del filo costante e preciso. Garantisce inoltre un’alimentazione del filo
precisa e priva di resistenza.
Il wire buffer può essere appeso ad un balancer oppure installato sul corpo del robot.

Tab. 4.5 - Codici di ordinazione wire buffer

Descrizione Codice Comau
Universal Wire buffer Support CR19078050

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4.7 TCP (Tool Center Point) calculation/check

devices
For calculation/check of the TCP (Tool Center Point) the following devices are available:
– Tool Master (Calibrated tool assembly)
– Location point (optional)
– TCP Check (optional)
– TCP Check for second Robot (optional)

In the following diagram the method to calculate the TCP is represented.

A A

A - Tool Master (Calibrated tool assembly)

B - Location point (optional)
C - TCP Check (optional) / TCP Check for second Robot (optional)

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4.7.1 Tool Master (Calibrated tool assembly)

The tool master is a calibrated iron round bar section used for the Tool Center Point
(TCP) calculation.
The tool master is supplied on the NS robot outfitted for arc welding application.

The A tool master, if necessary, must be installed on the on the threaded hole M6 B on
the anti-collision kit.

Tab. 4.6 - Tool Master order code

Description Comau Code
Tool Master (Calibrated tool assembly) L=117 81783801

Further programming deepening are available installation manual, paragraph

Tool Master installation.

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SMART5 RobotNS12

4.7.2 Location point (optional)

To check the torch alignment the Location Point can be installed as an alternative to the
TCP Check (optional).
The location point is to be used for manual checks that do not require precision. To use,
the operator has to manually store the check position (the wire tip aligned to the location
point).
Subsequent checks have to be made bringing the robot to the check position and
visually checking the alignment.
It is the task of the integrator to position the location point.

Tab. 4.7 - Location point order code

Description Comau Code
Location point 166542200400

The location point can be replaced with any type of reference point decided by the
user.

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4.7.3 TCP Check (optional)

To check the torch alignment the TCP Check can be installed as an alternative to the
Location point (optional).
The TCP Check is connected directly by a specific cable to the High Speed Input (HSI
1, X136/C5G-HSK5) on the C5G-HSK5 module (not included in the current option, see
par. 3.1.3 High speed inputs Kit C5G-HSK5 (optional) on page 20).
The kit includes:
– TCP Check, which includes:
- Aluminium base§
- 2 optical sensors
- one location point
– connection cable between TCP Check and Control Unit
– Control Unit internal cable
– “SmartArc Tcp Check” software option (see Tab. 8.2), to use the TCP Check with
SmartArc sw.
The operating principle consists of an automatic program in which the Robot, with
appropriate movements, identifies the position of the wire interrupting the beam emitted
by the two optical sensors positioned at 90° to each other. The position calculated by
the wire tip (Tool Center Point, TCP) is checked to control that it is within the range set
by the operator and updated in automatic mode.
The X82 connectors matched with the cable deriving from the TCP Check, merge on the
Arc outfitting board.

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SMART5 RobotNS12

Tab. 4.8 - TCP Check order codes

Description Comau Code
TCP Check includes:
– TCP Check
– TCP Check cable, length 10 m (32.8 ft)
– Control Unit internal connection cable (CR16006560)
CR16502780
– Software option for the use of the device (SmartArc TCP
Check).
Note: the TCP check requires the -HSK5 C5G option on the
Control Unit.
Support column for TCP Check, height 800 mm (31.50 in) 16654580
HSK5 C5G option for Control Unit CR17132680

“TCP Check” Aluminium board dimensions TPC board Supporting Column dimensions
Plan view Frontal view

Connection cable between TCP Check and Control Unit

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4.7.4 TCP Check for second Robot (optional)

To allow the use of the TCP Check also for the second Robot (called Robot Slave)
connected by means of a multi machine solution, a divider and additional cables are
necessary.
With this kit, the TCP Check (optional) is connected to the High Speed Input (HSI 1,
X136//C5G-HSK5) of the first robot and to the High Speed Input (HSI 1, of the second
IAM1 of ARM2) of the second robot.

The inspection procedure cannot be activated contemporaneously on two

Robots.

The kit includes:

– the divider
– connection cable between TCP Check and Control Unit
– Control Unit internal cable.
The kit has to be coupled to TCP Check (optional).
The X82 connectors matched with the cable coming from the TCP Check, merge on the
Arc outfitting board.

Tab. 4.9 - TCP Check for Robot Slave order codes

Description Comau Code
TCP Check for second Robot containing:
– divider
CR16650980
– TCP Check cable, length 10 m (32.8 ft)
– Connection cable inside cabinet

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SMART5 RobotNS12

4.8 Robot support (optional)

With the support, the correct positioning is obtained for the robot, which is fastened on
the upper base.
Different types of supports are available for robots with different heights.

Tab. 4.10 - Robot support order code

Description Comau Code
Support for robot H=500 mm (1.64 ft) CR82283422
Support for robot H=600 mm (1.96 ft) CR82283426
Support for robot H=750 mm (2.46 ft) CR82283423
Support for robot H=1000 mm (3.28 ft) CR82283424
Support for robot H=1300 mm (4.26 ft) CR82283425

For further information please see the manuals ”Technical specifications” and
”Transport and Installation” of the robotNS12.

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4.9 Balancer assembly (optional)

The balancer assembly is used to support the cable pack and the welding wire.
It is advised to install the balancer assembly to avoid that the cables pack interferes with
the robot movements.

A correct installation is composed

of:
– support structure A
(Planning and carrying out
by the integrator)
– balancer B, to be connected
to the structure through a
carabiner by using one of
the two holes diameter 8mm
(Maximum reach: 4-6 kg)
– cradle C, to be connected
through the carabiner of the
balancer.

Tab. 4.11 - Balancer assembly order code

Description Comau Code
Balancer assembly (4-6 Kg) (8.82-13.23 lb) 19060472
Rubber support CR19078029

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Generator

5. GENERATOR
In this chapter are shown the following topics:
– General information
– Generator connection to the main power supply
– Generator connection to the Control Unit
– Welding process
– Type of cooling
– Communication mode
– Generator order codes
– External RS422 Serial cable (From Control Unit to Generator)
– Welding ground connection cable for the Generator
– Transport trolley (optional)
– 3x500V autotransformer (optional)
– Remote control unit RCU 5000i

5.1 General information

The generator is supplied independently and receives the control signals via RS422
Serial cable connection coming from the Control Unit.

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5.2 Generator connection to the main power

supply
The generator is connected to the mains power supply through the adequate power
supply cable.
The generator power supply characteristics are listed in Tab. 5.1.

5.3 Generator connection to the Control Unit

The generator includes the RS422 I/O serial module. The GTWFR serial interface
developed for the C5GControl Unit is exclusively for Comau use.
The generator serial port RS422 is connected to the serial port COM2 of the
ASM-AP820 module.

5.4 Welding process

Generators are available for:
– synergic MIG/MAG with TPS4000 Fronius
– synergic pulsed MIG/MAG with TPS4000 Fronius
– synergic pulsed Brazing MIG/MAG with TPS4000 Fronius.

5.5 Type of cooling

The generator cooling is carried out by means of a water circuit in the generator.

5.6 Communication mode

The generator communicates by means of the serial cable.

5.7 Generator order codes

Tab. 5.1 - Codes table
Power supply Communication
Fronius Type of process Comau code Cooling
characteristics method
Synergic 3x400V +/- 15%
MIG/MAG, 3x500V +/- 10% *¹
TPS4000
synergic pulse, 50 / 60 Hz CR16660280 Serial Water
SER CMT
synergic pulsed 12,2 kVA
Brazing cos ϕ 0.99
*¹:To be used with 3x500V autotransformer (optional) only

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Generator

5.8 RS422 Serial cable

The RS422 serial cable connects the AMS-APC820 (COM2) module of the Control Unit
to the generator.
If the configuration is with double Robot, the second RS422 serial cable connects the
AMS-APC820 (COM1) module of the Control Unit to the Generator via the
RS232-RS422 converter.

Description Comau Code

Serial cable, length 7 m (23 ft) CR16041460
Serial cable, length 12 m (39.4 ft) CR16041461
Serial cable, length 17 m (55.8 ft) CR16041462
Serial cable, length 22 m (72.2 ft) CR16041463
Serial cable, length 27 m (88.6 ft) CR16041464
Serial cable, length 32 m (105 ft) CR16041465

C5G side Generator side

CONNECTION SCHEME
COM2 COLOR AWG SIGNAL RS422/TS-TPS

White

Brown

Green

Yellow

Grey

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For further information see the circuit diagram of Arc Welding System.

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Generator

5.9 Welding ground connection cable

The welding ground connects the generator to the equipment holding the item to be
welded.
The cable must be fastened to the equipment using an eyelet (12 mm diameter) through
an adequate screw.

Description Comau Code

Welding ground 95 mm², 10 m (32.8 ft) 19060484

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5.10 Transport trolley (optional)

The transport trolley permits easy handling of the generator.
It can sustain the generator models indicated in this manual, including, if required, a
3x500V autotransformer (optional).

Tab. 5.2 - Transport trolley order code

Description Comau Code
Transport trolley CR16657580

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Generator

5.11 3x500V autotransformer (optional)

The autotransformer is used to supply the generator in cases of a 550 Vac +/- 10%
power supply from the mains. The module is installed in the lower zone of the generator.
The generator base profile is not changed.
When the autotransformer is installed, the generator power supply cable comes out
directly from the autotransformer module and the main switch to cut out electric power
is on the new autotransformer module.

Tab. 5.3 - 3x500V autotransformer order code

Description Comau Code
3x500V autotransformer CR19061436

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 Generator

5.12 Remote control unit RCU 5000i

The remote control unit RCU 5000iallows to create and operate directly ont eh
component to be welded all thecaracterisitc bends and operations, and also to monitor
the welding data.

Description Comau Code

Remote control unit RCU 5000i CR16657680
Connecting cable 5 m (16.4 ft) CR19076016

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Torch cleaning assembly and lubricator

6. TORCH CLEANING ASSEMBLY AND

LUBRICATOR

This chapter contains:

– Mechanical milled torch cleaning assembly
– Digital I/Os cable from mechanical torch cleaning assembly to C5G
– Wire-cutter (optional)

6.1 Mechanical milled torch cleaning assembly

The mechanical torch cleaning assembly is a device that removes the accumulation of
splatter by milling Since this is a mechanical operation, the device can be applied to all
wire welding processes.
The mechanical milled torch cleaning assembly includes:
– cleaning unit
– lubricator
– holder column.
The assembly can be used with the Wire-cutter (optional)
The installation requires the Arc outfitting board.
The assembly is electrically connected to the Control Unit C5G by a multi pole cable and
it uses the I/Os of the C5G SDM module.
To operate it requires (not included in the cleaning assembly):
– Digital I/Os cable from mechanical torch cleaning assembly to C5G
– compressed air supply: dry air must be provided with a supply pressure of 0,4 - 0,6
MPa (4 - 6 bar).

Torch cleaning assembly and lubricator Torch cleaning assembly and lubricator
(rear view) (frontal view)

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Tab. 6.1 - Mechanical milled torch cleaning assembly order

codes
Description Comau code
Mechanical milled torch cleaning assembly Robacta REAMMER,
with lubricator and holder column, height 700 mm (27.56 in). 16689494
Use the adequate milling to the chosen torch type.
Milling for RA280 Torch with nozzle diam. 12 mm CR19074019
Milling for RA400 Torch with nozzle diam. 12 mm CR19074019

6.2 Digital I/Os cable from mechanical torch

cleaning assembly to C5G
This cable is used to connect the mechanical torch cleaning assembly to the C5G
control Unit with a multi pole cable and uses the I/Os C5G-SDM X8 module (that
becomes X8A e X8B in cse of double torch cleaning assembly).

Description Comau code

Digital I/Os cable
CR16654180
length 8 meters (26.25 ft)
Digital I/Os cable
CR16654280
length 15 meters (49.21 ft)
Digital I/Os cable
length 8 meters (26.25 ft) CR16655980
(Double Robot)
Digital I/Os cable
length 15 meters (49.21 ft) CR16656080
(Double Robot)

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Torch cleaning assembly and lubricator

6.3 Wire-cutter (optional)

The wire-cutter is a mechanical type controlled by a pneumatic switch. The wire cutter
is to be installed close to the Torch cleaning assembly and lubricator.
The wire cutter is to be installed close to the Mechanical milled torch cleaning assembly
with which it shares the compressed air supply.

Tab. 6.2 - Wire-cutter order code

Description Comau code
Wire cutter for Mechanical milled torch cleaning assembly 19060447

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 Coil holder support or Marathon PAC Bell

7. COIL HOLDER SUPPORT OR

MARATHON PAC BELL

The welding wire is usually available in coil or in a container depending on the welding
volumes and needed autonomy.
One of these alternatives can be installed:
– Coil holder support on robot on trolley (per filo in bobina), installato sul gruppo
trainafilo
– Marathon Pac kit (for wire in container), that can be positioned according to
installation requirements, considering a maximum distance between bell and wire
puller.
It is advised to support the cables pack and welding wire with the specific Balancer
assembly (optional).

7.1 Coil holder support on robot on trolley

The coil holder support is installed on the wire pulley trolley.
Tis solution is typically used for small welding volumes and allows a limited autonomy
because of the big dimensions of the coil

Wire puller assembly Wire puller assembly (with open side door)

For more details refer to par. 4.3 Gruppo traina filo on page 27.

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Coil holder support or Marathon PAC Bell

7.2 Marathon Pac kit

The Marathon bell Pac includes a cover and a wire guide sheath inserted in the wire
feeder assembly.
The Marathon Pac bell is installed to cover of the welding wire container.
Such solution is typically adopted for big welding volumes and allows a high autonomy,
because the coil dimensions are small.
One of these alternatives can be installed:
– Circular cover
– Octagonal cover

Circular cover Octagonal cover

Tab. 7.1 - Marathon pac cover order codes

Description Comau code
Circular cover
Circular Marathon Pac Kit with 3.5 m (11.48 ft) shealth CR16100980
Circular Marathon Pac Kit with 5 m (16.4 ft) shealth CR16101408
Circular Marathon Pac Kit with 6.35 m (20.83 ft) shealth CR16101080
Circular Marathon Pac Kit with 8 m (26.24 ft) shealth CR16101180
Octagonal cover
Octagonal Marathon Pac Kit with 1,6 m (5.24 ft) shealth CR16100580
Octagonal Marathon Pac Kit with 3.5 m (11.48 ft) shealth CR16100680
Octagonal Marathon Pac Kit with 5 m (16.4 ft) shealth CR16101380
Octagonal Marathon Pac Kit with 6.35 m (20.83 ft) shealth CR16100780
Octagonal Marathon Pac Kit with 8 m (26.24 ft) shealth CR16100880

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 SmartArc Application Software

8. SMARTARC APPLICATION SOFTWARE

It is an application software, installed on the C5G Control Unit, to manage a Arc Welding
System in a simple and homogeneous manner.
The software is only supplied together with the outfitted robot and is configured
according to the order of the Customer. The user interface is available on the teach
pendant.
The basic configuration consists of the SmartArc package, to which additional functions
can be added through optional packages.

For information, see the SMART-ARC software manual.

Tab. 8.2 - SmartArc software and optional packages code

Comau code Description Notes
Main software package for wire welding applications (arc
13620060 SmartArc
welding).
Requires SmartArc package.
13620160 SmartArc Spot Software option to execute an intermittent process without
stopping the robot motion.
Requires SmartArc package.
13620360 SmartArc OverLap
Software option to restart overlapping the weld bead.
Requires SmartArc package.
Software option to ensure the correct TCP (Tool Center
13620460 SmartArc TCP Check
Point) definition.
Only available with TCP Check option
Requires SmartArc package.
SmartArc Wire Search Software option to allow the joint seam tracking using the
13620560
Fronius welding wire.
Only available with Joint seam track option

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Options

9. OPTIONS
In this chapter are listed the options available for the Arc Welding System:

In order to facilitate the search, the options are here listed and organised per
topic.
The related details are directly described in the pertaining chapter.

Available options
SMART5 RobotNS12
– TCP Check (optional)
– Location point (optional)
– Balancer assembly (optional)

Generator
– Transport trolley (optional)
– 3x500V autotransformer (optional)
–
– Remote control unit RCU 5000i

Torch cleaning assembly and lubricator

– Wire-cutter (optional)

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 Options

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COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
comau.com/robotics Original instructions