Hi HANDLING

SMART H / C3G Plus

HANDLING SYSTEM MANUAL

00757055 - GB 3Hi HANDL. - 00/0501

The in for ma tion con ta i ned in this ma nual is the pro perty of COMAU S.p.A.
Re pro duc tion of text and il lu stra tions is not per mit ted wit ho ut prior writ ten ap pro val by COMAU S.p.A.
COMAU S.p.A. re ser ves the right to al ter pro duct spe ci fi ca tions at any time wit ho ut no tice or obligation.

PRINTED IN ITALY - 05/2001

Copyright  2001 by COMAU
 PREFACE

PREFACE
This manual describes the Hi Handling system that uses the SMART H robot and the C3G Plus cell control-
ler.
The manual consists of an introduction and chapters containing the following information:

· The PREFACE contains general information concerning the structure of the handbook and its contents.

· The SAFETY REGULATIONS chapter provides details of all the safety measures that must be complied
with when using the handling system

· The DESCRIPTION OF THE Hi Handling SYSTEM chapter describes the characteristics of the system and
a technical description of the main parts, also contains the SPARE PARTS list.

SYMBOLS
The symbols used to indicate CAUTION, WARNING and NOTES are explained below..
This symbol identifies operating procedures, technical information and precautions which, if
not complied with and/or performed correctly, may cause injury to personnel.

☞
This symbol indicates functioning procedures, technical information and precautions that are
to be highlighted.

This symbol indicates that the paragraph contains suggenstions or hints to correct the errors.

REFERENCE DOCUMENTS
· Further information concerning the SMART H robot is available in the following manuals:
- SMART H Specifiche tecniche / Technical Specifications,
- SMART H Uso e manutenzione / Use and Maintenance.

· Further information concerning the C3G Plus control unit is available in the following manuals:
- C3G Plus Specifiche tecniche / Technical Specifications,
- C3G Plus Use and Maintenance.

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PREFACE

SUMMARY
This manual contains:
Page

CHAPTER 1 - SAFETY REGULATIONS

Responsability ............................................................................................................................................1-1
Safety Regulations .....................................................................................................................................1-1

CHAPTER 2 - SYSTEM DESCRIPTION

Technical characteristics ............................................................................................................................2-1
Overview................................................................................................................................................2-1
Technical characteristics of main system components...............................................................................2-2
C3G Plus.................................................................................................................................................2-2
Robot .....................................................................................................................................................2-2
Media Panel...........................................................................................................................................2-2
Control Unit - robot connection cable kit and hose kit ..........................................................................2-2
Performance ...............................................................................................................................................2-3
Maximum load to be applied to robot .........................................................................................................2-3
Maximum working pressure of air hose ......................................................................................................2-3
Air supply panel ..........................................................................................................................................2-4
Overview................................................................................................................................................2-4
Pneumatic part ......................................................................................................................................2-5
Adjustment of air pressure.....................................................................................................................2-5
Calibration of air pressure switch ..........................................................................................................2-6
Electrical part.........................................................................................................................................2-7
Media panel-robot air hose kit ....................................................................................................................2-7
Description and assembly .....................................................................................................................2-7
Standard dressing on board handling robot ..............................................................................................2-8
Description.............................................................................................................................................2-8
Spare parts ............................................................................................................................................2-8

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C3G Plus SMART H HANDLING SYSTEM

SAFETY REGULATIONS
SYSTEM DESCRIPTION
1
2
E

SUMMARY
Paragraph Page

Responsability 1-1
Safety Regulations 1-1
This page has been lefty intentionally blank
 SAFETY REGULATIONS

RESPONSIBILITY

SAFETY REGULATIONS
· The “integrator” is responsible for incorporating the robot system in a manufacturing or research
environment, for issuing the declaration of conformity and applying the EC label to the system in
compliance with the safety principles of the Machine Directive.

· COMAU S.p.A. shall not be held responsible for injury or damage resulting from incorrect or im-
proper use of the robot system, use of unspecified spare parts and tampering with circuits, compo-
nents and system software.

· The foremen who manage / supervise the operations specified in point 3 are responsible for ensur-
ing that these safety rules are enforced. They must make sure that all authorized personnel have
been instructed as regards the rules contained in this document and the general safety rules appli-
cable to the robot system and that the aforesaid personnel comply with all these rules.

· Failure to comply with safety regulations may result in injury to personnel and damage to controller
components.

SAFETY REGULATIONS
1. PURPOSE
1.1 The purpose of these safety regulations is to define a series of behaviour rules and duties to be
observed when performing the activities listed in point 3, to ensure the safety of personnel, equip-
ment and the surrounding environment.

2. DEFINITIONS
2.1 Robot System
The term Robot System refers to the functional assembly consisting of: control unit, robot, porta-
ble programming and/or emergency terminal and any options.
2.2 Protected Area
Protected Area is the area that is enclosed by protective barriers, in which the robot is to be in-
stalled and operated.
2.3 Authorized Personnel
Authorised Personnel is the group of persons that have been appropriately trained and delegated
to perform the activities listed in point 3.
2.4 Foremen
Foremen are personnel who direct or supervise the activities assigned to subordinate workers as
defined in the previous paragraph.
2.5 Installation and Commissioning
The term installation refers to the integration of the robot system mechanics and electrics into a
manufacturing situation or research environment in accordance with the safety requirements laid
down in the Machines Directive.
The term commissioning refers to the operations involved in verifying system operation once the
system has been installed.
2.6 Operation during Programming
Operating mode under operator control. This mode excludes automatic operation and permits the
following activities: manual movement in the various different modes, programming of work cycles
at reduced speed, programmed cycle testing at reduced speed and when permitted, at working
speed.
2.7 Automatic Operation
Operating mode in which the robot performs the programmed cycle autonomously at working
speed inside the protected area, with protective barriers closed and interlocked with the emer-
gency stop circuit, and with local (situated outside the protected area)or remote start/stop.
2.8 Emergency Manual Operation
Operating mode that permits movement of the robot with downgraded safety system in the case
of a fault, under operator control and with protective barriers closed.

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 SAFETY REGULATIONS

DEFINITIONS - Continued
SAFETY REGULATIONS

2.9 Maintenance and Repairs

Maintenance and repair operations refer to periodic checking and/or replacement of parts (me-
chanical, electrical, software) or of robot system components and tracing of the causes of any
faults and ends with resetting of the robot system to original operating conditions.
2.10 Removal from Service and Dismantling
Removal from Service refers to the removal of the robot system (mechanical and electrical) from
the manufacturing situation or research environment. Dismantling involves the demolition and dis-
posal of the components that make up the robot system.
2.11 Integrator
The integrator is the qualified person responsible for application of the robot system.
2.12 Incorrect Use
The integrator is the qualified person responsible for the application of the robot system.
2.13 Work Envelope
The robot work envelope is the area in which the robot, including fixtures, operates.

3. FIELD OF APPLICATION
3.1 These regulations must be complied with when performing the following activities:

· installation and commissioning;

· operation during programming;

· automatic operation;

· emergency manual operation;

· maintenance and repairs;

· removal from service and dismantling;

4. OPERATING MODES
4.1 Installation and Commissioning
4.1.1 Commissioning is allowed only when the robot system is incorporated in a manufacturing system
or in a research environment that guarantees the use of safety conditions.
4.1.2 Installation and commissioning of the system must be performed by authorized personnel only.
4.1.3 The system must only be installed and commissioned inside a protected area of a suitable size to
house the robot and its relative dressing, without any part of these being outside the safety
guards. Also, make sure that during normal robot movements this does not collide with other parts
inside the protected area (for instance, structural pillars, mains, etc.). If necessary, restrict the ro-
bot work area by means of mechanical stops.
4.1.4 The robot installation area must be kept free, as far as possible, from any materials that may ob-
struct or limit visibility.
4.1.5 During installation, handle the robot and control unit as specified in the Product User Manual; if
they must be lifted, check that the eyebolts are secured correctly and use only suitable slings and
equipment.
4.1.6 Secure the robot to the support with all the bolts provided.
4.1.7 Remove any anchoring brackets from the axes and check that the robot fixtures are secured cor-
rectly.
4.1.8 Check that the robot guards are fixed correctly and that there are no loose or loosened parts,
check also that the control unit components are in good condition.

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 SAFETY REGULATIONS

Installation and Commissioning - Continued

SAFETY REGULATIONS
4.1.9 When required, connect the robot's pneumatic system to the air distribution network and check
carefully to make sure that the pressure is set correctly. If the pressure of the balancing system is
not correct it will affect the robot's movements. Also install filters to collect any condensate in the
system.
4.1.10 Install the control unit so that the control panel can only be operated from outside the protected
area.
4.1.11 Check that the pre-engineered voltage on the power supply transformers indicated on the specific
rating plate corresponds to the power mains voltage.
4.1.12 Before making the electrical connections to the control unit, make sure that the power mains cir-
cuit breaker is locked in the open position.
4.1.13 The connection between the control unit and the mains circuit breaker must be effected by means
of a shielded quadripole cable (3-phases + ground) of suitable dimensions for the control unit
power installed
4.1.14 The supply cable must enter the control unit through the appropriate raceway and locked cor-
rectly.
4.1.15 After connecting the ground conductor (PE), connect the power conductors of the power cable to
the main circuit breaker or to the terminals on the controller Assemble the protective cover on the
main circuit breaker or on the input terminals.
4.1.16 Connect the supply cable to the circuit breaker on the power mains after checking, with the use of
an appropriate instrument, that the circuit breaker terminals are disconnected.
4.1.17 The controller can be provided with an internal lighting circuit and service socket connected down-
stream of the main circuit breaker. Should it be necessary to power the circuits independently
from the main circuit breaker, it will be necessary to alter an internal connection by connecting a
shielded three-core cable (2 phases + ground) to the mains, scaled according to the protection
rating of the mains, in the same way and according to the same sequence of operations as speci-
fied for connection of the power supply.
4.1.18 Connect the earth wire and the signals and power cables between the control unit and the robot.
4.1.19 Check that the control unit door(s) is/are locked with the special key.
4.1.20 The components of the control unit may be permanently damaged if the connectors are con-
nected incorrectly.
4.1.21 The C3G Plus internally makes the main safety interlocks (gates, enable button, etc.). Should it be
necessary to connect to the signals provided to make additional external circuits, make sure that
these signals are used according to safety regulations. The safety of interlock signals leading from
the transfer line (emergency stop, gates safety, etc.), i.e. providing correct and safe circuits is the
task of the robot system integrator.
System safety cannot be guaranteed if these interlocks are missing, incomplete or incorrectly es-
tablished.
4.1.22 Stopping due to tripping of the protective barrier safety devices causes uncontrolled stopping of
the robot with possible loss of the trajectory programmed. To stop the robot with controlled
ramping down, it is advisable to connect the interlock signals so as to activate a Drive Off com-
mand before the emergency stop.
Example: opening of the protective barrier safety locks causes Remote Drive Off; opening of the
protective barriers causes an emergency stop.
4.1.23 If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and
AUTO REMOTE states, an emergency stop and/or opening of the safety gates causes controlled
stopping of the robot (EN 60204-1), category 1 stop). In this way, power is cut off (opening of the
power contactor) after 1 second. In PROGR. programming status, the power is cut off immediately
(EN 60204-1, category 0 stop). These times must be taken into account when installing the pro-
tective barriers in particular if light curtains are used.
4.1.24 Check that the environmental and operating conditions do not exceed the limits specified in the
product User Manual.

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 SAFETY REGULATIONS

Installation and Commissioning - Continued

SAFETY REGULATIONS

4.1.25 Calibration operations must be carried out with extreme care as specified in the User Manual, and
must be completed by checking the correct machine position.
4.1.26 Only the original disks, supplied by COMAU S.p.A. with the robot, must be used to load or update
the system software (e.g. after replacing cards). After loading the software, always run a safety
test cycle from outside the protected area. When loading the system software, follow the proce-
dure described in the Product User Manual to the letter.
4.1.27 Make sure that the safety barrier around the protected area has been correctly fitted.
4.2 Operation during Programming
4.2.1 The robot must be programmed by authorized personnel only.
4.2.2 Before programming, the operator must check the robot system to ensure there are no potentially
dangerous anomalous conditions and (ensure) that there is nobody inside the protected area.
4.2.3 Whenever possible, programming must be carried out from outside the protected area.
4.2.4 Whenever work must be carried out inside the protected area, the operator outside the protected
area must make sure that all the necessary protections have been installed and are operational
and in particular that the portable programming unit functions correctly (reduced speed, enable
pushbutton, emergency stop, etc.).
4.2.5 The operator can enter the protected area during programming only if he has the programming
terminal.
4.2.6 During programming, only the operator with the programming terminal may remain within the pro-
tected area. If the presence of another operator is absolutely necessary, he must have a further
three-position safety device connected to the control system.
4.2.7 During programming, the operator must keep far enough away from the robot to be able to avoid
any unexpected movements from the robot, and in a position to avoid being caught between the
robot and parts of the surrounding structure( pillars, safety barrier, etc.), or between moving parts
of the robot.
4.2.8 During programming, the operator must not approach any parts of the robot that may drop or lift
due to the gravity.
4.2.9 The motors must always be activated (Drive On) from outside the robot's work envelope after
checking there is none inside the area involved. The Drive On operation is concluded when the
relevant machine status message is displayed.
4.2.10 Programmed cycle testing at working speed (a function that is included only if specific request is
made), in situations which require close visual observation with the operator inside the protected
area, must only be carried out after a complete test cycle has been run at reduced speed. Testing
must be controlled from a safe distance.
4.2.11 Be extremely careful when programming from the portable programming terminal: the hardware
and software safety devices are in operation, but robot movement is under the operator's control.
4.2.12 The first time a new program is run, the robot may move along an unexpected path. The modifica-
tion of steps in the program (e.g. shifting one step from one part of the program to another, incor-
rect recording of a step, modification of the robot position outside the path that joins two steps in
the program), may give rise to movements that were not envisaged by the operator during pro-
gram testing.
In both cases, it is extremely important to proceed with caution, and remain outside the robot's
work envelope.

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 SAFETY REGULATIONS

4.3 Automatic Operation

SAFETY REGULATIONS
4.3.1 The robot system can only be activated for automatic operation by authorised personnel when the
protective barriers are closed and electrically interlocked as specified in the safety standards.
4.3.2 Prior to activating automatic operation, the operator must check the robot system and the pro-
tected area to make sure there are no potentially dangerous anomalous conditions.
4.3.3 The operator can only activate automatic operation after checking that:
· the robot system is not being maintenanced or repaired;

· the protective barriers have been positioned correctly;

· there is none inside the protected area;

· the control unit doors are locked by properly key.

· the safety devices (emergency stop, protective barrier safety devices) are working properly;

· the portable programming terminal has been placed in its housing (this condition is requested
by the controller in Auto-Remote status).

4.3.4 Special attention must be paid when selecting the automatic- remote status, in which the line PLC
may automatically switch on the motors and start the program.
4.4 Emergency Manual Operation
(In case the manual emergency operation state is provided for)
4.4.1 Emergency Manual Operation can be activated by authorized personnel only.
4.4.2 This operating mode must only be used when special robot system conditions will not allow the
use of manual movement during programming.
4.4.3 Emergency manual operation must be controlled from outside the protected area since the safety
system is downgraded.
4.4.4 If it is absolutely necessary to work inside the protected area, The robot system integrator must
realize an appropriate safety circuit that allows the operator to move the robot with the safety bar-
riers deactivated.
In that case, before performing manual emergency operations, the operator must check, while re-
maining outside the protected area, the correct functioning of the safety devices that are active in
this state and the teach pendant utilized as a portable emergency pushbutton panel.
4.4.5 Take great care during emergency manual operation remaining outside the work envelope of the
robot and its fixtures and pay particular attention to the axes that may drop due to the force of
gravity.
4.4.6 Braking release device of robot axes. With the driving force excluded, the robot can be moved
by the manual brake release device, directly connected to the robot or installed on it, which only
permits the deactivation of the brake of each axis individually .In this situation all the system
safety devices (including the emergency stop and enable buttons) are excluded. Any axes to be
handled (that could drop due to the force of gravity) should be put in slings.

4.5 Removal from Service and Dismantling

4.5.1 Only authorised personnel may remove the robot system from service.
4.5.2 Position the robot ready for transport and fit anchoring brackets when required.
4.5.3 Prior to starting the removal from service procedure it is obligatory to disable the power grid circuit
breaker and lock it in the open position.
4.5.4 After using a specific instrument to check that the terminals are disconnected, disconnect the sup-
ply cable from the power mains circuit breaker by first disconnecting the power conductors and
then the ground connector. Disconnect the main circuit breaker supply cable on the control unit
and remove this.

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 SAFETY REGULATIONS

Removal from Service and Dismantling - Continued

SAFETY REGULATIONS

4.5.5 Disconnect the cable that powers the internal lighting and the service socket (if these circuits are
powered from outside) on the controller after locking the corresponding circuit breaker on the
mains supply in the open position, and (after) checking that the system is not live disconnecting
first of all the phase conductors and then the ground conductor.
4.5.6 Disconnect the cables connecting the robot and the control unit, then disconnect the earth.
4.5.7 Disconnect the robot pneumatic system from the air distribution network (if applicable).
4.5.8 Make sure that the robot is correctly balanced and, if necessary, harness it correctly and then dis-
assemble the robot anchor bolts from the support structure.
4.5.9 Remove the robot and the controller from the work area complying with all the prescriptions given
in the manuals provided. If the equipment is to be lifted, check that the eyebolts are correctly se-
cured and use suitable rigging and equipment.
4.5.10 Before starting to dismantle the robot system components (disassembly, demolition and disposal),
contact COMAU SYSTEMS, or one of its branches. Depending on the type of robot and control
unit, they will provide information regarding the operations to be carried out so as to comply with
the current safety regulations, and protect the environment.
4.5.11 Any waste must be disposed of in accordance with the current legislation of the country where the
robot system has been installed.
4.6 Maintenance and Repairs
4.6.1 Only authorised personnel may perform operations relating to maintenance, troubleshooting and
repairs.
4.6.2 An appropriate notice must be posted on the control panel of the control unit while maintenance
and repairs are being carried out; this notice must not be removed until the operations have been
completed even if they are temporarily suspended.
4.6.3 Maintenance operations and the replacement of components or the control unit must be carried
out with the main circuit breaker padlocked in the open position.
4.6.4 Even when the main circuit breaker is open and the control unit is therefore not supplied, intercon-
nected voltages may come from peripheral units (e.g. input/output 24 Vdc or 110 Vac) or from ex-
ternal power supplies (e.g. internal lighting system 110 Vac or 220 Vac). The relevant external
sources should therefore be deactivated when work is to be carried out on the system.
4.6.5 The main circuit breaker must be padlocked in the open position before removing panels, protec-
tive screens, grilles, etc.
4.6.6 Faulty components must be replaced with others having the same code.
4.6.7 Checks for faults on the control unit must, whenever possible, be performed outside the protected
area.
4.6.8 If the control unit needs to be powered in order to proceed with the troubleshooting, all the pre-
cautions required by the safety standards regarding personnel working in the presence of danger-
ous voltages must be taken.
4.6.9 All troubleshooting on the robot must be carried out with the power off (Drive off).
4.6.10 All deactivated safety devices (panels, protective screens, interlocks, etc.) must be restored upon
completion of maintenance and troubleshooting.
4.6.11 Upon completion of any maintenance, repairs and troubleshooting, the robot system and all its
safety devices must be checked for correct operation from outside the protected area.
4.6.12 Only the original disks, provided by COMAU S.p.A. with the robot, must be used to load software
(e.g. after replacing electronic cards). Always run a safety test cycle from outside the protected
area, once the software has been loaded. When loading the system software, follow the proce-
dure described in the Product User Manual to the letter.

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C3G Plus SMART H HANDLING SYSTEM

SAFETY REGULATIONS 1
SYSTEM DESCRIPTION 2 E

SUMMARY
Paragraph Page

Technical characteristics 2-1

Overview 2-1
Technical characteristics of main system components 2-2
C3G Plus 2-2
Robot 2-2
Media Panel 2-2
Control Unit - robot connection cable kit and hose kit 2-2
Performance 2-3
Maximum load to be applied to robot 2-3
Maximum working pressure of air hose 2-3
Air supply panel 2-4
Overview 2-4
Pneumatic part 2-5
Adjustment of air pressure 2-5
Calibration of air pressure switch 2-6
Electrical part 2-7
Media panel-robot air hose kit 2-7
Description and assembly 2-7
Standard dressing on board handling robot 2-8
Description 2-8
Spare parts 2-8
This page has been left intentionally blank
 SYSTEM DESCRIPTION

TECHNICAL CHARACTERISTICS

OVERVIEW

Fig. 2-1 - System assembly drawing

The SMART H handling system comprises:

· C3G Plus control unit (1);

· SMART H1 L/XL; H2; H2L robots (4);

· Air supply panel (media panel) (3);

· Media panel-robot air hose kit (2);

· Dressing on board robot:

- Plate on axis 3 (5).
- Cable and hose bundle from axis 3 to handling unit (6).

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SYSTEM DESCRIPTION

TECHNICAL CHARACTERISTICS OF MAIN SYSTEM COMPONENTS

The technical characteristics of the main system components are listed below.

☞ For additional and more detailed information, please refer to the specific documentation de-
scribing system components specified in the introduction to this manual.

C3G Plus
Total power installed 7 kVA
Power available to axes 5,6 kVA
Mains voltage supplies 380-400; 415-440; 480-500 Vca
Ground handling fork truck or transpallet
Hoist by means of eye bolts, also with application
Hoist
box

ROBOT
The robot features the same technical characteristics as robots equipped for welding. Robots that require a
power supply of up to 5.6 kVA to the axes can be used for the application. On board handling dressing is cur-
rently available for SMART H1 L/XL and H2 / H2L robots.

MEDIA PANEL
The characteristics of the Media Panel are described in the specific chapter in the handbook. Instead of us-
ing the Media Panel, the customer may use its own air panel (External User Media Panel), which must be
connected to the X31 interface connector on the control unit (available upon request).

CONTROL UNIT - ROBOT CONNECTION CABLE KIT AND HOSE KIT

Cables
Control unit - Robot 5-10-15-20-30-40 m cables
Control unit – Teach pendant 7 m std. (with extension up to 18 m.)
Control unit - I/O device with sec. 18AWG @ 24V nom.
digital inputs max. 330 m.
digital outputs 0.1A max. 330 m
0.5A max. 120 m.
1A max. 60 m.
2A max. 30 m.
analogue I/O max. 150 m

Hoses
Media Panel - Robot 5-10-15-20-30-40 m hoses

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 SYSTEM DESCRIPTION

PERFORMANCE
Performance ratings for the C3G Plus and SMART H robots are defined in the respective Technical Specifi-
cations handbooks.

MAXIMUM LOAD TO BE APPLIED TO ROBOT

To define the maximum load that can be applied to the robot flange, refer to the SMART H Specifiche
Tecniche/Technical Specifications handbook.

MAXIMUM WORKING PRESSURE OF AIR HOSE

· Hoses from Media Panel to robot base:
- DN12 = 2 MPa (Air);

· Hoses from robot base to axis 3:

- DN12 = 2 MPa (Air);

· Hoses from robot axis 3 to handling unit:

- DN10 = 2 MPa (Air).

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SYSTEM DESCRIPTION

AIR SUPPLY PANEL

OVERVIEW

Code Description
16683180 Air supply panel (PLUS)

The air supply panel developed by COMAU is capable of monitoring and treating the compressed air neces-
sary to ensure the correct operation of a robotized handling system.
Specific connectors are located on the rear part of the panel for fastening this to the left or right side of the
control unit (already pre-engineered).
The signal/power supply interface between the panel and the control unit must be effected by the user. This
interface must have the same technical characteristics as a normal I/O connection cable, and must be ef-
fected via the specific X2 terminal strip in the signal box of the panel.
Basically the panel consists of two parts:

· pneumatic (compressed air for handling unit and accessories);

· electrical (sensors, terminal strip box).

Fig. 2-2 “Layout of pneumatic part”

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 SYSTEM DESCRIPTION

Fig. 2-3 “Drawing of pneumatic part”

PNEUMATIC PART
Figure 2-3 illustrates the pneumatic diagram. Functionally, the pneumatic part consists of (fig. 2-2):

· (17) Straight fitting with yellow collar for DN16 hoses (60° male taper, M26x1.5). Connect the compressed
air hose from the works mains supply to this fitting and screw the fitting to the union (15).

· (8) 1/2” manual valve.

· (1)...(5) Air treatment unit with pressure regulator, pressure gauge and filter.

· (16) straight union (60° female taper, M22x1.5). Connect the hose that delivers air to the robot to this un-
ion. Standard media panel-robot hoses are already supplied with the specific fittings (straight fitting with
yellow collar for DN12 hoses 60° male taper, M22x1.5) that must be screwed to the union (16).

· A mechanical pressure switch with adjustable membrane (6) controls the pressure of the compressed air
supply.

ADJUSTMENT OF AIR PRESSURE

The pressure of the compressed air can be adjusted by means of the regulator (2) (fig. 2-2):

· raise the regulator lever.

· turn clockwise/anti-clockwise to increase/reduce the pressure until the required value, which is displayed
on the pressure gauge (3), is reached.

· lower the regulator lever.

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SYSTEM DESCRIPTION

CALIBRATION OF AIR PRESSURE SWITCH

It is possible to calibrate the threshold at which the pressure switch is triggered [fig. 2-2 part (6)]:

· disconnect the air supply by means of the gate valve (8) and vent the pressure downstream of the valve
(raise the collar (18) to enable venting);

· in this condition, the LED on the pressure switch connector must be yellow/orange;

· pressurize the system by means of the gate valve (8);

At this stage, one of the following conditions may occur (fig. 2-4):

· If the LED on the pressure switch connector stays yellow/orange, back off the lock screw (A) on the regula-
tor (B):
- turn the regulator (B) slowly anti-clockwise until the LED turns green;
- turn the regulator (B) again in the same direction by approximately another 1/4 turn.
Or:

· if the LED on the pressure switch connector turns green, calibration is OK.
In order to check pressure switch calibration, especially during initial installation, back off the lock screw (A)
and turn the regulator (B) clockwise until the LED switches to yellow/orange and then proceed as described
above.

Fig. 2-4 - Calibration of air pressure switch

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 SYSTEM DESCRIPTION

ELECTRICAL PART
Fig. 2-5 illustrates the electrical connections on the X2 terminal strip of the air supply panel.
The user must make the connections to the control unit. Three PG9 grommets for cables with a diameter of
5-10 mm are available for tapping any signals from the X2 terminal strip.

1 - BROWN

BLUE
AIR PRESSURE
SWITCH 3 - BLACK AIR PRESSURE
OK

YELLOW / BLACK

Fig. 2-5 - Electrical part

MEDIA PANEL-ROBOT AIR HOSE KIT

DESCRIPTION AND ASSEMBLY

Code Length
16686060 Length 5 m
16686061 Length 10 m
16686062 Length 15 m
16686063 Length 20 m
16686065 Length 30 m
16686064 Length 40 m

Basically, the kits consist of:

· 1 adapter (1/2” - M22x1.5) to be fitted to the air inlet on the robot base;

· 1 compressed air delivery hose:

- black DN12 hose with yellow collars;
- straight fittings for DN12 hoses (60° male taper, M22x1.5);
connect to the “Ê” fitting on the media panel and to the “AIR” fitting on the robot base (to which the
adapter has already been fitten).

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STANDARD DRESSING ON BOARD HANDLING ROBOT

DESCRIPTION

Code Description
SMART H1 and H1L robots
18615380 cable/hose bundle and relative supports
82152000 support plate on AX3
SMART H1XL robot
18615381 cable/hose bundle and relative supports
82152000 support plate on AX3
SMART H2 and H21L robots
18615382 cable/hose bundle and relative supports
82152000 support plate on AX3

The most important parts are listed below:

· a support plate, to be assembled on the robot’s axis 3, including an adjustable support pipe,

· an adapter with fitting (female taper, M15x1.5) to be mounted on the air fitting of the robot’s axis 3 (to
which the hose of the bundle must be fitted),

· an adjustable support to be mounted on the robot’s axis 6 ,

· a bundle comprising:
- a black DN10 hose complete with straight fittings (male taper, M16x1.5);
- a signal cable comprising:
- 2 connectors to be connected to X90-X91 on board the robot;
- 1 Harting connector of the 09-16-042-3101 type (42 pin female).
The cable diagram is illustrated in fig. 2-6.

SPARE PARTS

Code Description
SMART H1 and H1L robots
SMART H2 and H2L robots
18628360 Cable and hose bundle
SMART H1 XL robot
18628361 Cable and hose bundle

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BURNDY 26 pin Connector

HARTING Connector

BURNDY 19 pin Connector

Fig. 2-6 - Diagram of signal cable for standard dressing

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